SM MLS V1.0en

Release 1.
0 May 2002
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This document is designed to print in A4 paper format.
For A5 printing your printer driver must be compatible.
( You can use the option 2 pages on one print layout )
For clearly text printing with monochrome laserprinters

you can use the " text for black "option in the printer menu.
All numbered pages are used for odd pages.

For the even pages you can use the last page with caption NOTES.
So notes can be written down there were needed,
KEMPPI CUSTOMER SERVICE / SERVICE DEPARTMENT
Direct Printing
Linking instruction
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Version 1.0
Service manual Master/tig MLS Series

Included Models:
Master 2500 / 3500
Mastertig 2500 (W)
Mastertig 3500 (W)
Mastercool 10
The information contained in this document is subject to change without notice.

Check the KEMPPI database regular for new updates. Authorised personel only!
This product is based in whole or in part on technology developed by KEMPPI OY
Service manual for Kemppi Master/tig MLS machines
Release 1.0
May 2002
INDEX
SUBJECT PAGE
General
• Index …………...…………………………………………………………... 02
• Master(tig) MLS family ….…….………………………………………….. 03
• General features …......…………………………………………………… 04
• Machine specifications …….……………………………………………... 05
• Torch specifications …....….……………………………………………... 06
• Panel functions settings
( MEL MTL MTM MTX ) ...……………………………………..… 07
• Panel set-up functions ……………..……………………………………...17
• Layer quick view .……….………………………………………………….21
• Mastercool 10 ……………………………………………………………... 22
• Torch connection ………………………………………………………….. 23
• Remote control lines ............................................................................24
Main circuit
• General ....................……………………………………………………… 25
• Main circuit boards ..............................................................................27
• Layout of the boards ...........……..............………………………….…...29
• Connectors & pins …...…………………………………………………… 31
Troubleshooting
• General …..………………………………………………………………....32
• MMA models …………………………………………………………...…..33
• TIG models …….……….…………………………………...…………….. 36
• Cooling Unit …...………………………….……………………………….. 39
Diagrams
• Master MLS 2500/3500 …...……………………………………………... 42

• Mastertig MLS 2500/3500 ..…………………………………………...…. 43
• Mastercool 10 …….…………………………………………...………..….44
Kemppi OY or Kemppi subsidiary shall not be liable for errors contained herein
or for incidental or consequential damages to the equipment.
THIS FILE DOCUMENT IS PROPARTY OF KEMPPI OY FINLAND. DESIGN BY KEMPPI CUSTOMER SERVICE / SERVICE DEPARTMENT
Service manual for Kemppi Master/tig MLS machines Version 1.0 Service
02
Master(tig) MLS family
Powers sources & cooling units

Visit www.kemppi.com for the latest
update of all parts concerning the
total MLS series.
Type : Mastercool 10 Master 2500 MLS Master 3500 MLS

Art. no : 6122350 6104250 6104350
Type : Mastertig 2500 MLS Mastertig 3500 MLS

Art. no : 6114250 6114350
Function panels
Type : MEL Panel MTL Panel MTX Panel MTM Panel

Art. no : 6106000 6116000 6116005 6116010
Torches & remote control units
Type : TTC Torches R11F R10 RTC 10 RTC 20

Art. no : See Page 06 6185407 6185408 6185477 6185478
Transport units & accessories
Type : T200 T110 Water/current adapter Control adapter

Art. no : 6185258 6195251 3148710 3148720
03
General features
General
Master, Mastertig 2500 and Master, Mastertig 3500 are DC-MMA-TIG welding power sources in the
250 – 300 A and 350 – 400 A range. They are intended for 3-phase line voltage connection.
Inverter power circuitry and microcontroller technology are used.
Fitting different panel versions to the power source can form different function combinations for different
welding applications. Panel installation does not require any tools.
Mastercool 10 cooling unit can easily be connected to TIG power sources for water-cooled TIG torches.
Side plates of the power source or the water unit need not to be opened during connection.
The power source is lightweight and portable but can also be moved using a transport unit T 200 especially
when the cooling unit is attached and a gas bottle needs to be moved.
Supply voltage range is 3~400V and recommended fuse size is 10 A in 2500 machines and 16 A in 3500.
Features
• Totally digital microcontrolled panel and microcontrolled power source

• Separately programmable panel and power source
• ICS™ = Isolated Cooling System with seperately tunnel for electronics and power parts
• Panel type with switches on the boardcircuit instead of a membrame
• Four programmable layers in panel for excellent tuning of the machine
• Errror messages are displayed like text
• Four types of function panels that are easy to change
• Easy software update
• Cooling unit totally controlled by power source and panel

• No PCBs in cooling unit
• PTC flowswitch in cooling unit
• No extra mechanical elements
• No HF circuit through the cooling unit
• Cooling unit is easy to install( plug in )
• Good protections against overloading

• Good protections against HF disturbance
• TTC torches with fine remote controlling

• Undercarriage T200
• Undercarriage T110 for gas cooled machines
Kemppi Unique ICS™ technology
04
Machine specifications
MASTER MASTER MASTERTIG MASTERTIG MASTER

2500 MLS 3500 MLS 2500 MLS 3500 MLS COOL 10
Mains voltage 3~50/60Hz 400V 400V 400V 400V

Absolute min / max input 360V…460V 360V…460V 360V…440V 360V…440V
1
Rated power 40% ED 250A / 9,4KVA / 13,6A 350A / 14,7KVA / 21,2A 300A / 8,7 KVA / 12,6A 400A / 13,4 KVA / 19,3A
60% ED 205A / 7,3KVA / 10,5A 285A / 11,1KVA / 16,0A 205A / 5,0 KVA / 7,2A 285A / 7,9 KVA / 11,4A ------------
100% ED 160A / 5,4KVA / 7,8A 220A / 7,9KVA / 11,4A 160A / 3,6 KVA / 5,2A 220A / 5,4 KVA / 7,8A
Connection cable 4X2,5mm2 - 5M 4X2,5mm2 - 5M 4X2,5mm2 - 5M 4X2,5mm2 - 5M

Fuse 10A slow-blow 16A slow-blow 10A slow-blow 16A slow-blow
1
Loading capacity 250A - 30,0V / 40% 350A - 34,0V / 40% 300A - 22,0V / 40% TIG 400A - 26,0V / 40% TIG
(nominal values) 205A - 28,2V / 60% 285A - 31,4V / 60% 250A - 18,2V / 60% TIG 285A - 21,4V / 60% TIG
160A - 26,4V / 100% 220A - 28,8V / 100% 160A - 16,4V / 100% TIG 220A - 18,8V / 100% TIG
------------
Control range MMA 5A / 10V…250A / 36V 5A / 10V…350A / 45V 5A / 10V…250A / 36V 5A / 10V…350A / 45V
for welding TIG ---------- ---------- 5A / 10V…300A / 22V 5A / 10V…400A / 26V
2
Open circuit voltage 80V DC / 40V DC 80V DC / 40V DC 80V DC / 40V DC 80V DC / 40V DC
Open circuit power 10W 10W 10W 10W

------------
Operation frequency 20Khz 20Khz 20Khz 20Khz
Efficiency with nom. values 86% (250A / 30V ) 86% (250A / 30V ) 86% (250A / 30V ) 86% (250A / 30V )
Power factor at nom. values 0,95 ( 250A/ 30V ) 0,95 ( 250A/ 30V ) 0,95 ( 250A/ 30V ) 0,95 ( 250A/ 30V )
Storage temperature range -40 …+60°C -40 …+60°C -40 …+60°C -40 …+60°C -40 …+60°C
3
Operation temperature range -40 …+60°C -40 …+60°C -40 …+60°C -40 …+60°C
H (180°C)
Temperature class H (180°C) / B (130°C) H (180°C) / B (130°C) H (180°C) / B (130°C) H (180°C) / B (130°C) B (130°C)
Degree of protection IP 23C IP 23C IP 23C IP 23C IP 23C
External demensions length 500 mm 500 mm 500 mm 500 mm 500 mm

without handless width 180 mm 180 mm 180 mm 180 mm 180 mm
height 390 mm 390 mm 390 mm 390 mm 260 mm
Weight 20 Kg 21 Kg 22 Kg 23 Kg 10 Kg
Empty
Voltage supply for cooling

2~400V AC
unit trough connector X10
------------ ------------ ------------ ------------ 250 VA
Power used by cooling unit
100%
By PTC
Fuse
Cooling power
1,05 KW
Max. pressure
4,5 Bar
Connections MS 58
------------ ------------ ------------ ------------ Quick snap
Tank volume 3L
20%-40%
Cooling Liquid glycol-water
1
Input voltage 3~400VAC 50HZ. IL = I PH for currentvalue. Values for loading capacity in MMA mode for Mastertig MLS are according to Master Mls.
2
Open voltage can be changed to 40VDC by panelsetting A7 into "1".
3
Operation temperature range depends on the sort of cooling liquid used.
*)
All these machines meets the construction and safety requirements according to norms IEC 60974-1/2 and EN 50199
05
Torch specifications
Air cooled torches

TTC 130 TTC 130F TTC 160 TTC 160S TTC 220
Length 4m 627013004 627013104 627016004 627016204 627022004
8m 627013008 627013108 627016008 627016208 627022008
16 m 627013016 627013116 627016016 627016216 627022016
Loading capacity
DC- 40 %ED 130 A 130 A 160 A 160 A 220 A
100 %ED - - - - -
Electrode sizes to be used Ø 1.0…2.4 1.0…2.4 1.0…2.4 1.0…2.4 1.0…3.2
Class Voltage L L L L L
Cooling air air air air air

Connection to TIG-unit
Gas/current R1/4 R1/4 R1/4 R1/4 R1/4
Water - - - - -
Liquid cooled torches

TTC 200W TTC 250W TTC 250WS
Length 4m 627020504 627025504 627025704
8m 627020508 627025508 627025708
16 m 627020516 627025516 627025716
Loading capacity
DC- 40 %ED - - -
100 %ED 200 A 250 A 200 A
Electrode sizes to be used Ø 1.0…3.2 1.0…4. 1.0…4.0
Class Voltage L L L
Cooling liquid liquid liquid
min. 1 l/min min. 1 l/min min. 1 l/min
In inlet: In inlet: In inlet:
max 50°C max 50°C max 50°C
min 1bar min 1bar min 1bar

max max max
Connection to TIG-unit
Gas/current R1/4 R1/4 R1/4
Water snap snap snap

connector connector connector
06
MEL panel
Indicator lights at panel upper section
ON
Green ”power on” –light lights up when power is switched on.
Yellow over-heat alarm light lights up when internal temperature
A φ 2.0 φ 2.5 φ 3.25 φ 4.0 φ 5.0
SS-RUTILE 20-45 40-80 70-120 100-160 140-220
REMOTE limit is reached. Over or under voltage alarm light lights up
Fe- RUTILE 40-80 50-110 80-150 120-210 170-290
Fe- BASIC 50-80 80-110 110-150 140-200 200-260
when line voltage is out of range or blinks when one phase is
missing and power source is loaded. Accepted voltage range is
from 320…330 V to 480 … 490V and outside this range welding
A is prevented. If the over voltage level reaches 590 V the power
A
source shuts off completely and starts again if voltage drops below 480 V.
V
min max
HOT START
0
ARC FORCE
0
Current is regulated by a panel or remote control potentiometer.
The ranges are 10...250 A/350A for MMA and 5...300A/400 A
for TIG. Maximum current sets itself with the power source size
min max min max automatically. Set value is displayed in stand by state and actual
value while welding. Precision of the digital display is +/- 2,5 %
or +/- 2 A for current.
MASTER MLS MEL
TM
Voltage metering is on if “A/V” toggle switch is at “V” position and actual pole voltage is displayed.
Accuracy is +/- 0,5V.
Local / remote control –switching is performed by toggle switch. Connector for remote control devices is below the
panel. Remote device is identified if connected and panel potentiometer setting is in force always without remote
control device regardless of switch position.
MMA / TIG switch makes it possible to perform TIG welding with a special torch having manual gas valve. Scratch
start ignition method is not recommended but use of internal control for contact ignition method instead. Hot start
and arc force are switched off in TIG.
Arc Force control (dynamics) with a scale from -9 (soft) to +9 (rough) is also featured, displays – on the left and +
on the right portion of the window, 0 in the middle. Displayed while turning the knob, returns to current display
automatically after a few seconds
Hot start pulse depends on set welding current according to certain function. Maximum current is 450A with 350 A
power source. Displayed while turning the knob.
Antifreeze function, which drops down the current if the electrode is stuck in the workpiece, is active as default. Off
switching is in SETUP and is possible with MTL, MTM and MTX panels.
Information about current vs. electrode size is given as a table on panel (shaded area printed on panel).
MMA – Table for correct welding current selection

φ1.6 φ2.0 φ2.5 φ3.25 φ4.0 φ5.0
SS-rutile 18-40 20-45 40-80 70-120 100-160 140-220
Fe-rutile 30-60 40-80 50-110 80-150 120-210 170-290
Fe-basic 30-55 50-80 80-110 110-150 140-200 200-260
Cellulosic 40-70 65-130 90-175 140-225
High rec. 85-125 130-170 180-230 250-350
07
MTL panel
Indicator lights on panel upper section
ON
Indicator lights operate like in MEL-panel, already described.
PULSE
HF Current control and display are like in MEL-panel, but digital
CONTACT
WATER FILL
potentiometer is used for adjustment. Acceleration feature when
MINILOG
turned fast for coarse adjustment.
MINILOG
A
V Voltage meter shows actual pole voltage during welding.
4T
s
Precision is like in MEL.
2T
RETURN
TIG Up and down slope time control and display

PANEL • up slope, 0.0s –10.0s, resolution 0,1 s
PEDAL
• down slope, 0.0s – 15.0s, resolution 0,1 s
ARC FORCE
PEDAL LO / HI
Gas times
SETUP
MMA
HOT START
REMOTE • pre gas time, 0.0s – 10.0s, resolution 0,1 s
GAS TEST
• post gas time, 1s – 30s, resolution 1 s
MASTERTIG MLS MTM
MTL
TM
ASTERTIG
Adjusting welding parameters (applies to all MLS TIG panels)
V
A s
RETURN
There is a figure indicating normal welding process: gas and current flow with slopes up and down and LED (light
emitting diode) lights on each step. Beside the panel potentiometer there are two buttons with arrow symbols: left and
right. With these buttons the LED is moved through the figure. LED lights show where the cursor is. When the intended
parameter is reached adjustment is done with the digital pulse potentiometer. The display is following automatically
and shows the numeric values and the units of the parameters.
When pressing the ‘RETURN’ - button the cursor jumps to welding current adjustment. When pressed in welding
current position the cursor jumps to the last adjusted parameter. Cursor jumps automatically to welding current after 10
seconds.
During welding cursor LED shows in which program step operation currently is. When in post –gas touching any
control causes cursor to jump to the welding current adjustment. Also it’s possible to move with ‘arrow’ - buttons and
adjust parameters during post-gas flow. Post-gas continues to flow until the pre-set time is reached although cursor LED is
not in post-gas position
08
MTL panel next
4T
2T
There are two operation modes (tact’s) for the TIG torch switch, 2T and 4T. 2T needs continuous
pressing of the torch switch and by 4T you can release the switch after the arc start. 'TIG' – button
TIG
selects TIG –mode when panel is in MMA –mode. By reactivation of TIG the last selected tact mode
is returned.
Operation of the 2T-function:
TORCH
SWITCH
WELDING CURRENT
UPSLOPE DOWNSLOPE
PREGAS POST GAS
Pressing the torch switch starts the pre-gas time, if set. Releasing the switch during pre-gas stops the gas flow and
resets the sequence. After pre-gas the arc ignition is performed. After the arc has ignited on a certain current, up
slope will start.
TORCH
SWITCH If the torch switch is released during upslope current goes to the downslope and then to the
post-gas. If tacking automatics is on (SETUP A9 = “1”) current doesn’t go to downslope if
UPSLOPE there is less than three seconds from the arc start.
When pre-set welding current is reached and the torch switch is released downslope will start and the current cuts
off on a certain level, if the torch switch is not pressed again during the downslope. Post-gas will flow the time
set. If a new start is given during post-gas the arc strikes immediately without pre-gas delay.
In 'tacking automatics on' mode the downslope will only start if the time elapsed from arc start is more than three
seconds. If the switch is released before that time the current will stop immediately without downslope.
TORCH
SWITCH
If the switch is pressed during downslope the current will rise with the upslope
steepness. It’s possible to modify steepness with SETUP b6.
DOWNSLOPE
09
MTL panel next
TORCH
SWITCH
Downslope can be interrupted by a quick (< 0,4 s) press of torch switch if SETUP A8
DOWNSLOPE is "1". Also if tacking automatics is on, short trigger action will cut downslope. Post-gas
starts always after the current flow has stopped and will end after the pre set time.
When a new arc start is performed during post-gas the set pre-gas time will be omitted.
SETUP modification possibilities in 2T with following details, see the end of this chapter:
• slope times vary with current / times as set (A1, A2)

• tacking automatics on/off (A9)
• interruption using short switch action cuts off the current / does not cut it off (A8)
• non-linear / linear downslope (A11)
• current freezing function on / off (A14)
• downslope interruption causes the current to jump up or to slope up with the steepness of upslope / downslope (b6)
Operation of the ”traditional” 4T-function:
short or long short or long short short or long long
TORCH
SWITCH
WELDING CURRENT
DOWNSLOPE
UPSLOPE
POST GAS
PREGAS
When the torch switch is pressed, gas flow starts. When the switch is released, the pre-gas time starts, if it is set and if the press
was short. When pressed long the pre-gas timer is not activated. After that the arc ignition is performed. After the arc has
ignited on a certain current, up slope will start and if the torch switch is pressed during that time current continues
upslope to the welding current and when the switch is released the downslope starts.
The current will remain on the reached level if 'current freezing' in SETUP A14 is "1". When the switch
is released, current goes to the downslope.
When preset welding current is reached and the torch switch is pressed and released the downslope starts and
the current cuts off on a certain level (SETUP A6 and b3) if the torch switch is not pressed again before that.
10
MTL panel next
When pressed shortly during downslope the current rises with the steepness of the upslope (or with downslope,
SETUP b6). With a long press the current decreases further and ends on a certain level, if released before end of the
downslope, current goes to the upslope. In case the 'current freeze' feature is active (SETUP A14=”1”) current stays the
same as long as the switch is pressed and continues decreasing after releasing.
Post-gas starts always after the current has stopped and will end after the pre-set time.
Possible modifications in SETUP are the same as in 2T except for interruption of current (A8).
TIG arc can be started either with high frequency (HF) or without (contact ignition). HF ignition is
chosen when the LED on the flash symbol is lighted. There is a certain level of current set for the
ignition procedure for both HF (SETUP b4) and contact ignition from which the arc starts.
HF HF voltage is about 10 kV peak but can be adjusted on the HF card by trimmer if needed. No pre-gas is
CONTACT
given in contact ignition mode.
Gas Test function is also included and is activated by the same button as Hot Start for MMA.
Gas starts flowing with a short press and stops automatically after 10 s or if pressed again during gas flow.
MMA functions of 'MTL' TIG panel
MMA method is selected by ‘MMA’ - button. Welding current is adjusted with

ARC FORCE
the panel potentiometer like in TIG.
PEDAL LO / HI Remote control of MMA current can be carried out with a conventional unit or also by using
the TIG torch remotes.
TIG
MMA Arc Force and Hot Start for MMA are included with a numeric scale from -9 to +9.
HOT START Arc Force affects the dynamic behaviour of the MMA and Hot Start controls the current
GAS TEST
pulse at arc start.
PANEL
PEDAL
If you choose to adjust the welding current with a remote control unit you first connect the unit and
then select it with the ‘REMOTE’ - button. The ‘PANEL’ - LED goes off and then it’s possible
to select between the connected units. There is an automatic recognition of remote control
units with potentiometers and only the symbol of a unit connected can be chosen.
(Panel => 'bone' or foot pedal => torch control => panel).
SETUP The up / down control of the torch is active together with panel pulse potentiometer when
REMOTE connected. If SETUP A16 is “1” up / down control is active only when selected from
‘REMOTE’ - button.
The foot pedal control works only in 2T and the slopes are not in use.
11
MTM panel
ON
SYNERGIC SPOT
PULSE SPOT Indicator lights, current control, voltage metering, HF / contact

HF PULSE
CONTACT OFF ignition selection, Local/ torch / remote control –selection, Arc
Force control for MMA, Hot start pulse control for MMA, Up-
WATER FILL
MINILOG
SPOT and downslope and gas times are the same as in MTL.
MINILOG V %
4T A s Hz In addition to MTL-panel functions there are:
2T
RETURN
2-T / 4-T / Minilog selection
TIG
PANEL
• 2-T as in MTL, also 4 -T
SET
• Minilog :
• Minilog current, 10 –90 % of welding current, range can be
PEDAL
ARC FORCE
ON
PEDAL LO / HI
modified
MMA MEMORY
OFF
CH
SET
SAVE
SETUP
REMOTE • Search arc current, 5-90 % of welding current, range can be
modified
HOT START
GAS TEST
ch clear ch remote
MASTERTIG MLS MTM

TM
Pulse -TIG
• pulse current
• pulse ratio 10...70%, range can be modified
• pulse frequency 0,2 ... 300Hz, (5s-3.33ms pulse time), range can be modified
• base current 5...70% of pulse current, range can be modified
Synergic pulse -TIG

• average current setting min ... max
• varies with current
• no other adjustments but parameters are displayed
Spotwelding
• spot time adjustment 0.0s – 10.0s, range can be modified
Memory channels:
• channel number display: 0...9
MINILOG Minilog function is selected by using the 2T/4T/MINILOG switch when the upper LED is lit.
4T This gives you a possibility to reduce the welding current during the welding with
a short switch action on the torch.
2T
You can set the reduced level of current, called Minilog current, by choosing the function
with the cursor LED and then adjusting the current with the potentiometer. Minilog current
TIG setting is a percent value of the set welding current, so changing welding current changes also
Minilog current amperage.
12
MTM panel next
Setting of parameters is performed in a same manner as in MTL panel. The selectable parameters on the
current flow diagram depend on which functions are activated (Minilog, Pulse ...).
More detailed description of Minilog usage:
short or short short short long action:

long action >0,5 s
TORCH
SWITCH
MINILOG
When the torch switch is pressed, gas flow starts. When the switch is released, the pre gas time starts, if it is set. After that
the arc ignition is performed. After the arc has ignited on a certain current, the search arc current is set if activated in
SETUP A13.
With a short switch action upslope will start and if the torch switch is pressed and released during that time the current
will go to the downslope. If “current freeze” function is activated (SETUP A14) current will remain on the reached
level. When welding current is reached short torch switch action drops current to the Minilog current. Again short
torch switch action and current rises to the welding current.
When the switch is pressed for more than 0,7 s while on welding current or on Minilog current and then released the
downslope will start. If switch is pressed during downslope the operation is the same as in 4T, see 'MTL'-section.
Pulsing is not on during Minilog current, neither on Search arc current.
Modifications in SETUP in addition to 4T:

• Search arc on/off A13
• Tacking automatics is not in operation
Pulse operation
There are two pulse welding methods selectable from the panels having the pulse function:
synergic pulse and long pulse.
SYNERGIC SPOT
PULSE SPOT
PULSE
OFF
Pressing the ‘PULSE’ - button on the panel activates pulsing. The 'long pulse' - LED is
first lighted (single pulse symbol) ( => synergic pulse => spot => synergic & spot => OFF)
13
MTM panel next
In Pulse – mode it´s possible to adjust main current and all pulse parameters. Parameters are however binded
together so adjusting one parameter can change other parameters. Base current is a percentage value of pulse current
so if pulse current changes, base current amperage changes too, but the base current percentage remains.
When adjusting main current, a new pulse current is calculated using pulse ratio and base current percentage values.
When adjusting the pulse current, a new main current is calculated using pulse ratio and base current percentage values.
When adjusting pulse ratio main current remains and a new pulse current is calculated. If pulse current reaches its
maximum value system starts to calculate new main current value.
When adjusting base current percentage, new main current is calculated.
After pressing the 'PULSE' - button for the second time the 'SYNERGIC' - LED is lighted.
Only main welding current can be adjusted, while all other pulse parameters are fixed. By 'arrow' - buttons it’s
possible to check the used pulse parameters but in synergic mode it´s not possible to change them.
Pulsing is on during up- and downslopes and at the end downslope the pulse current defines the cut off level.
Pulsing is not on during search current, tail current and Minilog current.
Spot welding
SPOT
SPOT
Use of Spot welding is possible on MTM-panel by pressing
PULSE the ‘PULSE’ - button three times and then moving the cursor
OFF
to spot time LED and then adjusting the spot time with the
potentiometer. The set spot time is the time between up and
downslopes that add to the actual time if used. Spot function
SPOT
can be used in 4T, but not with 4T-LOG and Minilog. Spot
function can be used also with synergic pulse but not with
long pulse.
MMA functions are the same as on 'MTL' panel.
Memory functions
SET
There is a possibility to save all the panel settings using the memory feature of the
MTM panel. Up to ten channels can be saved.
ON Note! The SETUP settings are not saved.
OFF SET The memory is activated by pressing the 'MEMORY' - button. 'ON' - LED is lighted
MEMORY CH SAVE and if some data is already saved it can be recalled by selecting the correct channel
(0 ... 9) with 'CH' - button. Empty channels are not shown when in 'ON' – mode.
ch clear ch remote If nothing has been stored only the 'SET' - LED will blink.
When the correct channel is selected welding can be started with the saved parameters. Adjustment of the parameters
already saved can be performed by moving from 'ON' - mode to 'SET' - mode by pressing the ‘MEMORY’ - button.
Technical service manual for Kemppi Master/tig MLS machines Version 1.0 Service
14
MTM panel next
Saving settings:
Press 'MEMORY' – button until 'SET' – LED is lighted. If the 'SET' – LED is blinking it means that nothing has
been stored in this channel.
After setting the values to be saved, starting from the values before entering 'MEMORY', and selecting the
wanted channel and by pressing the 'SAVE' - button the parameters are saved.
It's also possible to directly jump into ‘SET' - mode by pressing the 'SAVE' - button while the memory function is
in off-mode (no LED lights). Then the values currently in the panel can be saved.
Pressing of 'CH' - button for more than 1,5 s will return to channel number '0'.
Channel can be cleared by pressing ‘MEMORY’ - and ‘CH’ - buttons simultaneously in ‘SET’ - mode.
Remote use of channels is possible by pressing the ‘CH’ and ‘REMOTE’ - buttons together when memory is in
‘ON’ - mode. Then the 'bone' control potentiometer will select five channels 1-5. Also torch potentiometer can
control channels 1-5. The corresponding remote LED will blink when activated.
If both remote and torch potentiometer are connected, remote control selects the channels.
The torch up / down switches can control channels 0 – 9 (SETUP A15 to “1”) then blinking ch digit decimal point
indicates activation. If SETUP A16 is “1” then torch remote – mode has to be selected before entering memory.
15
MTX panel
ON
SYNERGIC SPOT
Indicator lights, power control, current and voltage meter, Arc
PULSE SPOT
Force control for MMA, Hot start pulse control for MMA, Up
HF
CONTACT
PULSE
OFF and down slope and gas times, HF / contact ignition selection,
WATER FILL
Local- / Torch control / Remote control –selection, SETUP -
SPOT
function are the same as in MTL and MTM.
MINILOG
4T LOG V %
4T A s Hz 2T / 4T / 4T LOG - selection
2T 4T LOG:
• search arc and tail arc current 5...90%, range can be
RETURN
TIG
PANEL
modified.
PEDAL
Using 4T LOG function
ARC FORCE
PEDAL LO / HI
SETUP Welding with search and tail arc is selected when the LED light
MMA REMOTE
HOT START
GAS TEST
is pointing the 4T LOG symbol on the 2T / 4T / 4T LOG switch.
ch remote
Pulsing is not active during search or tail arc.
MASTERTIG MLS MTM
MTX
TM
ASTERTIG
Torch switch operation is described below:
TORCH
SWITCH
welding current
downslope
upslope
tail arc
search arc
CURRENT pregas postgas
Pressing the torch switch activates the pre-gas if it has been set. The arc ignites after the pre-gas time and the set
search arc current is reached. When the torch switch is released the upslope begins and after that the welding current
is reached, where the machine stays as long as the switch is again pressed starting the downslope to the tail current.
Tail current stays on until the switch is released causing the arc stop. Gas flow is on during the set post-gas time.
Modifications:
Search arc function can be removed in the SETUP by setting SETUP A13 to “1”. Then after the arc has ignited starts
the upslope without search arc. If during the upslope the switch is released the current jumps directly to the welding
current. Before moving to downslope the switch must be released (normally right after upslope) . From this point on
the operation is the same as with search arc on.
Modifications are the same as in MTL and MTM – panels.
16
Panel setup
PANEL SETUP FUNCTION
• Activate SET UP by pressing the "REMOTE"-key >3s

• Led lights go off, only LED´s showing the adjusted parameter are lighted, left display shows A 1
• Entering SET UP layers A to D, press "REMOTE" together with "RETURN" for >3s,
LED lights disappear, only LED´s showing the adjusted parameter are lighted
MOVING BETWEEN LAYERS
• The displayed letter tells to the User / Service the layer and the number tells the parameter to be adjusted.
• Example : A3 means layer A in jumper functions / position 3 TIG Anti freeze ON / OFF
• After entering SET UP move between layers with short press of REMOTE key
• Inside the layer Arrow buttons are used to select wanted jumper
• SET UP value can be setted by using the panel potentiometer
• After changing the layer always the first numbered place is displayed
EXIT SETUP
• To exit from SET UP press >3s on the REMOTE.
• This results that all parameters that were modified are stored in the memory and
the panel functions are back to normal, LED´s light up
• Changes made in SET UP are valid right after Exit
• Exiting from SET UP does not require re-power up except in some special cases like when
’Restoring factory settings'
• Exiting from SET UP can also be performed by switching off the machine but then all
of the changes are lost with out saving and the panel goes back to the state before entering SET UP
* SET UP function includes four layers of special settings where the User / Service can move back and forth.
A layer is for jumper functions, B layer includes some jumper functions and also user changeable deeper level values
C layer is for adjusting minimum limits for panel parameters, D layer is for maximum limits setting
17
Default factory settings are marked with * Layer A

A1 1 Up slope time depends on the set current value
0* Up slope time is constant after setting
A2 1 Down slope time depends on the set current value

0* Down slope time is constant after setting
A3 1* TIG antifreeze on
0 TIG antifreeze off I2
T2 I1
T1
A4 1* MMA antifreeze on A1
0 MMA antifreeze off
I2
I1 T2
A5 1 MMA Hot start pulse time dependent ( no function )

A2
T1
0* Not time dependent
A6 1 TIG slopes to minimum current

0* TIG current at arc stop is an adjustable % of welding current A6
A7 1 No load voltage 40 V ( no function )
0* No load voltage 80 V
A8 1 2T Down slope is cut off by short ( < 0,4 s ) press of torch switch A8
0* Current can be sloped down and up again
A9 1 Tacking automatics ON ( 3 s )
0* Tacking automatics OFF A10
A10 1 Slightly sloped current, arc start at currents over 100 A - 0,2 s
slope from half value if Up slope is 0,0 s )
0* Current goes straight up at arc start A11
A11 1 Non linear down slope
( quick current drop of set % and then linear slope )
0* Linear Down slope A11
A12 1 MMA / TIG change by remote control

( on the first half value of pot TIG, and MMA if above ) T > 0.7s
0* Current setting with the remote control A18
A13 1* Search -arc on
0 Search -arc off
A14 1 Current freezing is possible during down slope and with 4T also with Up slope
0* Not possible
A15 1 Torch up / down switches control the memory channels when memory is on
0* Torch up / down switches control the welding current
A16 1 Torch up / down switches control the current only when selected by REMOTE
0* Torch up / down switches
A17 1* Water cooler flow watch active

0 Not active
A18 1* Normal ending procedure of minilog and 4-takt in MTM panel ( prg A2 onwards )
0 Start of down slope by long press on torch switch and end of weld by releasing the switch
A19 1 Circulation of watercooler is controlled by micro processor ( prg A4 onwards )

0* Continuous circulation
A20 1* Future possibilities

0 Future possibilities
18
Layer B
System -settings
The setting of the most important internal parameters. The values can be changed with the potentiometer.
b1* Setting the contact current:
The current value used in contact ignition can be influenced. Short circuit current during contact.
Factory setting is 20A, can be changed between 10A – 40A.
b2 Setting the HF ignition duration:
Time for HF burst. Factory setting is 1.0s, can be changed between 0.2 – 2.0s.
b3 Setting the downslope cut off level:
By setting the percent value for cut off level, the end current value can be changed (percents of welding current).
Factory setting is 10%, can be changed between 5% – 40%.
Note! To get the set cut off level effective, jumper A6 must be "0".
b4 Current level at ignition:
Sets the start current level when the upslope is used. Setting is a percent value of the welding current.
Factory setting is 20%, can be changed between 5% – 40%.
b5 Recalling factory settings:
The factory settings can be recalled by giving the factory settings the value 1 (the change will be active only
after quitting the SETUP-mode and switching off the power.
If the factory settings jumper is changed back to zero (0) before leaving the setting adjustment, the factory
settings will not be recalled when the machine is switched on the next time.
If the contents of the memory slot are to be saved, but the factory settings should be recalled into display,
the SETUP mode should not be exited with the normal long press of SETUP-button, but the factory setting must first be set
to value 1 and then the machine should be restarted without leaving the SETUP-mode.
If also the content of the memory locations should be cleared, the SETUP-mode should be left with a long press
of ‘REMOTE’ - button and after that the machine must be restarted.
NOTE! Recalling the factory settings will also clear the SETUP-settings.
b6 Interrupted downslope action.
Upslope with: 1 =straight up, *2 =upslope steepness, 3 =downslope steepness
b7 Non-linear downslope current
Percentage of the set welding current where the current starts sloping.
Factory setting is 35%, can be changed between 15% -60%.
B6 B7
* Notice that letter B in a“ 7 segments display “ is shown like b.
19
Layer C / D
Layer C is used for adjusting the minimum settings

Minimum limits for the panel set values for modifying adjustment range.
Moving in the SETUP –layer is done by using the ‘arrow’ - buttons.
The value on welding scheme can be changed with the adjustment potentiometer.
C1 pregas time 0.0s, can be modified 0.0s-2.0s

C2 upslope 0.0s, can be modified 0.0s-4.0s
C3 TIG current 5A, can be modified 2A-14A
Changing the TIG minimum current affects all minimum current values e.g.
pulse base-, Minilog -, tail arc, search arc- current and cut off level of downslope.
C4 MMA current 10A, can be modified 5A-30A
C5 remote current 5A, can be modified 5A-30A
C6 downslope time 0.0s, can be modified 0.0s-5.0s
C7 postgas time 1s, can be modified 0s-10s
C8 spot time 0.0s, can be modified 0.0s-5.0s
C9 pulse frequency 0.2Hz, can be modified 0.1Hz-9.9Hz
C10 pulse base current 5%, can be modified 0%-50%
C11 pulse ratio 10%, can be modified 5%-50%
C12 pulse current 10A, can be modified 2A-200A
C13 search arc 5%, can be modified 2%-30%
C14 tail arc 5%, can be modified 2%-30%
C15 minilog current 10%, can be modified 10%-50%
Layer D is used for adjusting the maximum settings

Maximum limits for the panel set values for modifying the adjustment range.
Moving in the SETUP –layer is done by using the ‘arrow’ - buttons.
The value on welding scheme can be changed by the adjustment potentiometer.
d1* pregas time 10.0s, can be modified 5.0s-20.0s

d2 upslope time 10.0s, can be modified 5.0s-20.0s
d3 TIG current 400/300A, can be modified 100A-400/300A
d4 MMA current 350/250A, can be modified 100A-350/250A
d5 remote current 400/300A, can be modified 100A-400/300A
d6 downslope time, 15.0s, can be modified 10.0s-25.0s
d7 postgas time 30s, can be modified 15s-150s
d8 spot time 10.0s, can be modified 6.0s-15.0s
d9 pulse frequency 300Hz, can be modified 10Hz-500Hz
d10 pulse base current 70%, can be modified 60%-90%
d11 pulse ratio 70%, can be modified 60%-90%
d12 pulse current can be modified from 'TIG maximum current(d3)' to 400/300A,
d13 search arc 90%, can be modified 30%-95%
d14 tail arc 90%, can be modified 30%-95%
d15 minilog base current 90%, can be modified 60%-150%
* Notice that letter D in a “ 7 segments display “ is shown like d.
20
Layer quick view

Arrow-buttons
Upslope Downslope TIGantifreeze MMA antifreeze MMA hot start TIGcurrent at arc No load voltage 2T downslope Tacking Current at arc Downslope MMA/TIG Search Arc Current freezing +/- switches +/- switches acti- Flowwatch MTMDown Water cooler
LAYER 'A': 1=depending on 1=depending on 0=off 0=off pulse time stop. 0=%of 0=70V torch switch automatics start 0=linear change by 0=off function controls the vated. 0=always 0 = not actived -Slope technique control
Setup the current the current 1=on 1=on dependent welding current / 1= 40V funtion. 0=cut off/ 0=off 0=straight up 1=non -linear remote 1=on 0=off / 1=on memory channels / 1=only when 1 = activeted 0 = normal 0 = Automatic
jumpers 0=constant 0=constant 0=off / 1=on 1= min current 1=can be sloped 1=on 1=slightly cut 0=off / 1= on 0=off / 1=on selected by 1 = modified 1 = Manual
(A1) (A2) (A3) (A4) (A5) (A6) (A7) up&down (A8) (A9) (A10) (A11) (A12) (A13) (A14) (A15) 'remote' (A16) (A17) (A18) (A19)
Short press of the 'REMOTE' -button
Setting of contact Setting of HF Setting of Setting of current Recalling factory Interrupted Nonlinear
LAYER 'b': current value ignition duration downslope cut off level of ignition settings downslope downslope
System level 0=normal action: 1=straight current percent
settings 1=recall up, 2=upslope, setting
(b1) (b2) (b3) (b4) (b5) 3=downslope(b6) (b7)
Pregas time Upslope time TIGminimum MMA minimum Remote minimum Downslope time Postgas time Spot time Pulse frequency Pulse base Pulse ration % Pulse current Search arc % Tail arc % Minilog current %
LAYER 'C': minimumsetting minimumsetting current setting current setting current setting minimumsetting minimumsetting minimumsetting minimumsetting current % minimumsetting minimumsetting minimumsetting minimumsetting minimumsetting
Minimum minimumsetting
settings
(C1) (C2) (C3) (C4) (C5) (C6) (C7) (C8) (C9) (C10) (C11) (C12) (C13) (C14) (C15)
Pregas time Upslope time TIGmaximum MMA maximum Remote Downslope time Postgas time Spot time Pulse frequency Pulse base Pulse ration % Pulse current Search arc % Tail arc % Minilog current %
LAYER'd': maximumsetting maximumsetting current setting current setting maximumcurrent maximumsetting maximumsetting maximumsetting maximumsetting current % maximumsetting maximumsetting maximumsetting maximumsetting maximumsetting
Maksimum setting maximumsetting
settings
(d1) (d2) (d3) (d4) (d5) (d6) (d7) (d8) (d9) (d10) (d11) (d12) (d13) (d14) (d15)
A10 = At current over 100A , 0,2s slope from half value if upslope is 0,0s.
A16 = If setting = 0 then torch up/down switches control the welding current simultaneously with the panel, if setting is 1 then up/down switches control the current only when selected by ’REMOTE’.
A18 = If A18 = 1 then current freezing function is not active (A14).
Entering Setup Layer 1: 'REMOTE' - button is pressed for three seconds and the leds go off, only leds showing the adjusted parameter are lighted. Left display shows “A1”.
Entering Setup Layers 1 to 4 (whole Setup): 'REMOTE' - button is pressed together with 'RETURN' - button for three seconds and the leds go off, only leds showing the adjusted parameter are lighted.
• Spot led is blinking if ’contact spot’ is activated.

• Remote led is blinking fast if CH-remote function is activated.
• Remote led is blinking in long intervals if MMA/TIG change by remote is activated.
• The dot is blinking in memory display if +/- swithes are selected to control the memory channels.
21
Mastercool 10
General
For water cooled TIG-torches Mastercool 10 cooling unit is needed. The unit is controlled totally by the power source.
Supply voltage for the pump motor and sensor signals are fed through the bottom plate of the power source.
It is not allowed to extend these wires for using the cooling unit elsewhere than
below the power source for safety and operational reasons.
The pump motor voltage is 400 V coupled through a 3-way plastic connector and a separate lead for protective
earth (yellow – green). Connections for the flow sensor and temperature sensor go through a 6-way connector.
These electrical connections must be made first when installing the unit and they are situated on the bottom
of the power source behind a removable cover plate. This plate is turned 180 degrees and attached again with
the same screws, it won´t be lost when needed. After that the mechanical fixing is done with four M5 x 12 hex socket screws,
two on both sides, delivered with the Mastercool 10 unit. Also a hexagonal key is included in the package.
On-off control
The power source identifies the connection of the water-cooled torch control plug, and the power source will not
start if the cooler is not connected protecting the torch from running dry. 'COOLER' text will be displayed until
the water-cooled torch is disconnected or a cooler is connected properly to the system. If everything is in order,
the cooling unit will start immediately when the torch switch is pressed.
After the welding current has stopped the cooler stays on for four minutes.
Operation of the temperature control
Maximum temperature (60 degrees) is limited with a PTC resistor, which cuts off the welding current if exceeded.
Water circulation and welding will also stop if the control connector of the water-cooled torch is disconnected
or if either of the sockets of the cooler connection is disconnected.
Post circulation time is about four minutes after welding. New start action is required to make a new try.
Operation of the flow control
"Water Fill" function has been added to the TIG panels. When the hoses are empty in the beginning they must be filled
up by pressing this button for about 2 seconds to start the pump. When the water has returned back into the cooler the
signal from the flow watch PTC stops the pump if not stopped by releasing the button before that.
During this filling procedure the text "COOLER" will be displayed on the panel. The pump will always run “blind”
regardless of flow watch status. During post run the ‘water fill’ - button will not stop the run.
If you try to start welding with empty hoses ( as is the case after putting things
together) the machine stops after 5 seconds of arc and the text "COOLER" will
appear on the display. The pump will stay on for about 10 seconds and if the flow
signal is not received during this time the pump will stop. If received the machine
will be ready for welding and the "COOLER" text will disappear from the display.
NOTE : RETURN button clears the COOLER text. T h e Ma st e r c o o l 1 0
22
Torch connection
General
Connecting a gas cooled TIG-torch is performed as in older Kemppi TIG machines, conventional gas-current
is used. The control connector for start signal and the optional remote control signals are specially arranged for
Mastertig MLS. The old Kemppi TTM 13, 15, 15S, 22, 22S –type torches fit and an optional adapter can be used to
adapt to the new system. For connecting older water cooled torches a special adapter is also needed, see page 3.
TTC 200W and TTC 250W are designed to be used with Mastertig and Mastercool units.
A special TIG torch TTC 220 GV with a start switch and remote control on the torch has been developed to be used
with MEL panel and Master MMA power source in TIG. Any other torch for scratch start TIG can also be used
with MEL. Connection uses similar DIX-type connectors as used in MMA welding for current and the gas hose is
coupled directly to the bottle.
Torch functions and control connector
A start-switch is a standard function. In addition, for current control a possibility to install a potentiometer or two switches,
with current up/down control, is provided. This is done with two alternative function sections fitted to torch RTC 10
and RTC 20:
RTC 10
Potentiometer unit RTC 10 for TTC torches is selected into use from the panel when the TIG torch control symbol
is lighted. Welding current adjustment or selection of five memory channels can be performed. If both the hand remote
control and torch potentiometer control are connected simultaneously the hand remote will control the channels and the
torch will control the current.
RTC 10 current regulator start-switch
water cooled torch identification loop
RTC 20
RTC 20 unit for TTC torches
Up - down switches adjust the welding current in steps, 6 % per 120 ms up and 10 % per 120 ms down.
Also all the memory channels can be selected using up / down switches when activated in SETUP (A15) and when
memory function is in 'ON' position.
RTC 20 start-switch
switch 1 switch 2
Torch control connector is a 7 way
socket, Amphenol type with clocking
preventing illegal connections.
* For torch signals see chapter Remote control lines page 24.
water cooled torch identification loop
23
Remote control lines
Remote controlling
Remote control connectors are split into two parts.
Z003 1) is present on Master and Mastertig machines. This is the connection for normal remote controllers like
handcontrollers and footpedals. Traditional R10 type remotes can be used directly.
Footpedal R11F uses the signal system described below. Pedal min/max settings are in panel.
Slopes are switched off when a pedal is connected and it works only in 2T mode. Ignition is made with 20 A current.
Z005 2) is present only in Mastertig machines. This connector is used for torch remote commands like : start
up / down regulation and checking a watercooled torch.
Both are 7 Pole Amphenol connectors. To avoid conflicts between the torchconnectors, Z005 is mounted in 45° angle.
Also a C110T type wireless remote can be used.

When a remote control device with a potentiometer is disconnected, the panel will revert to panel control.
PIN VALUE CONNECTOR

A ………………… Gnd ……………………………..… A001 X12/9
A F B Spare A001 X12/4
G C ………………… +24V DC Supply voltage ……….. A001 X12/10
B E D Pedal start If + 5V A001 X12/2
C D
Z E ………………… Pot 0-5V ( Memory channel ) ….. A001 X12/5
0
0 F Spare A001 X12/11
3
G ………………… + 5V DC .......................…………. A001 X12/3
Master 2500 & 3500
A ………………… Gnd ……………………………..… A001 X12/9

A F
B Spare A001 X12/4
G
B E C ………………… +24V DC Supply voltage ……….. A001 X12/10
Z D Pedal start If + 5V A001 X12/2
C D 0
0
E ………………… Pot 0-5V ( Memory channel ) ….. A001 X12/5
3 F Spare A001 X12/11
G ………………… + 5V DC .......................…………. A001 X12/3
E
F D
G A ………………… Gnd ……………………………..… A003 X5/1
B Sw1 Up If + 5V A003 X5/2
A C
Z C ………………... Sw2 Dwn If + 5V ………..…….. A003 X5/3
0
B 0 D Torch start If + 5V A003 X5/4
5
E ………………… Potentiometer 0-5V ……………… A003 X5/5
Mastertig F Water torch detect If + 5V A003 X5/6
2500(W) & 3500(W) G ………………… + 5V DC ……………………….… A003 X5/7
Connection for automated or robot welding

Normal remote control socket, pin E, can be used to set the current reference given by robot controller, see the table for
signals. Voltage range is 0.0 – 5.0 V . ‘Start’ signal is at pin D on the same socket. ‘Arc established' signal with transistor
switch and connection points for external relay (X13 = +24Vdc and X14 = open collector) for 0,5mm2 leads on
control card A001 are also provided as a feedback channel to an automated- or robotcontroller.
1
Z003 input lines are filtered by ferriet L004 beforegoing into the A001 board.
2
Protection of HF shortcuts are filtered by LC networks on the A003 board.
24
Main circuit
General
Master(tig) MLS 3500 and 2500 are power sources meant for MMA and TIG welding with both DC current and
DC pulse current methods. They are inverter power sources. The primary inverter has been carried out by using
IGBT technology and the operating frequency in all the power sources is 20 kHz.
The functions of these machines are controlled by one or two micro controllers and this means that the welding
characteristics are controlled programmably. There is invariably one micro controller in the current source and sometimes
the front panel has a controller too. The front panel and the frame of the machine itself are separate products and the
customer can choose a front panel best suited for his needs. Also the machine works without panel as an MMA-machine
with a remote control and factory settings of arc force and hot start.
The system consists of several circuit boards and separate conponents. The boards and components vary according to
the construction and the size of the power source (mma/tig and 3500/2500).
First we present the separate components and later the circuit boards will be presented in following sections.
Overvoltage spikes protection and main switch

(R002, S001)
The group of three varistors (R002) forms an overvoltage clamp for low energy level voltage spikes. The varistors
are not on the circuit board because in case of a long time over voltage they can be destroyed violently (which means
destruction of a circuit board too if located on one). Note; varistors are before main switch and there is voltage in the
varistors even if the main switch (S001) is off.
Saturable choke, main transformer and choke for voltage reserve circuit
(L003, T001, L002)
Saturable choke (L003) is intended to reduce IGBTs anti parallel diodes reverse recovery currents and thus
power loss of IGBT module also. Together with a snubber (located in main circuit board Z001) circuit it reduces
the voltage stress of the IGBT.
Main transformer (T001) has two parallel primary windings (9 turns) and two parallel and two serial secondary
windings (2+2 turns). On secondary side there are also small extra windings (1+1 tunrns) for the voltage reserve circuit.
Turns ratio is 4.5 in the 3500 device and 5 in the 2500 device. The transformer is made by using liz wire and
U59 ferrite cores. Choke for voltage reseve circuit (L002) limits the current of extra secondary windings
to acceptable level (below 20A).
Secondary choke
(L001)
The secondary choke reduces the ripple in the secondary current. The value of inductance is quite small
and it will saturate aproximately in 120A current level. There is no need for ripple reduction in bigger current levels.
Output RFI filtering

(RC001, C001)
The varistor and capasitor circuit is made to reduce radio frequency interference (RFI) and to produce protection
against TIG ignition spark.
25
Main circuit next
Overheat protection
(RV101,RT101,RL101)
The main transformer, secondary choke and IGBT units are protected against overheat by PTC resistors. Switching
temperatures are shown in the appendix.
Cooling fans
(M001, M002)
There are two cooling fans in the 3500 device and the 2500 device has only one. The flow direction of cooling air is from
back of device to front.
Interference protection and damping chokes

(L004, L005, L006)
The purpose of those three chokes is to reduce TIG ignition spark interference activity inside the machine. Second function
of L005 is to reduce conducted electro magnetic interference to utility network.
Shunt resistor
(R001)
Secondary current of the machine is measured by the shunt resistor. The value of the resistor is 200 uV/A.
Tig devices only
Tig spark transformer

(T002)
Tig spark transformer is made by using U59 ferrite cores. The transformer has one primary turn and seven
secondary turns. It is located in the cooling air channel and thanks to this, its size is reduced (compared to still air solution).
Gas magnetic valve

(Y001)
The gas magnetic valve is of traditional type, and it is controlled by the micro controller via TIG inginition spark card.
26
Main circuit boards
EMI filtering
(Block 1)
This block is an EMI-filter (Electro Magnetig Interference) which is formed by capasitors and inductors (C-L-C-L).
The purpose of the circuit is to reduce conducted electro magnetic interference (EMI) to utility network below
borders which are specified in the norm EN50199.
Rectifier
(Block 2 )
Three phase rectifier unit rectifies main voltage to DC-link voltage which can vary between (450...690)Vdc in the
normal operation condition of the power source.
Startup overvoltage damping

(Block 3)
In start situation overvoltage may occur due to LC resonance oscillation (the leakage inductance of utility network
versus dc-link capasitors). The purpose of this circuit is to damp the oscilation and prevent excess
DC-link voltage. The high equivalent serial resistance (ESR) of electrolytic capasitors is used as a damping
resistance.
Power state
(Block 4)
The power state is a traditional half bridge circuit. DC-link voltage is divided to half by working capacitors (CZ110-115).
Power switches are formed by using IGBT half bridge modules (100A or 150A/1200V in 250A/350A power
source accordingly).
Snubber circuit
(Block 5)
Snubber circuit reduces LC oscillation (main tranformers leakage inductance versus stray capacitance) after
IGBT turn off. It also reduces the voltage stress of the IGBT module.
27
Main circuit next
Main secondary rectifier

(Block 1)
The circuit is a full wave rectifier which rectifies the main secondary current. There are (9+9) diodes in parallel in
the 3500 device and (7+7) in the 2500 device. Snubber circuits are made by using CZ1/RZ1 and CZ5/RZ10. The snubbers
reduce the voltage stress of diodes after reverse recovery current snaps off (the voltage stress is caused by
leakage inductance and stray capacitance oscillation). Varistors RZ2/RZ8 are for TIG ignition spark protection.
Secondary diodes are plastic stud diodes ( 30 A, 600 V ). Master 3500 = 9 + 9, Master 2500 = 7 + 7
Diode set part number 4297990 ( 9 pcs ). Diode set part number 4297980 ( 7 pcs )
Voltage reserve circuit

(Block 2)
Circuit for voltage reserve rising. Diodes VZ20/VZ10 rectify currents produced by the extra windings of
main transformer. The circuit elevates secondary voltage in the small secondary current (<40A). There are also snubber
circuits and VDR protection against TIG ignition spark (analogy with block 1).
Machine size coding

230 V (Block 3)
AC
Zero resistors are installed for machine size coding according
to the table in the appendix.
No load voltage auxiliary circuit

(Block 4)
No load voltage auxiliary circuit. The circuit is like

175 V a peak value indicator. In no load condition the
AC current source controls secondary voltage and reduces
duty cycle to minimum.
175 V
AC
Appendix
With minimum duty cycle the magnetization

current of the main transformer is low, so ferrite
230 V losses are low (there is no need to switch the fans on).
AC The losses of main transformer are at minimum which
means very low open circuit power (< 20 W).
28
Layout of the boards 1/2
A001 & A002

Ptcs tripping voltage
is 1,5V or higher.
Three serial ptcs
are connected between
X3/1 and X5/2
+
Digital interface between V
panel and powersource. _
X10
SPI- & PARALLEL BUS X3 X4 X5 X8 X9 X3 X4 X5
Secondary overvoltage
X6 H3 Fan voltage 24VDC
+
Service connector :
For program updating V_
ST 7
and storing settings.
SCI- & ISP BUS X8 or X9
X11 X20
X21
Service connector
X18 Board supplies
X19
Feedback control
jumpers
H1 H2 Primairy control
A001 R51
IGBT1 puls IGBT2 puls
Basic frequency
Remote control IGBT gate connections
input lines X1 X2
X12 X7 16 pole flatcable connection
to PCB A003 for Tig
control in mastertig MLS
A001 Master / tig MLS ( Control power source )
Output supply for

boards internal &
input voltage control
X2 A002
5V X3
H1
- 580V
24 V 580V DC direct from

H2 primary rectifier.
LED Output This supply is converted
16V + 580V
into 24V / 16 / 5V output
control for DC H3 X1
internal voltages
A002 Master / tig MLS ( Auxiliary power )
29
Layout of the boards 2/2
A003 & P001 16 pole flatcable connection

to board A001. Tig control
in Mastertig MLS
X1 Gas valve 24VDC

Torch remote lines X5 +
X4 V_
A003
X4
Power supply for HF, Current protection

directly from T001 for cooler pump
secondary side.
CCW
INCREASE
Primary side HF Input for cooler

transformer HF voltage 2~ 400V AC
X3 L1 L2 cooler
X2 R48
X13 X PTCs connection
10 X11 to cooler
Power supply
to cooler
A003 Mastertig MLS ( TIG control and HF )
X1 X2
Service connector
Service connector : ST7

For program updating
and storing settings.
SCI- & ISP BUS * Digital interface between
panel and power source.
SPI- & PARALLEL BUS
P001
* Pictures may vary according to the panel type used.

P001 Master / tig MLS ( 4 types of panels )
30
Connectors & pins
A001 general connector A003 board connector *
X10/1 +24Vdc X1/1 tig ignition spark control

X10/2 +16Vdc X1/2 gas magnetic valve control
X10/3 +5Vdc X1/3 the water pump control of cooler
X10/4 gnd X1/4 tig start button
X10/5 dc-link voltage measure X1/5 water flow indicator (analogical signal)
X10/6 auxiliary power supply pwm measure X1/6 water over temperature indicator
X10/7 machine size identification 1 (analogical signal)
X10/8 machine size identification 2 X1/7 water torch recognition
X10/9 gnd X1/8 additional tig switch 1
X10/10 secondary voltage X1/9 additional tig switch 2
X10/11 not used X1/10 torch potentiometer
X10/12 not used X1/11 not used
X1/12 not used
X1/13 +5V
A001 panel connector ( spi / parallel bus ) X1/14 +24V
X1/15 gnd
X6/1 hot start potentiometer (mel) X1/16 gnd
X6/2 arc force potentiometer (mel)
X6/3 current reference potentiometer (mel) A003 connectors
X6/4 digit selector for hundreds (mel)
X6/5 digit selector for tens (mel) X2/1-2 power supply to spark generator
X6/6 master in slave out MISO (tig panels) X3/1-3 voltage to spark transformer
X6/7 digit bit 3 (mel) X4/1-2 gas magnetig valve
X6/8 acknowledgemet to panel/panel or
remote switch (tig panels/mel) A003 tig torch control connector
X6/9 digit selector for ones (mel)
X6/10 digit bit 2 (mel) X5/1 gnd
X6/11 digit bit 0 (mel) X5/2 torch switch 1
X6/12 clock singnal from panel (tig panels) X5/3 torch switch 2
X6/13 digit bit 1 (mel) X5/4 tig start switch
X6/14 master out salve in MOSI X5/5 torch potetiometer
decimal point control (tig panels/mel) X5/6 water torch recognation
X6/15 +5V X5/7 +5Vdc
X6/16 gnd X5/8 not used
X5/9 not used
X5/10 not used
A001 service isp / sci connector X5/11 not used
X5/12 not used
X11/1 gnd
X11/2 data signal (isp) Z001 Connectors
X11/3 gnd
X11/4 clock signal (isp)
X11/5 enabled signal (isp) XZ101...103 main utility network
X11/6 reset signal (isp) XZ104...105 the pump motor of cooler unit
X11/7 +5Vdc XZ107...108 auxiliary power supply
X11/8 select signal (isp)
X11/9 transmitted data (sci) Z002 Connectors
X11/10 received data (sci)
XZ201 and 204 "voltage reserve choke"
XZ214 and 215 the connection terminals of "voltage reserve choke"
A001 other connectors XZ212 and 213 the power supply of tig ignition spark generator
XZ202 and 203 main secondary curret path to rectifier
X1/1-2 upper igbt gate drive XZ205 and 206 rectified secondary current to the secondary choke
X2/1-2 lower igbt gate drive XZ207 the gnd connection of the no load
X3/1-2 igbt module's heatsink ptc 090ºC voltage auxiliary circuit
X4/1-2 main transformer ptc 140ºC XZ208-209 & 211 machine size coding
X5/1-2 secondary choke ptc 120ºC
X8/1-2 cooling fan 1 +24VDC 1=+
X9/1-2 cooling fan 2 +24VDC 1=+ Z003 Connectors
X1 Remote lines Direct connected to A001 / X12

A002 Connectors A=9 B=4 C=10 D=2 E=5 F=11 G=13
X1 dc-link voltage (+)

X3 dc-link voltage (-) Z005 Connectors
X2/1 +24Vdc
X2/2 +16Vdc X1 Torch connection Direct connected to A003 / X5
X2/3 +5Vdc A=1 B=2 C=3 D=4 E=5 F=6 G=7
X2/4 gnd
X2/5 dc-link voltage measure
X2/6 auxiliary power supply * Note : Connector P001 X2 = X6 in A001, A003 X1 = X7 in
pwm measure (for fast shutdown) A001, P001 X1 uses same signals as X11 in A001.
31
Troubleshooting
Before you start
WARNING ! 400V AC 50/60HZ and

580 V DC or higher
inside the machine
WATCH OUT FOR THE MAINS VOLTAGE!
DISCONNECT THE POWER SOURCE FROM MAINS VOLTAGE
BEFORE REMOVING COVER PLATES OR ANY TESTING OR MEASUREMENT.
DANGEROUS DC VOLTAGE STILL EXISTS AFTER REMOVAL OF

INPUT VOLTAGE. WAIT AT LEAST TWO MINUTES FOR DISCHARGING THE MACHINE.
General
This troubleshooting information is a direct link to problems that may occure in the field.
Analyzing the problem tells us that in many cases wrong conclusions are made.
To save time, handle the standard checkpoints first:
Always check the "simple" things first :
Is there a stable 3~ 400V AC input inside the machine ?

Are there any breaks in the cables ?
Are the cables and the torch correctly connected ?
Is the machine in the shut down mode ?
Are your settings OK ?
Are there any loose components ?
Never forget to get a right MACHINE FAILURE DESCRIPTION !
Troubleshoot chart
The troubleshoot chart is a simplified flowchart referenced to different tables.
The tables show a possible cause and the right solution for it.
Charts are split up in MMA models, TIG models and the Cooling unit.
Measurement tools
Most of the measurements on the Kemppi Master/tig MLS machines can be done with a normal DMM.
( DMM = Digital Multi Meter ). To get the right value for your measurements it is neccessary that you
take care of the specs of your DMM. Look at the ratings for AC voltage ranges.
For measurements in the powercircuit you need a DMM wich can measure a frequency of
minimal 20 KHz true RMS. Frequency in auxilary power card is approx. 60 Khz
Using a DMM with lower frequency range, can result in totally different values.
Kemppi tools
Some special measurement tools are available at the Kemppi Subsidiary.
Contact your subsidiary to what is available at the moment.
Special instructions for mounting parts are delivered inside the spare part box!
32
START HERE
MMA models
SWITCH ON THE MACHINE troubleshooting
OFF
ON
No
DOES THE DISPLAY Follow Checkpoint MMA1
LIGHT UP ?
Yes
IS THE OUTPUT No
VOLTAGE OK ?
Follow Checkpoint MMA2
Yes
IS THE OUTPUT No
Follow Checkpoint MMA3
CURRENT OK ?
Yes
IS THE MACHINE Yes

IN SHUTDOWN ? Follow Checkpoint MMA4
MODE
No
IS THERE Yes
ANOTHER PROBLEM ? Follow Checkpoint MMA5
No
PERFORM A TEST WELDING
See MMA Reference Table on page 34&35
33
MMA models
troubleshooting 1/2
MMA Checkpoint Reference Table
No Possible cause Solution
# Blown fuses in the main supply power >> Check all three supply voltage phases for
blown fuses. Replace if needed.
>> Faulty component on the primary side of the machine.

Check the condition of the following components* :
- Main switch.
- Primary rectifier.
- Igbt.
- PCB for burn components. Replace if needed.
1
# Broken auxiliary powercard A002 >> Check the output LEDs on the power card A002.
All leds must be lighted.
Replace the PCB A002 if needed.
# Bad main supply cable or mains plug >> Check for loose wires in the mains plug
Replace the cable or the plug if needed.
# Wrong feedback signals from output power >> Check feedback wires on the output + and - terminals.
+ wire goes directly from X002 into X10/9 on PCBA001.
- wire goes from the shuntresistor R001 ( +/brown ) into
X12/6 on PCB A001.
2 # Faulty control card A001 >> Faulty pwm control on PCB A001.
Replace if needed.
# Secondary shortcut overload >> Shortcut in the welding cables circuit

Check the welding cables circuit connections.
# Secondary rectifier malfunction >> Shortcut or open diodes in the secondary rectifier on
PCB Z002.
Replace if needed.
# Wrong feedback signals from output terminals >> Check feedback wires on the output + and - terminals.
+ wire goes directly from X002 into X10/9 on PCB A001.
- wire goes from the shuntresistor R001 ( +/brown ) into
X12/6 on PCB A001.
3
# Faulty control card A001 >> Faulty pwm control on PCB A001.
Replace if needed.
# Secondary shortcut >> Shortcut in the welding cables circuit

Check the welding cables circuit connections.
>> # NEXT ON PAGE 35 ...................................................................................................................................................>
* Contact KEMPPI or the nearest KEMPPI authorized servicepoint for more information !
34
MMA models
troubleshooting 2/2
MMA Checkpoint Reference Table
# Wrong input voltage >> Check all three supply voltage phases.The voltage
must be similar to the voltage input ratings
>> Check the connections inside the mains plug.

In a four wire network the blue wire is also phased
and not the neutral line.
>> Bad mains supply cable.

Replace if needed.
# Inside temperature is too high >> Tripping temperature is reached in normal situation.
Reason for this can be:
- Too heavy load for the machine. See the output

ratings of the machine. The ED is based on 40ºC
- Machine is closed up. Be sure that the machine is
is placed so, that the ingoing air easily flows into
4 the machine.
- The machine is very dirty. Heat exchangers of
the powerparts don't work properly, if they are
too dirty. Cleaning up these machine parts will help.
>> Check the rotating fans at higher loads.

The fan(s) must rotate after the welding has stopped.
If not, check the following parts :
- Disconnect the fan(s) from the PCB A001

and check them. The fans working voltage is 24 V DC.
If OK check the next shooting.
# PTC malfunctions >> Check the PTCs cut-off voltage. Measurepoint :

PCB A001 X3/1 & X5/2 ( see page 029 ). Above
1,5VDC the machine is behaving in cut-off mode*.
In an ambiance of 18ºC the resistances of the PTCs
are 100Ω separately.
# Remote control unit doesn't work properly >> Defective remote control unit. Check the signals
in the connector according to the signal levels given
on page 24. Values are 0-5V DC.
>> Broken panel or PCB A001

Remote switch on the panel is broken. Replace
if needed. Control card A001 is not recognizing
the remote control unit. Replace PCB A001 if needed.
5
# Short breaks in welding, input led blinking >> Unstable mains supply input voltage.
When more power is needed during welding
( like in slow pulse mode ) the mains supply voltage
decreases so much that it reaches the under
voltage limit. Often too long or bad mains cables are
used. Check the incoming voltage inside the machine.
# Strange sounds coming out of the machine >> Strange sounds coming out of the machine can be the
result of a moisture or very dirty envoirment. Cleaning
and drying the electronics often helps.
* The expression "Cut-off" stands for the shutdown of the machine.

This happens in cases of overheating, overloading and wrong mains supply.
35
START HERE
TIG models
troubleshooting
SWITCH ON THE MACHINE
OFF The Tig part is based on the powerpart of the MMA power source. If there are
ON some disturbance in the powercircuit, the Tig part will react on this problem.
Therefore always check first the machine in MMA mode for any disturbances !
No
DOES THE DISPLAY Follow Checkpoint TIG1
LIGHT UP ?
Yes
ARE THE No
PANEL FUNCTIONS Follow Checkpoint TIG2
OK ?
Yes
ARE THE TORCH No

FUNCTIONS Follow Checkpoint TIG3
OK ?
Yes
DOES THE HF Yes

WORK OK ? Follow Checkpoint TIG4
No
IS THERE Yes
ANOTHER PROBLEM ? Follow Checkpoint TIG5
No
See TIG Reference Table on page 37&38
36
TIG models
troubleshooting 1/2
TIG Checkpoint Reference Table
1 # General problem in the powersource >> Start troubleshooting MMA machines (page 33)
# Broken panel flatcable >> Replace the panel to check the functions.
# Some function switches are not working >> Broken panel switches. Check the plastic
switch adapter placed between the panel sticker
2 and board switch. Replace the panel if needed.
# Only LEDs are lighted. >> Seven segment drivers are faulty.
Red digit display will not light up Replace the panel if needed.
# Panel software doesn't run ok. >> Reset the panel by resetting to the factory settings.
Use "jumper" b5 for recalling factory settings. Update
panel software if neccesary. Replace panel if needed.
# Machine doesn't react on the torch contact >> Broken torch contactlines or switch.
Repair or replace the torch if needed.
>> Faulty control card A003.

Replace if needed.
# Machine can't be switched to torch remote >> Broken torch contact lines or potentiometer.
3 Repair or replace the torch if needed.
>> Faulty control card A003.

Replace if needed.
# Display shows the output voltage but the >> Broken gas/current cable in the torch. ( TTC Type )
torch doesn't start welding. Repair or replace the torch if needed.
HF is ok. There is no weld-
current in contact tig
>> Broken contact in the welding power circuit. Check
the power cables and earth clamp for loose contacts.
# HF is missing or too weak >> Malfunction on PCB A003.

HF spark adjustment is controlled by trimmer R48.
Replace PCB A003 if needed.
>> Broken HF transformer T002.

Broken ferriet or windings in the HF transformer.
Replace T002 if needed.
>> HF leakage through components .

4 HF leakages can go to chassis.
Bad or dirty terminal outputs or bad
filtering capacitors on the chassis.
>> Shielding gas is missing or not enough gasflow.

Check gasflow. Leakage in the torch or bad
gas solenoid.
>> # NEXT ON PAGE 38 ...................................................................................................................................................>
* The expression "water cooled torch" stands for a liquid cooled torch.
37
TIG models
troubleshooting 2/2
TIG Checkpoint Reference Table
# HF is conducted to the gasnozzle >> Bad or old wolfram electrode.

Change the electrode if needed.
4
# HF is conducted to the torch body >> Bad condition of the torch.
Repair or replace the torch if needed.
# Standard remote control is not working >> Check wires and potentiometer connections.
Check remote terminal supply voltage:
A = 0V, G = 5VDC , E = 0-5VDC.
Replace A001 if needed.
# Welding quality is bad : >> One phase in the mains supply is missing or
• Arc is not stable mains cable is cut or loose inside the plug.
• Bad arc start
• Less HF power
• Lack of power >> Faulty main switch S001 or primary rectifier VZ101.
• Porisity in the weld Replace if needed.
>> Faulty commutation/buffer capacitors on PCB Z001.

Replace PCB Z001 if needed.
>> Blown diode(s) in the secondary rectifier card

Z002. Replace PCB Z002 if needed.
5
>> Shielding gas is missing or gas leakage in the Tigtorch.
Check gasflow and solenoid valve.
Repair or replace if needed.
>> Broken contact in the welding power circuit.

Check the power cables and the earth clamp
for loose contacts.
# Occasional disturbances during welding >> Faulty torch contact in the Tigtorch.
The arc is stopping intermittently Replace if needed.
>> Broken or faulty Tigtorch.

Loose wires in the Tigtorch.
>> Bad contact in the remote terminal Z005.

Repair or replace if needed.
# The program is not following the >> Panel software is not running ok.
adjusted parameters Make a hardware reset by panel setting b5.
Update panel software if neccesary.
Replace panel if needed.
38
START HERE
Mastercool 10
SWITCH ON THE MACHINE
troubleshooting
OFF
ON
No
DOES THE DISPLAY Follow Checkpoint COOL1
LIGHT UP ?
Yes
DOES "COOLEr"
TEXT APPEAR ?
Yes
DOES THE PUMP No

START MANUALLY ? Follow Checkpoint COOL2
No Yes
IT APPEARS Yes
DURING WELDING Follow Checkpoint COOL3
IS THERE Yes
ANOTHER PROBLEM ? Follow Checkpoint COOL4
No
See TIG Reference Table on page 40&41
39
Mastercool 10
troubleshooting 1/2
COOL Checkpoint Reference Table
1 # General problem in the power source >> Start troubleshooting MMA machines ( page 33 ).
# Coolers electric connections are bad >> Check the electrical connection between power source
and cooling unit. Connectors must be placed in
X10 and X11 on PCB A003.
# Gas cooled torch is connected >> If a cooling unit is installed a watercooled torch*
MUST be connected. Water cooled torches are
marked with the "W" extension.
# Identification watercooled* torch is missing >> Check the direct link on pin G and F inside
the torchconnector. It is directly soldered.
# Start capacitor C001 is bad or broken >> Check the C001 conditions.
Use a multimeter for capacitance and
resistance measuring.
It has to be the value printed on it. Replace if needed.
# Pump doesn't rotate properly >> The pump is dirty inside.

Try to rotate by hand Open the pumphouse and clean all parts.
Normally it gives a little bit resistance Check also the tank for dirty elements.
2
# Pump motor uses too much current >> Check the output voltage on X10/2 and X10/3
on PCB A003. If it is less then 200V AC it is
proteced by PTC on PCB A003.
>> Check PCB A003 for bad PTC group. ( R40 etc )
>> Pump is dirty inside.

Open the pumphouse and clean all parts.
Check also the tank for dirty elements.
>> Bad start capacitor C001
# Bad temperature- or flowsensors >> Check the resistances of the temp. and flow PTCs
In an ambiance of 18ºC the resistances are :
Flow : Blue / R001 40Ω - 60Ω
Temp : White / R002 60Ω - 80Ω
>> Bad contacts in connector X11 on PCB A003.

Bad contacts in connector XW201
from the cooling unit.
Replace the connectors if needed.
# Broken panel and / or panel switch >> Replace the panel if needed
3 # NEXT ON PAGE 41...................................................................................................................................................>
* The expression "water cooled torch" stands for a liquid cooled torch.
40
Mastercool 10
troubleshooting 2/2
COOL Checkpoint Reference Table
# Disturbances in the cooling circuit >> Returning coolant is too hot.

Stop welding but don't switch off the machine.
After a while the system has cooled down.
Be aware of using the right torch for your
needed current.
>> Leakage in the cooling circuit.

Some leakage in the cooling circuit is the reason
that there is a flow less than 0,5 Liter / minute.
>> Blockage in the cooling circuit.

Some blockage in the cooling circuit is the
reason that the flow is less then 0,5 Liter / minute.
Problem can be inside the torch. Replace if needed.
3 Problem can be inside the heat exchanger of the
cooling unit. Replace if needed.
>> Air bubbles in the cooling circuit.

Air bubbles in the cooling circuit can make problems.
Specially after replacing elements that are part of
the cooling circuit. Air bubbles are the reason
that there is less then 0,5 Liter / minute detected
while these bubbles are passing the flowsensor.
# Incorrect temperature- or flowsensors >> Check the resistances of the temp. and flow ptc
In an ambiance of 18ºC the resistances are :
Flow : Blue / R001 40Ω - 60Ω
Temp : White / R002 60Ω - 80Ω
>> Bad contacts in connector X11 on PCB A003.

Bad contacts in connector XW201
from the cooling unit.
Replace the connectors if needed.
# Leakage inside the cooling unit >> Bad rubber seals inside the cooling unit.
Replace if needed.
>> Blockage inside the heat exchanger.

In some cases it's possible to unblock the
circuit with some air pressure.
4 >> Leakage in the heat exchanger.
Replace if needed.
>> Pump sealing.

Leakage at the axle between motor and pump.
Repair with a repairing set.
Replace the pump if needed.
Spare
41
NOTES
Master/tig MLS
Service manual
For Master/tig MLS Series
KEMPPI OY
P.O. Box 13
FIN – 15801 LATHI
FINLAND
Tel. : +358 3 899 11
Fax. : +358 3 899 428
www.kemppi.com
DOCUMENTATION
Reference materials by Tuomo Mattila,

Pekka Mäkisalo, Marko Tuomi
Paul van Steenpaal
Document design by Paul van Steenpaal,
Sami Lehtinen
Produced by Kemppi Service Department
E-mail : service@kemppi.com
The information contained in this document is subject to change without notice.

Service manual for Kemppi Master/tig MLS machines
Release 1.0
Service

SM MLS V1.0en

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KEMPPI CUSTOMER SERVICE / SERVICE DEPARTMENT

Service manual Master/tig MLS Series

The information contained in this document is subject to change without notice.

Service manual for Kemppi Master/tig MLS machines

• Master MLS 2500/3500 …...……………………………………………... 42

Master(tig) MLS family

Powers sources & cooling units

Type : Mastercool 10 Master 2500 MLS Master 3500 MLS

Type : Mastertig 2500 MLS Mastertig 3500 MLS

Type : MEL Panel MTL Panel MTX Panel MTM Panel

Torches & remote control units

Type : TTC Torches R11F R10 RTC 10 RTC 20

Transport units & accessories

Type : T200 T110 Water/current adapter Control adapter

• Totally digital microcontrolled panel and microcontrolled power source

• Cooling unit totally controlled by power source and panel

• Good protections against overloading

• TTC torches with fine remote controlling

Kemppi Unique ICS™ technology

MASTER MASTER MASTERTIG MASTERTIG MASTER

Mains voltage 3~50/60Hz 400V 400V 400V 400V

Connection cable 4X2,5mm2 - 5M 4X2,5mm2 - 5M 4X2,5mm2 - 5M 4X2,5mm2 - 5M

Open circuit power 10W 10W 10W 10W

Degree of protection IP 23C IP 23C IP 23C IP 23C IP 23C

External demensions length 500 mm 500 mm 500 mm 500 mm 500 mm

Voltage supply for cooling

Air cooled torches

Length 4m 627013004 627013104 627016004 627016204 627022004

8m 627013008 627013108 627016008 627016208 627022008

16 m 627013016 627013116 627016016 627016216 627022016

DC- 40 %ED 130 A 130 A 160 A 160 A 220 A

Electrode sizes to be used Ø 1.0…2.4 1.0…2.4 1.0…2.4 1.0…2.4 1.0…3.2

Cooling air air air air air

Gas/current R1/4 R1/4 R1/4 R1/4 R1/4

Liquid cooled torches

Length 4m 627020504 627025504 627025704

8m 627020508 627025508 627025708

16 m 627020516 627025516 627025716

100 %ED 200 A 250 A 200 A

Electrode sizes to be used Ø 1.0…3.2 1.0…4. 1.0…4.0

Cooling liquid liquid liquid

min. 1 l/min min. 1 l/min min. 1 l/min

In inlet: In inlet: In inlet:

max 50°C max 50°C max 50°C

min 1bar min 1bar min 1bar

Gas/current R1/4 R1/4 R1/4

Water snap snap snap

Indicator lights at panel upper section

MMA – Table for correct welding current selection

Indicator lights on panel upper section

TIG Up and down slope time control and display

Adjusting welding parameters (applies to all MLS TIG panels)

MTL panel next

Operation of the 2T-function:

PREGAS POST GAS

MTL panel next

• slope times vary with current / times as set (A1, A2)

Operation of the ”traditional” 4T-function:

short or long short or long short short or long long

MTL panel next