Kemppi MasterTig 535ACDC User manual

MasterTig 535ACDC
Operating manual - EN
MasterTig 535ACDC
MasterTig Cooler MXL
© Kemppi 11921940 / 2140

MasterTig 535ACDC
Operating manual - EN
CONTENTS
1. General 4
1.1 Equipment description 5
2. Installation 7
2.1 Installing mains plug 8
2.2 Installing cooling unit (optional) 9
2.3 Installing equipment on cart (optional) 12
2.4 Connecting TIG torch 15
2.5 Connecting earth return cable and clamp 17
2.6 Connecting MMA electrode holder 18
2.7 Installing remote control (optional) 19
2.8 Installing gas bottle 22
2.9 Installing gas bottle on cart 23
2.10 Replacing control panel 24
2.11 Lifting MasterTig 535 equipment 28
3. Operation 30
3.1 Operating power source 31
3.2 Operating control panel MTP35X 32
3.2.1 Home view 33
3.2.2 Weld Assist view 34
3.2.3 Memory channels view 38
3.2.4 Start & stop sequence view 39
3.2.5 Pulse view 41
3.2.6 Current mode view 43
3.2.7 Settings view 44
3.2.8 Info view 47
3.2.9 Screen saver 48
3.3 Operating cooling unit 49
3.4 Remote control 50
4. Maintenance 52
4.1 Troubleshooting 53
4.1.1 Error codes 54
4.2 Disposal 56
5. Technical data 57
5.1 Power source MasterTig 535ACDC 58
5.2 Cooling unit MasterTig Cooler MXL 60
5.3 TIG guide tables 61
5.4 Welding processes and features 62
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MasterTig 535ACDC
Operating manual - EN
5.5 Ordering info 68
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MasterTig 535ACDC
Operating manual - EN
1. GENERAL
These instructions describe the use of Kemppi's MasterTig 535ACDC welding power source. The system consists of
MasterTig power source with MTP35X control panel (factory installed), optional MasterTig Cooler MXL water cooler,
optional transport unit and Flexlite TX TIG welding torch.
Important notes
Read the instructions through carefully. For your own safety, and that of your working environment, pay particular atten-
tion to the safety instructions delivered with the equipment.
Items in the manual that require particular attention in order to minimize damage and harm are indicated with the
below symbols. Read these sections carefully and follow their instructions.
Note: Gives the user a useful piece of information.
Caution: Describes a situation that may result in damage to the equipment or system.
Warning: Describes a potentially dangerous situation. If not avoided, it will result in personal damage or fatal injury.
DISCLAIMER
While every effort has been made to ensure that the information contained in this guide is accurate and com-
plete, no liability can be accepted for any errors or omissions. Kemppi reserves the right to change the spe-
cification of the product described at any time without prior notice. Do not copy, record, reproduce or transmit
the contents of this guide without prior permission from Kemppi.
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MasterTig 535ACDC
Operating manual - EN
1.1 Equipment description
Kemppi MasterTig 535 AC/DC welding equipment is designed for professional industrial use, with characteristics espe-
cially suitable for welding materials like aluminum and stainless steel. The multipurpose MasterTig power source is suit-
able for MMA welding, TIG welding and pulsed TIG welding with both direct current (DC) and alternating current (AC).
Power source model:
•MasterTig 535ACDC GM, multi-voltage and generator compatible (500 A AC/DC) *
* A dedicated VRD(Voltage Reduction Device)model version, where the VRD function is locked on, is also available.
Control panel:
•MTP35X control panel (AC/DC, 7" TFT LCD display panel).
Equipment:
1. MasterTig 535 power source
2. MasterTig Cooler MXL (optional)
3. TIG torch
4. Electrode holder
5. Earth return cable and clamp
6. Remote control (wired or wireless)
7. Foot pedal remote control (wired or wireless)
8. Lifting eyes
9. Power ON/OFFswitch.
Connections:
a. External remote control connector
b. TIG welding cable connector (connection type R1/4)
c. Control cable connector
d. DIX connector (-)
e. DIX connector (+)
f. Coolant liquid inlet and outlet (color-coded)
g. Gas hose connection
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MasterTig 535ACDC
Operating manual - EN
h. Mains cable
i. Cooling unit connection.
EQUIPMENT IDENTIFICATION
Serial number
Serial number of the device is marked on the rating plate or in another distinctive location on the device. It is
important to make correct reference to the serial number of the product when ordering spare parts or making
repairs for example.
Quick Response (QR) code
Device-related information or a web link to such information may be found in the form of a QR code on the
device. The code can be read, for example, with a mobile device camera and a QR code application.
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MasterTig 535ACDC
Operating manual - EN
2. INSTALLATION
Do not connect the equipment to the mains before the installation is complete.
Do not attempt to move or hang the equipment mechanically (e.g. with a hoist) from the handle on the power
source unit. The handle is meant only for manual moving when the equipment is installed on a cart.
Place the machine on a horizontal, stable and clean ground. Protect the machine from rain and direct sunshine.
Check that there is enough space for cooling air circulation in the machine vicinity.
Before installation
•Make sure to acknowledge and follow the local and national requirements regarding installation and use of high
voltage units.
•Check the contents of the packages and make sure the parts are not damaged.
•Before you install the power source on site, see the requirements for the mains cable type and fuse rating given in
the "Technical data" on page57 chapter.
Distribution network
MasterTig 535ACDC: Provided that the public low voltage short circuit power at the point of common coupling is
higher than or equal to the value stated on the list below, this equipment is compliant with IEC 61000-3-11 and IEC
61000-3-12 and can be connected to public low voltage systems. It is the responsibility of the installer or user of the
equipment to ensure, by consultation with the distribution network operator if necessary, that the system impedance
complies with the impedance restrictions.
•MasterTig 535ACDC: 3.4 MVA
According to the EMC classification (Class A), the MasterTig equipment is not intended to be used in residential loc-
ations where the electrical power is provided by the public low-voltage supply system.
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MasterTig 535ACDC
Operating manual - EN
2.1 Installing mains plug
Only an authorized electrician is allowed to install the mains cable and plug.
Do not connect the machine to the mains before the installation is complete.
Install the 3-phase plug according to the MasterTig power source and site requirements. Refer also to "Technical data"
on page57 for power source specific technical information.
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MasterTig 535ACDC
Operating manual - EN
2.2 Installing cooling unit (optional)
For instructions on installing the equipment on cart, refer to "Installing equipment on cart (optional)" on page12.
The cooling unit must be installed by authorized service personnel.
Do not attempt to move the power source with a hoist from its handle. The handle is meant for moving the equip-
ment when installed on cart.
Tools needed:
1. Remove the power source's rear cover.
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MasterTig 535ACDC
Operating manual - EN
2. Route the cooling unit's connection cables so that they remain accessible through the next steps.
3. Lift the power source with a hoist from the lifting eyes and place it on top of the cooling unit so that the fixing
plates align and go into their slots. Fix the units together with two screws in the front and two screws in the rear.
Ensure that the cooling unit's connection cables are not caught and/or damaged between the edges.
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MasterTig 535ACDC
Operating manual - EN
4. Connect the cooling unit cables and put the rear cover back.
5. Fill the cooling unit with cooling liquid.
>> MasterTig Cooler MXL tank volume is 3 litres and the recommended coolant is MPG 4456 (Kemppi mixture).
Avoid cooling liquid contact with skin or eyes. In case of an injury, seek for medical advice.
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MasterTig 535ACDC
Operating manual - EN
2.3 Installing equipment on cart (optional)
There is a 4-wheel transport unit available for use with the MasterTig welding equipment.
Tools needed:
1. Install the cooling unit on the cart.
2. Fix the cooling unit to the cart with two screws (M5x12) in the front and two screws (M5x12) in the rear.
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MasterTig 535ACDC
Operating manual - EN
3. Route the cooling unit's connection cables so that they remain accessible through the next steps.
4. Install the power source on top of the cooling unit. Refer to "Installing cooling unit (optional)" on page9 for install-
ation details.
5. Secure the power source with two screws (M5x12) in the front and two screws (M5x12) in the rear.
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MasterTig 535ACDC
Operating manual - EN
6. Secure the equipment to the cart with the rear connection bracket. Rear screws:M8x16, top screws:M5x12.
For lifting the equipment, refer to "Lifting MasterTig 535 equipment" on page28.
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MasterTig 535ACDC
Operating manual - EN
2.4 Connecting TIG torch
Gas-cooled TIG torch:
1. Assemble the TIG torch according to the instructions delivered with the torch.
2. Connect the TIG torch cables to the power source. Secure by turning the connectors clockwise.
Water-cooled TIG torch:
The cooling unit must already be installed and in place at this stage. Refer to "Installing cooling unit (optional)" on
page9.
1. Assemble the TIG torch according to the instructions delivered with the torch.
2. Connect TIG torch cables and the water cooling inlet and outlet hoses to the units. Secure by turning the con-
nectors clockwise.
The water cooling connectors are color-coded.
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MasterTig 535ACDC
Operating manual - EN
Tip: For Kemppi welding torches, refer also to userdoc.kemppi.com.
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MasterTig 535ACDC
Operating manual - EN
2.5 Connecting earth return cable and clamp
Keep the work piece connected to earth to reduce the risk of injury to users or damage to electrical equipment.
1. Connect the earth return cable to the negative (-) connector on the power source.
2. Ensure the earth return clamp is secured tightly to the work piece or work surface.
3. Ensure that the clamp's contact surface is as large as possible.
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MasterTig 535ACDC
Operating manual - EN
2.6 Connecting MMA electrode holder
1. Connect the MMA electrode holder to the positive (+) connector on the power source.
2. Connect the earth return cable to the negative (-) connector on the power source.
3. Ensure the earth return clamp is secured tightly to the work piece or work surface.
4. Ensure that the clamp's contact surface is as large as possible.
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MasterTig 535ACDC
Operating manual - EN
2.7 Installing remote control (optional)
To enable remote operation, set the Remote control mode in the control panel settings. For MTP35X control panel,
refer to "Settings view" on page44.
When the Remote mode is selected on the control panel, and both wireless and wired remotes are connected, the
wired remote will be used.
Refer to the (+) and (-) signs on the battery holder and in the remote for the correct positioning of batteries.
Tools needed:
T15
Wireless hand remote control (HR45)
1. Take the remote control battery holder out. Install the batteries (3 x AAA) and put the holder back into the remote.
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MasterTig 535ACDC
Operating manual - EN
2. Turn on the Wireless remote in the control panel settings.
3. Keeping the wireless remote close to the power source, long press (3 sec.) the wireless remote pairing button on the
remote.
4. Once connected, the blue LED on the left of the connection button is lit. The green LED blinks when the battery is
low.
5. To enable remote operation, select Remote mode in the control panel settings.
Remote control with cable (HR43, FR43)
1. Connect the remote control cable to the power source.
Wireless foot pedal (FR45)
Refer to the (+) and (-) signs on the battery holder and in the remote for the correct positioning of batteries.
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