Kemppi Master M 353 User manual

Master M 353, 355
Operating manual - EN
Master M 353, 355
© Kemppi 11921960 / 2307

Master M 353, 355
Operating manual - EN
CONTENTS
1. General 4
1.1 Equipment description 6
1.2 Master M device 8
1.2.1 Wire feed mechanism 9
1.3 Master M Cooler cooling unit (optional) 11
2. Installation 12
2.1 Installing power source mains plug 13
2.2 Installing cooling unit (optional) 14
2.3 Installing equipment on cart (optional) 16
2.4 Connecting welding gun 18
2.5 Connecting earth return cable 19
2.6 Installing remote control (optional) 20
2.7 Installing and changing wire 21
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 Filling cooler and circulating coolant 33
3.2 Calibrating welding cable 34
3.3 Using control panel 35
3.3.1 Control panel: Main view 36
3.3.2 Control panel: Memory channels 38
3.3.3 Control panel: Welding process 38
3.3.4 Control panel: Trigger logic 39
3.3.5 Control panel: Weld Assist 40
3.3.6 Control panel: Welding parameters 41
3.3.7 Control panel: System settings 43
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 MAX Position process 48
3.4.5 MAX Speed process 48
3.4.6 Trigger logic functions 49
3.4.7 WiseFusion feature 50
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Master M 353, 355
Operating manual - EN
3.4.8 WeldEye with DCM (optional) 50
3.5 Using remote control 52
3.6 Changing welding polarity 53
3.7 Lifting Master M equipment 54
4. Maintenance 56
4.1 Daily maintenance 57
4.2 Periodic maintenance 58
4.3 Service workshops 59
4.4 Troubleshooting 60
4.5 Error codes 62
4.6 Installing and cleaning power source air filter (optional) 64
4.7 Disposal 66
5. Technical data 67
5.1 Master M devices 68
5.2 Master M cooling unit 72
5.3 Master M ordering info 73
5.4 Wire feeder consumables 74
5.5 Welding program work packs 76
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Master M 353, 355
Operating manual - EN
1. GENERAL
These instructions describe the use of Kemppi's Master M welding equipment designed for light- to medium-duty pro-
fessional use in MIG/MAG welding.
Master M welding machines include both manual and automatic welding processes. Pulse welding is possible with the
Master M 355 series machines.
Master M series:
Master M product series Master M device model
Master M 353 Master M 353 G
Master M 353 GM
Master M 355 Master M 355 G
Master M 355 GM
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.
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Master M 353, 355
Operating manual - EN
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 353, 355
Operating manual - EN
1.1 Equipment description
Master M device models (350 A)
•Master M 353 G
>> Generator-compatible
>> Standard device with automatic 1-MIG process
•Master M 353 GM
>> Generator-compatible and multi-voltage
>> Standard device with automatic 1-MIG process
•Master M 355 G
>> Generator-compatible
>> Pulse device with automatic 1-MIG and pulse processes. Advanced MAX processes as optional.
•Master M 355 GM
>> Generator-compatible and multi-voltage
>> Pulse device with automatic 1-MIG and pulse processes. Advanced MAX processes as optional.
All Master M device models have a 4-roll wire feed mechanism with the maximum wire spool diameter of 300 mm.
For the Master M device part descriptions, refer to "Master M device" on page8.
Master M control panels
•Color LCD display
Master M cooling units
•Master M Cooler
•Master M Cooler MV (multi-voltage).
For the cooling unit part descriptions, refer to "Master M Cooler cooling unit (optional)" on page11.
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)
•Additional 1-MIG and pulse programs (on-demand / at the time of purchase)
•Additional MAX processes for Master M 355 (on-demand / at the time of purchase).
For more information on acquiring welding programs and additional welding processes, contact your local Kemppi
dealer.
Subfeeders
Subfeeder support can be added with a separate installation kit (contact your Kemppi dealer / service workshop for
more information).
•SuperSnake GTX subfeeder.
For more information on the SuperSnake GTX subfeeder, refer to Kemppi Userdoc.
Optional accessories
•4-wheel carts
•2-wheel carts
•Remote control HR40 (2-knob control)
•Remote control HR43 (1-knob control)
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Master M 353, 355
Operating manual - EN
•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 353, 355
Operating manual - EN
1.2 Master M device
Front
1. Transportation handle (also for mechanical lifting when the device is not installed on a cooling unit or cart)
2. Control panel
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. Control cable connector
5. Earth return cable connector
6. Welding cable euro connector
7. Front locking interface
>> For locking on top of the cooling unit or on the cart
8. Connector for subfeeder synchronization kit (optional)
9. Wire feed cabinet hatch.
Rear
1. Shielding gas hose connector
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Master M 353, 355
Operating manual - EN
2. Mains cable
3. Power switch
4. Rear locking interface
>> For locking on top of the cooling unit or on the cart.
Inside wire feed cabinet
1. Gas regulating valve (Master M 355)
>> For setting the gas flow rate in the device lower than the gas flow rate from the gas supply
2. USB connector
3. Polarity terminals
4. Wire inch button
>> Drive the filler wire forward (with arc off)
5. Gas test button
>> Test the shielding gas flow and flush the gas line
6. Wire feed mechanism (refer to "Wire feed mechanism" below)
7. Wire spool.
1.2.1 Wire feed mechanism
1. Drive rolls and drive roll mounting caps
2. Middle guide tube locking clip
3. Middle guide tube
4. Inlet guide tube
5. Pressure handles
6. Pressure rolls and pressure roll mounting pins
7. Pressure roll locking arms
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Master M 353, 355
Operating manual - EN
8. 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 353, 355
Operating manual - EN
1.3 Master M Cooler cooling unit (optional)
Front
1. Cooler container cap
2. Cooling liquid level indicator
3. Cooling liquid circulation button
>> Keeping the button pressed activates the pump and circulates the cooling liquid throughout the system. Once
released, the pump stops.
4. Front locking interface
>> For locking on the cart
5. Front locking interface
>> For locking to the power source
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 353, 355
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 power source 350A: Provided that the short circuit power of public low voltage system at the point of com-
mon coupling is higher than 2.4 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 353, 355
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 3-phase plug according to the Master M device and site requirements.
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
350 A (380-460 V) 4 mm216 A
350 A (380-460 / 220-230 V) 4 mm216 / 32 A
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2.2 Installing cooling unit (optional)
The Master M 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 fixing plates align and go into their slots.
Ensure that the cooling unit's connection cables are not caught and/or damaged between the edges.
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4. Fix the units together with two screws (M5x12) in the front and two screws (M5x12) in the rear.
5. Connect the cooling unit cables.
6. Replace the small connector cover.
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Master M 353, 355
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2.3 Installing equipment on cart (optional)
Master M has four transport unit options: a 4-wheel cart with a gas bottle rack (P45MT), a 4-wheel cart without a gas
bottle rack (P43MT), a 2-wheel cart with a gas bottle rack (T25MT) and a 2-wheel cart without a gas bottle rack (T35A).
The equipment installation principle and the bottom securing interface is the same with all carts.
Tools needed:
1. Install the cooling unit on the cart.
2. Fix the cooling unit to the cart with two screws (M5x12) in the front and two screws (M5x12) in the rear.
3. Install the Master M device on top of the cooling unit. Refer to "Installing cooling unit (optional)" on page14 for
installation details.
4. T25MT 2-wheel cart:Secure the equipment to the cart with the two side connection brackets.
With the T25MT cart, an additional securing bracket is attached to the device handle. Secure the bracket to the cart
with the screws provided (M8x16) .
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Master M 353, 355
Operating manual - EN
T35A 2-wheel cart: The cart must be in horizontal position during welding.
For lifting the Master M equipment, refer to "Lifting Master M equipment" on page54.
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Master M 353, 355
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" on page21.
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 353, 355
Operating manual - EN
2.5 Connecting earth return cable
Connect the earth return cable to the welding machine.
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Master M 353, 355
Operating manual - EN
2.6 Installing remote control (optional)
Remote controls are optional. To enable remote operation, connect the remote control device to the Master M welding
equipment. The remote control mode can be set and adjusted in the control panel settings ("Control panel: System set-
tings" on page43).
Remote control HR43/HR40
1. Connect the remote control cable to the control cable connector.
2. Adjust the remote control parameters in the control panel settings.
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