Kemppi MasterMig 353 User manual

MasterMig 353, 355
Operating manual- EN
MasterMig 353, 355
© Kemppi 11921960 / 2217

MasterMig 353, 355
Operating manual- EN
CONTENTS
1. General 4
1.1 Equipment description 6
1.2 MasterMig device 7
1.2.1 Wire feed mechanism 8
1.3 MasterMig Cooler cooling unit (optional) 10
2. Installation 11
2.1 Installing power source mains plug 12
2.2 Installing cooling unit (optional) 13
2.3 Installing equipment on cart (optional) 15
2.4 Connecting welding gun 17
2.5 Connecting earth return cable 18
2.6 Installing remote control (optional) 19
2.7 Installing and changing wire 20
2.8 Installing and replacing feed rolls 25
2.9 Installing and replacing wire guide tubes 27
2.10 Installing gas bottle and testing gas flow 28
3. Operation 30
3.1 Preparing welding system for use 31
3.1.1 Filling cooler and circulating coolant 31
3.2 Calibrating welding cable 33
3.3 Using control panel 34
3.3.1 Control panel: Main view 35
3.3.2 Control panel: Memory channels 37
3.3.3 Control panel: Welding process 37
3.3.4 Control panel: Trigger logic 38
3.3.5 Control panel: Weld Assist 39
3.3.6 Control panel: Welding parameters 40
3.3.7 Control panel: System settings 42
3.3.8 Control panel: Weld data 44
3.4 Additional guidance to functions and features 45
3.4.1 1-MIG 45
3.4.2 Pulse welding 45
3.4.3 MAX Cool process 45
3.4.4 MAX Position process 46
3.4.5 MAX Speed process 46
3.4.6 Trigger logic functions 47
3.4.7 WiseFusion feature 48
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MasterMig 353, 355
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3.4.8 WeldEye with DCM (optional) 48
3.5 Using remote control 50
3.6 Changing welding polarity 51
3.7 Lifting MasterMig equipment 52
4. Maintenance 53
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 63
5. Technical data 64
5.1 MasterMig devices 65
5.2 MasterMig cooling unit 69
5.3 Wire feeder consumables 70
5.4 MasterMig ordering info 72
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MasterMig 353, 355
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1. GENERAL
These instructions describe the use of Kemppi's MasterMig welding equipment designed for light- to medium-duty pro-
fessional use in MIG/MAG welding.
MasterMig welding machines include both manual and automatic welding processes. Pulse welding is possible with the
MasterMig 355 series machines.
MasterMig series:
MasterMig product series MasterMig device model
MasterMig 353 MasterMig 353 G
MasterMig 353 GM
MasterMig 355 MasterMig 355 G
MasterMig 355 GM
MasterMig is designed to be used together with Kemppi's Flexlite GX MIG welding guns with euro connector.
MasterMig 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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MasterMig 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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MasterMig 353, 355
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1.1 Equipment description
MasterMig device models (350 A)
•MasterMig 353 G
>> Generator-compatible
>> Standard device with automatic 1-MIG process
•MasterMig 353 GM
>> Generator-compatible and multi-voltage
>> Standard device with automatic 1-MIG process
•MasterMig 355 G
>> Generator-compatible
>> Pulse device with automatic 1-MIG and pulse processes. Advanced MAX processes as optional.
•MasterMig 355 GM
>> Generator-compatible and multi-voltage
>> Pulse device with automatic 1-MIG and pulse processes. Advanced MAX processes as optional.
All MasterMig device models have a 4-roll wire feed mechanism with the maximum wire spool diameter of 300 mm.
For the MasterMig device part descriptions, refer to "MasterMig device" on the next page.
MasterMig control panels
•Color LCD display
MasterMig cooling units
•MasterMig Cooler
•MasterMig Cooler M (multi-voltage).
For the cooling unit part descriptions, refer to "MasterMig Cooler cooling unit (optional)" on page10.
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.
Optional accessories
•4-wheel carts
•2-wheel carts
•Remote control HR40 (2-knob control)
•Remote control HR43 (1-knob control)
•Power source air filter
•Wire feed cabinet heater.
For more information on optional accessories, contact your local Kemppi dealer.
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1.2 MasterMig 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. Work lights ON/OFF
4. Work light
5. Control cable connector
6. Earth return cable connector
7. Welding cable euro connector
8. Front locking interface
>> For locking on top of the cooling unit or on the cart
9. Connector for subfeeder synchronization kit (optional)
10. Wire feed cabinet hatch.
Rear
1. Shielding gas hose connector
2. Mains cable
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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 (MasterMig 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
8. Outlet guide tube.
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For replacing the feed rolls, refer to "Installing and replacing feed rolls" on page25.
For replacing the wire guide tubes, refer to "Installing and replacing wire guide tubes" on page27.
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1.3 MasterMig 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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MasterMig 353, 355
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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.
MasterMig 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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MasterMig 353, 355
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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 MasterMig 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 MasterMig 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 MasterMig 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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2.3 Installing equipment on cart (optional)
MasterMig 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 MasterMig device on top of the cooling unit. Refer to "Installing cooling unit (optional)" on page13 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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T35A 2-wheel cart: The cart must be in horizontal position during welding.
For lifting the MasterMig equipment, refer to "Lifting MasterMig equipment" on page52.
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2.4 Connecting welding gun
MasterMig 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20.
4. Check the gas flow. Refer to "Installing gas bottle and testing gas flow" on page28 for more information.
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2.5 Connecting earth return cable
Connect the earth return cable to the welding machine.
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2.6 Installing remote control (optional)
Remote controls are optional. To enable remote operation, connect the remote control device to the MasterMig welding
equipment. The remote control mode can be set and adjusted in the control panel settings ("Control panel: System set-
tings" on page42).
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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2.7 Installing and changing wire
Always ensure that the feed rolls are suitable for the filler wire (diameter and material) in question. For more information,
refer to "Wire feeder consumables" on page70.
Install the welding gun to the MasterMig 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.
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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