Kemppi Master M 205 User manual

Master M 205, 323
Operating manual - EN
Master M 205, 323
© Kemppi 11922130 / 2313

Master M 205, 323
Operating manual - EN
CONTENTS
1. General 4
1.1 Equipment description 5
1.2 Master M 205 and 323 devices 6
1.2.1 Wire feed mechanism 7
1.3 Master Cooler 05M cooling unit (optional) 8
2. Installation 9
2.1 Installing power source mains plug 10
2.2 Installing cooling unit (optional) 11
2.3 Installing equipment on cart (optional) 13
2.4 Connecting welding gun 17
2.5 Connecting earth return cable 18
2.6 Installing and changing wire (200 mm spool) 19
2.7 Installing and changing wire (100 mm spool) 24
2.8 Installing and replacing feed rolls 26
2.9 Installing and replacing wire guide tubes 28
2.10 Installing gas bottle and testing gas flow 29
3. Operation 31
3.1 Preparing welding system for use 32
3.1.1 Preparing cooler 33
3.2 Calibrating welding cable 35
3.3 Using control panel 36
3.3.1 Control panel: Main view 37
3.3.2 Control panel: Memory channels 39
3.3.3 Control panel: Welding process 39
3.3.4 Control panel: Trigger logic 40
3.3.5 Control panel: Weld Assist 41
3.3.6 Control panel: Welding parameters 42
3.3.7 Control panel: System settings 44
3.3.8 Control panel: Weld data 45
3.4 Additional guidance to functions and features 47
3.4.1 1-MIG 47
3.4.2 Pulse welding 47
3.4.3 MAX Cool process 47
3.4.4 Trigger logic functions 48
3.5 Changing welding polarity 49
3.6 Lifting Master M equipment 51
4. Maintenance 53
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Master M 205, 323
Operating manual - EN
4.1 Daily maintenance 54
4.2 Periodic maintenance 55
4.3 Service workshops 56
4.4 Troubleshooting 57
4.5 Error codes 59
4.6 Installing and cleaning power source air filter (optional) 61
4.7 Disposal 62
5. Technical data 63
5.1 Master M devices 64
5.2 Master Cooler 05M cooling unit 68
5.3 Wire feeder consumables 69
5.4 Master M ordering info 71
5.5 Welding program work packs 72
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Master M 205, 323
Operating manual - EN
1. GENERAL
These instructions describe the use of Kemppi's Master M 205 and 323 welding machines designed for light- to medium-
duty professional use in MIG/MAG welding.
Master M 205 and 323 welding machines include both manual and automatic welding processes. Pulse welding is pos-
sible with the Master M 205 machine (220...240 V).
Master M is designed to be used together with Kemppi's Flexlite GX MIG welding guns with euro connector.
Master M can be used also for TIG * and MMA ** welding.
* TIG welding requires the use of a dedicated Flexlite TX TIG torch with euro connector.
** MMAwelding requires a dedicated DIX-euro adapter.
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.
Kemppi symbols: Userdoc.
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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Master M 205, 323
Operating manual - EN
1.1 Equipment description
Master M device models
•Master M 205 GM (200 A)
>> Generator-compatible and multi-voltage
>> Pulse device with automatic 1-MIG process (pulse welding with 220...240 V supply voltage only).
•Master M 323 GM (320 A)
>> Generator-compatible and multi-voltage
>> Standard device with automatic 1-MIG and MAX Cool process.
The Master M device models have a 2-roll wire feed mechanism. The maximum wire spool diameter is 200 mm.
For the Master M device part descriptions, refer to "Master M 205 and 323 devices" on the next page.
Master M cooling units
•Master Cooler 05M.
For the cooling unit part descriptions, refer to "Master Cooler 05M cooling unit (optional)" on page8.
MIG welding guns
•Flexlite GX welding guns with euro connector.
For more information on the Flexlite GX welding guns, refer to Kemppi Userdoc.
Welding programs
•Welding program work pack (factory-installed)
•Four welding programs for MAX Cool process in Master M 323 (factory-installed).
The welding programs included in the Master M work packs are shown here: "Welding program work packs" on page72.
Optional accessories
•2-wheel carts
•Protection sliders
•Power source air filter
•Wire feed cabinet heater.
For more information on optional accessories, contact your local Kemppi dealer.
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
The serial number and other device-related identification information may also be saved in the form of a QR
code (or a barcode) on the device. Such code can be read by a smartphone camera or with a dedicated code
reader device providing fast access to the device-specific information.
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Master M 205, 323
Operating manual - EN
1.2 Master M 205 and 323 devices
Front
1. Transportation handle (also for mechanical lifting when the device is not installed on a cooling unit or cart)
2. Control panel (and hinged control panel cover)
3. LED work lights with light switch in the middle
>> Light switch: First press turns the lights on (full brightness), second press dims the lights (medium brightness),
third press turns the lights off
>> Includes a built-in battery (the battery is charged when the equipment is connected to mains)
4. Earth return cable connector
5. Front locking interface
>> For locking on top of the cooling unit or on the cart
6. Welding cable euro connector
7. Wire feed cabinet hatch.
Rear
Master M 205 on the left and Master M 323 on the right.
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Master M 205, 323
Operating manual - EN
1. Shielding gas hose connector
2. Power switch
3. Mains cable
4. Rear locking interface
>> For locking on top of the cooling unit or on the cart.
Inside wire feed cabinet
1. Gas regulating valve for measuring and adjusting gas flow (Master M 323 only)
>> For setting the gas flow rate in the device lower than the gas flow rate from the gas supply
2. Polarity terminals
3. Wire feed mechanism (refer to "Wire feed mechanism" below)
4. Wire spool hub.
1.2.1 Wire feed mechanism
1. Drive roll and drive roll mounting cap
2. Inlet guide tube
3. Pressure handle
4. Pressure roll and pressure roll mounting pin
5. Outlet guide tube.
For replacing the feed rolls, refer to "Installing and replacing feed rolls" on page26.
For replacing the wire guide tubes, refer to "Installing and replacing wire guide tubes" on page28.
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Master M 205, 323
Operating manual - EN
1.3 Master Cooler 05M cooling unit (optional)
The cooling unit is not available for Master M 205 with 110...130 V supply voltage.
Front
1. Front locking interface
>> For locking to the power source
2. Cooler container cap
3. Cooling liquid level indicator
4. Cooling liquid circulation button
>> Keeping the button pressed activates the pump and circulates the cooling liquid throughout the system. Once
released, the pump stops.
5. Front locking interface
>> For locking on the cart
6. Coolant inlet connector (red)
7. Coolant outlet connector (blue).
Rear
1. Rear locking interface
>> For locking to the power source
2. Rear locking interface
>> For locking on the cart.
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Master M 205, 323
Operating manual - EN
2. INSTALLATION
Do not connect the equipment to the mains before the installation is complete.
Do not modify the welding equipment in any way, except for the changes and adjustments covered in the man-
ufacturer’s instructions.
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.
Distribution network
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the
public low-voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in
those locations, due to conducted as well as radiated radio-frequency disturbances.
Master M 323: Provided that the short circuit power of public low voltage system at the point of common coupling is
higher than 1.6 MVA, this equipment is compliant with IEC 61000-3-11:2017 and IEC 61000-3-12:2011 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.
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Master M 205, 323
Operating manual - EN
2.1 Installing power source 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 mains plug according to the Master M device and site requirements. Refer also to "Technical data" on page63
for device specific technical information.
The mains cable includes the following wires:
1. Brown: L1
2. Black: L2
3. Grey: L3
4. Yellow-green: Protective earth
Cable type and fuse rating requirements:
Unit amperage Cable type Fuse rating
200 A (220-230 / 110-130 V) 2.5 mm216 / 16 A
320 A (380-460 / 220-230 V) 2.5 mm216 / 32 A
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Master M 205, 323
Operating manual - EN
2.2 Installing cooling unit (optional)
The cooling unit is not available for Master M 205 with 110...130 V supply voltage.
The cooling unit must be installed by authorized service personnel.
Tools needed:
1. Remove the small connector cover in the rear of the power source.
2. Route the cooling unit's connection cables so that they remain accessible through the next steps.
3. Lift the Master M device on top of the cooling unit so that the locking interfaces align and the fixing plate goes into
its slot.
Ensure that the cooling unit's connection cables are not caught and/or damaged between the edges.
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Master M 205, 323
Operating manual - EN
4. Fix the units together with two screws (M5x12) in the front.
5. Connect the cooling unit cables.
6. Replace the small connector cover.
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Master M 205, 323
Operating manual - EN
2.3 Installing equipment on cart (optional)
Master M has two transport unit options: a 2-wheel cart with a gas bottle rack (T22M) and a 2-wheel cart without a gas
bottle rack (T32A).
You can install the Master M device on the T22M cart with or without the cooling unit. Do not install the cooling unit
on the T32A cart. Otherwise the bottom securing interface is the same with both carts.
The maximum recommended size of the gas bottle to be installed on the T22M cart is 20 liters.
Tools needed:
To install the Master M device on the T22M cart:
1. Install the Master M device on the cart.
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Master M 205, 323
Operating manual - EN
2. Fix the device to the cart with two screws (M5x12) in the front.
To install the Master M device and the cooling unit on the T22M cart:
1. Install the cooling unit on the cart.
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Master M 205, 323
Operating manual - EN
2. Fix the cooling unit to the cart with two screws (M5x12) in the front.
3. Install the Master M device on top of the cooling unit. Refer to "Installing cooling unit (optional)" on page11 for
installation details.
4. Secure the transportation handle to the cart with an additional bracket and a screw (M8x16).
To install the Master M device on the T32A cart:
1. Install the Master M device on the cart.
2. Fix the device to the cart with two screws in the front (M5x12).
The T32A cart must be in horizontal position during welding.
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Master M 205, 323
Operating manual - EN
For lifting the Master M equipment, refer to "Lifting Master M equipment" on page51.
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Master M 205, 323
Operating manual - EN
2.4 Connecting welding gun
Master M is designed to be used with the Kemppi Flexlite GX welding guns. For the Flexlite GX operating instructions,
refer to userdoc.kemppi.com.
Always check that the wire liner, contact tip and gas nozzle are suitable for the job.
1. Push the welding gun connector into the euro connector and hand-tighten the collar.
2. If your setup includes a water-cooled gun, connect the cooling liquid hoses to the cooling unit. The hoses are color-
coded.
3. Install and load the filler wire as described in "Installing and changing wire (200 mm spool)" on page19.
4. Check the gas flow. Refer to "Installing gas bottle and testing gas flow" on page29 for more information.
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Master M 205, 323
Operating manual - EN
2.5 Connecting earth return cable
Connect the earth return cable to the Master M machine.
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Master M 205, 323
Operating manual - EN
2.6 Installing and changing wire (200 mm spool)
This section describes how to install and change a 200 mm spool. The spool hub for a 200 mm spool is factory installed
on Master M 205 and 323 machines. For instructions on installing a 100 mm spool, refer to "Installing and changing wire
(100 mm spool)" on page24.
Install the welding gun to the Master M device before installing the wire spool.
When changing the wire spool, remove the remaining filler wire from the welding gun and wire feed mechanism
before removing the wire spool.
Always ensure that the feed rolls are suitable for the filler wire (diameter and material) in question. For more inform-
ation, refer to "Wire feeder consumables" on page69.
To remove the wire spool:
1. Open the wire feed cabinet hatch.
2. Loosen and remove the spool fastener and remove the wire spool.
To install a new wire spool:
1. Insert the wire spool onto the spool hub. Secure the wire spool in place by inserting and tightening the spool
fastener.
Ensure that the wire spool is facing the right direction, the filler wire running from the bottom of the spool to the
feed rolls.
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Master M 205, 323
Operating manual - EN
2. If needed, adjust the spool braking force by turning the spool hub fastener.
To install the filler wire:
1. Release the filler wire end from the spool and cut off any deformed section so that the end is straight.
Ensure that the filler wire does not spill from the spool when it is released.
2. File the tip of the filler wire smooth.
Sharp edges on the filler wire tip may damage the wire liner.
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