Kemppi Master M 358 User manual

Master M 358
Operating manual - EN
Master M 358
© Kemppi 11921980 / 2240

Master M 358
Operating manual - EN
CONTENTS
1. General 4
1.1 Equipment description 5
1.2 Master M 358 device 7
1.2.1 Wire feed mechanism 9
1.2.2 Control panel 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 Installing earth return cable 19
2.6 Installing remote control (optional) 20
2.7 Installing and replacing feed rolls 21
2.8 Installing and replacing wire guide tubes 23
2.9 Installing and changing wire 24
2.10 Installing gas bottle and testing gas flow 29
2.11 How to get welding programs 31
3. Operation 32
3.1 Preparing welding system for use 33
3.1.1 Filling cooler and circulating coolant 33
3.2 Calibrating welding cable 35
3.3 Using control panel 36
3.3.1 Control panel: Home view 37
3.3.2 Control panel: Weld Assist 38
3.3.3 Control panel: Channels 39
3.3.4 Control panel: WPS view 41
3.3.5 Control panel: Welding parameters 44
3.3.6 Control panel: Weld history 50
3.3.7 Control panel: Info view 50
3.3.8 Control panel: Device settings 51
3.3.9 Control panel: Applying welding programs 53
3.3.10 Control panel: Weld data view 55
3.4 Additional guidance to functions and features 56
3.4.1 Trigger logic functions 56
3.4.2 1-MIG 57
3.4.3 WiseFusion feature 57
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Master M 358
Operating manual - EN
3.4.4 WisePenetration+ feature 57
3.4.5 WiseSteel feature 58
3.5 Pulse welding 59
3.5.1 MAX Cool process 59
3.5.2 MAX Position process 60
3.5.3 MAX Speed process 60
3.6 Wireless connection (WLAN) 61
3.6.1 Digital Welding Procedure Specification (dWPS) 62
3.6.2 WeldEye ArcVision 62
3.6.3 WeldEye with DCM 63
3.6.4 USB backup and restore 64
3.6.5 USB update 64
3.7 Using remote control 66
3.8 Changing welding polarity 67
3.9 Lifting equipment 69
4. Maintenance 70
4.1 Daily maintenance 71
4.2 Periodic maintenance 72
4.3 Service workshops 73
4.4 Troubleshooting 74
4.5 Error codes 76
4.6 Installing and cleaning power source air filter (optional) 78
4.7 Disposal 80
5. Technical data 81
5.1 Master M 358 device 82
5.2 Master M cooling unit 86
5.3 Master M 358 ordering info 87
5.4 Wire feeder consumables 88
5.5 Welding program work packs 90
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Master M 358
Operating manual - EN
1. GENERAL
These instructions describe the use of Kemppi's Master M 358 welding equipment designed for both normal and pulsed
MIG/MAG welding.
Master M 358 is designed to be used together with Kemppi's Flexlite GX MIG welding guns with euro connector.
Master M 358 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.
General notices: 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 358
Operating manual - EN
1.1 Equipment description
Master M 358 device models (350 A)
•Master M 358 G
>> Generator-compatible
>> Pulse device with automatic 1-MIG and pulse processes. Advanced MAX processes as optional.
•Master M 358 GM
>> Generator-compatible and multi-voltage
>> Pulse device with automatic 1-MIG and pulse processes. Advanced MAX processes as optional.
Both Master M 358 device models have a 4-roll wire feed mechanism with the maximum wire spool diameter of 300 mm.
For the Master M 358 device part descriptions, refer to "Master M 358 device" on page7.
Master M 358 control panels
•2-knob 5.7" TFT/LCD control panel
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.
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.
Welding programs
•Welding program work pack (factory-installed)
•1-MIG Wise features: WiseSteel and WiseFusion
•1-MIG Wise features: WisePenetration+ (on-demand / at the time of purchase)
•Additional 1-MIG and pulse welding programs (on-demand / at the time of purchase)
•Additional MAX processes (on-demand / at the time of purchase)
The welding programs included in the Master M work packs are shown here:"Welding program work packs" on page90.
For more information on acquiring welding programs and additional welding processes, contact your local Kemppi
dealer.
Optional accessories
•4-wheel carts
•2-wheel carts
•Remote control HR40 (2-knob control)
•Remote control HR43 (1-knob control)
•Wire feeder cabinet heater
•Power source air filter
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Master M 358
Operating manual - EN
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 358
Operating manual - EN
1.2 Master M 358 device
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. 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. Front locking interface
>> For locking on top of the cooling unit or on the cart
7. Welding cable euro connector
8. Connector for subfeeder synchronization kit (optional)
9. Wire feed cabinet hatch.
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Master M 358
Operating manual - EN
Rear
1. Shielding gas hose connector.
2. Mains cable
3. Power switch
4. Rear locking interface
>> For locking on top of the cooling unit or on a cart.
Inside wire feed cabinet
1. Rotameter for gas
2. Polarity terminals
3. Wire inch button
>> Drive the filler wire forward (with arc off)
4. Gas test button
>> Test the shielding gas flow and flush the gas line
5. Wire feed mechanism (refer to "Wire feed mechanism" on the next page)
6. Wire spool.
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Master M 358
Operating manual - EN
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
8. Outlet guide tube.
For replacing the feed rolls, refer to "Installing and replacing feed rolls" on page21.
For replacing the wire guide tubes, refer to "Installing and replacing wire guide tubes" on page23.
1.2.2 Control panel
This section describes the controls and features of the Master M 358 control panel (TFT/LCD).
1. Left control knob (with push button function)
2. Right control knob (with push button function)
3. Memory channel selection (shortcut button)
4. View selection (shortcut button)
5. Welding parameters view (shortcut button).
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Master M 358
Operating manual - EN
For using the control panel, refer to "Using control panel" on page36.
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Master M 358
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.
© Kemppi 11 1921980 / 2240

Master M 358
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 358
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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Master M 358
Operating manual - EN
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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Master M 358
Operating manual - EN
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 358
Operating manual - EN
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 358
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 equipment" on page69.
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Master M 358
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24.
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 358
Operating manual - EN
2.5 Installing earth return cable
1. Connect the earth return cable to the Master M machine's earth return cable connector.
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Master M 358
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: Device set-
tings" on page51).
When the Remote mode is selected in the settings and both wireless and wired remotes are connected, the wired
remote will be used.
Remote control HR43/HR40
1. Connect the remote control cable to the control cable connector.
2. To adjust the remote control parameters, refer to "Control panel: Device settings" on page51.
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