Related Manuals for Kemppi MasterMig 353
Summary of Contents for Kemppi MasterMig 353
- Page 1 MasterMig 353, 355 Operating manual- EN MasterMig 353, 355 © Kemppi 1921960 / 2217...
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Page 2: Table Of Contents
MasterMig 353, 355 Operating manual- EN CONTENTS 1. General 1.1 Equipment description 1.2 MasterMig device 1.2.1 Wire feed mechanism 1.3 MasterMig Cooler cooling unit (optional) 2. Installation 2.1 Installing power source mains plug 2.2 Installing cooling unit (optional) 2.3 Installing equipment on cart (optional) 2.4 Connecting welding gun... - Page 3 MasterMig 353, 355 Operating manual- EN 3.4.8 WeldEye with DCM (optional) 3.5 Using remote control 3.6 Changing welding polarity 3.7 Lifting MasterMig equipment 4. Maintenance 4.1 Daily maintenance 4.2 Periodic maintenance 4.3 Service workshops 4.4 Troubleshooting 4.5 Error codes 4.6 Installing and cleaning power source air filter (optional) 4.7 Disposal...
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Page 4: General
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. - Page 5 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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Page 6: Equipment Description
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. -
Page 7: Mastermig Device
MasterMig 353, 355 Operating manual- EN 1.2 MasterMig device Front Transportation handle (also for mechanical lifting when the device is not installed on a cooling unit or cart) Control panel Work lights ON/OFF Work light Control cable connector Earth return cable connector... -
Page 8: Wire Feed Mechanism
MasterMig 353, 355 Operating manual- EN Power switch Rear locking interface >> For locking on top of the cooling unit or on the cart. Inside wire feed cabinet Gas regulating valve (MasterMig 355) >> For setting the gas flow rate in the device lower than the gas flow rate from the gas supply... - Page 9 MasterMig 353, 355 Operating manual- EN 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. © Kemppi 1921960 / 2217...
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Page 10: Mastermig Cooler Cooling Unit (Optional)
MasterMig 353, 355 Operating manual- EN 1.3 MasterMig Cooler cooling unit (optional) Front Cooler container cap Cooling liquid level indicator Cooling liquid circulation button >> Keeping the button pressed activates the pump and circulates the cooling liquid throughout the system. Once released, the pump stops. -
Page 11: Installation
MasterMig 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. -
Page 12: Installing Power Source Mains Plug
MasterMig 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 MasterMig device and site requirements. -
Page 13: Installing Cooling Unit (Optional)
MasterMig 353, 355 Operating manual- EN 2.2 Installing cooling unit (optional) The MasterMig cooling unit must be installed by authorized service personnel. Tools needed: Remove the small connector cover in the rear of the power source. Route the cooling unit's connection cables so that they remain accessible through the next steps. - Page 14 MasterMig 353, 355 Operating manual- EN Fix the units together with two screws (M5x12) in the front and two screws (M5x12) in the rear. Connect the cooling unit cables. Replace the small connector cover. © Kemppi 1921960 / 2217...
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Page 15: Installing Equipment On Cart (Optional)
MasterMig 353, 355 Operating manual- EN 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). - Page 16 MasterMig 353, 355 Operating manual- EN 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. © Kemppi 1921960 / 2217...
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Page 17: Connecting Welding Gun
Operating manual- EN 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. -
Page 18: Connecting Earth Return Cable
MasterMig 353, 355 Operating manual- EN 2.5 Connecting earth return cable Connect the earth return cable to the welding machine. © Kemppi 1921960 / 2217... -
Page 19: Installing Remote Control (Optional)
MasterMig 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 MasterMig welding equipment. The remote control mode can be set and adjusted in the control panel settings ("Control panel: System set- tings"... -
Page 20: Installing And Changing Wire
MasterMig 353, 355 Operating manual- EN 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. - Page 21 MasterMig 353, 355 Operating manual- EN If needed, adjust the spool brake by turning the spool brake tightening knob in the center of the spool hub. To install the filler wire: Release the filler wire end from the spool and cut off any deformed section so that the end is straight.
- Page 22 MasterMig 353, 355 Operating manual- EN Guide the filler wire through the inlet guide tube (a), middle guide tube (b) and into the outlet guide tube (c), which feeds the filler wire to the welding gun. Push the filler wire by hand into the gun so that the wire reaches the wire liner.
- Page 23 MasterMig 353, 355 Operating manual- EN Adjust the pressure of the feed rolls with the pressure adjustment wheels. The pressure is the same for both feed roll pairs. The graduated scales on the pressure handle indicate the pressure applied to the feed rolls. Adjust the pressure of the feed rolls according to the table below.
- Page 24 MasterMig 353, 355 Operating manual- EN Before welding, ensure that the welding parameters and settings conform to your welding setup. * Feed roll profiles and corresponding symbols Feed roll profile Symbol V-groove V-groove, knurled U-groove © Kemppi 1921960 / 2217...
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Page 25: Installing And Replacing Feed Rolls
MasterMig 353, 355 Operating manual- EN 2.8 Installing and replacing feed rolls Replace the feed rolls when the filler wire diameter or material changes. Select the feed rolls according to the tables in "Wire feeder consumables" on page 70. Open the wire feed cabinet hatch. - Page 26 MasterMig 353, 355 Operating manual- EN The pressure rolls' mounting pins have central axles attached to them, whereas the drive rolls' central axles act as drive shafts attached directly to the wire feed mechanism/motor. Remove the drive rolls and pressure rolls.
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Page 27: Installing And Replacing Wire Guide Tubes
MasterMig 353, 355 Operating manual- EN 2.9 Installing and replacing wire guide tubes The wire feed mechanism includes three wire guide tubes. Replace them when the filler wire diameter or material changes. Select the wire guide tubes according to the tables in "Wire feeder consumables" on page 70. -
Page 28: Installing Gas Bottle And Testing Gas Flow
- Install the welding gun to the welding device before installing and testing the gas bottle. - Do not use the whole contents of the bottle. Contact your local Kemppi dealer for choosing the gas and the equipment. Without gas bottle cart: Place the gas bottle in a suitable, secure location. - Page 29 MasterMig 353, 355 Operating manual- EN Open the gas bottle valve. Press the gas test button (a) to test and adjust the gas flow. Use the gas regulating valve (b) (in MasterMig 355 only) or an external flow meter and regulator.
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Page 30: Operation
MasterMig 353, 355 Operating manual- EN 3. OPERATION Before using the equipment, ensure that all the necessary installation actions have been completed according to your equipment setup and instructions. Welding is forbidden in places where there is an immediate fire or explosion hazard! The wire feed cabinet hatch must be kept closed when welding. -
Page 31: Preparing Welding System For Use
Preparing cooler Fill the coolant container inside the cooler with Kemppi cooling liquid. For instructions on filling the cooler, refer to "Filling cooler and circulating coolant" below. To weld, you must pump the coolant through the system by pressing the coolant circulation button in the front panel of the cooling unit. - Page 32 MasterMig 353, 355 Operating manual- EN Open the cooler cap. Fill the cooler with coolant. Do not fill over the max. marking. Close the cooler cap. To circulate the coolant: Press the coolant circulation button in the cooler front panel. It activates the motor, which pumps the coolant to the hoses and to the welding gun.
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Page 33: Calibrating Welding Cable
MasterMig 353, 355 Operating manual- EN 3.2 Calibrating welding cable The welding cable resistance can be measured using the built-in cable calibration function without an additional meas- urement cable. This calibration function is available only in MIG operation mode. Connect the earth return cable between the welding device and work piece. -
Page 34: Using Control Panel
MasterMig 353, 355 Operating manual- EN 3.3 Using control panel The MasterMig control panel includes features and functions for MIG welding with the options to use MasterMig also for TIG and MMA welding. General Settings display Welding display Indicators (for descriptions of the symbols, refer to the Indicators table below) Memory channels button (MIG only) >>... -
Page 35: Control Panel: Main View
MasterMig 353, 355 Operating manual- EN General notification There is a problem that requires attention. Service / repair Power source Cooling unit High temperature indicator (overheating) VRD (Voltage Reduction Device): White and red VRD symbols are off = VRD is off White VRD symbol is on = VRD is on Red VRD symbol is blinking = There is a fault with VRD that prevents welding. - Page 36 MasterMig 353, 355 Operating manual- EN Memory channel (and filler wire and shielding gas settings, if set) Active welding process Applied welding functions* Applied trigger logic function Wire feed speed >> The value range is defined by the active welding program, step 0.1, default = 5.0 m/min...
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Page 37: Control Panel: Memory Channels
MasterMig 353, 355 Operating manual- EN Hot start, Powerlog (power levels) and crater fill ON. 3.3.2 Control panel: Memory channels There are 6 memory channels available in MIG welding. Selecting memory channel Turn the right control knob to highlight the desired memory channel. -
Page 38: Control Panel: Trigger Logic
MasterMig 353, 355 Operating manual- EN Selecting welding process Turn the right control knob to highlight the desired welding process. Only a welding process that supports the set filler wire and shielding gas combination can be selected. If the filler wire and shielding gas settings have not been made, then only manual MIG process is available. -
Page 39: Control Panel: Weld Assist
MasterMig 353, 355 Operating manual- EN Tip: To turn off Powerlog and activate the 2T trigger logic, press the trigger logic button. 3.3.5 Control panel: Weld Assist Weld Assist is a wizard-like utility for easy selection of welding parameters. The utility walks the user step-by-step through the selection of required parameters, presenting the selections in an easily understandable way. -
Page 40: Control Panel: Welding Parameters
MasterMig 353, 355 Operating manual- EN Weld Assist gives you a recommendation for these welding parameters: >> Wire feed speed >> Current >> Voltage Confirm the Weld Assist’s recommendation for welding parameters by saving the parameter values to a memory channel. - Page 41 MasterMig 353, 355 Operating manual- EN Confirm the new value / selection by pressing the right control knob. Welding parameters Manual MIG welding parameters The parameters listed here are available for adjustment only with the manual MIG process. Parameter Parameter value Description -30 ...
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Page 42: Control Panel: System Settings
MasterMig 353, 355 Operating manual- EN Pulse / DPulse / MAX Position welding parameters (MasterMig 355 only) The parameters listed here are available for adjustment with the pulse and MAX Position welding processes in addition to the MIG and 1-MIG welding parameters. For more information on the processes, refer to "Additional guidance to functions and fea- tures"... - Page 43 MasterMig 353, 355 Operating manual- EN Remote min. Defined by the active welding program Minimum and maximum limits for the remote wire feed speed adjustment. Remote max. Defined by the active welding program Cable calibration Start/Cancel Calibration information on the previous (MIG only) calibration is also shown.
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Page 44: Control Panel: Weld Data
MasterMig 353, 355 Operating manual- EN Factory reset Reset/Cancel Restores factory settings. Note that the Default = Cancel arc verification parameter value is also reset. 3.3.8 Control panel: Weld data After each weld, a weld summary is displayed briefly. © Kemppi... -
Page 45: Additional Guidance To Functions And Features
MasterMig 353, 355 Operating manual- EN 3.4 Additional guidance to functions and features This section summarizes some of the MasterMig functions and features and how to use them. 3.4.1 1-MIG 1-MIG is a MIG/MAG welding process where the voltage is defined automatically when you adjust the wire feed speed. -
Page 46: Max Position Process
MasterMig 353, 355 Operating manual- EN >> To fine-tune the heat output, in the Main view, turn the right control knob. MAX Cool supports these filler wire and shielding gas combinations: • Fe solid & Ar + 8…25 % CO (1.0 mm, 1.2 mm) -
Page 47: Trigger Logic Functions
MasterMig 353, 355 Operating manual- EN • Fe MC & Ar + 18% CO (1.2 mm) • Ss solid & Ar + 2% CO (1.0 mm, 1.2 mm). 3.4.6 Trigger logic functions Switch between the 2T and 4T trigger logic by pressing the control panel's trigger logic button. -
Page 48: Wisefusion Feature
For more information on Wise products, visit www.kemppi.com. 3.4.8 WeldEye with DCM (optional) Kemppi's WeldEye welding management software is also available for use with MasterMig. For this, an additional Digital Connectivity Module (DCM) device is required. DCM is connected directly to the MasterMig's control connection with the cables and adapters delivered with the DCM device. - Page 49 MasterMig 353, 355 Operating manual- EN >> Includes quality verification functionalities with digital WPS and qualification compliance control against auto- matically collected digital welding data. • Welding management >> Includes document register functionalities and features for comprehensive welding project documentation and management.
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Page 50: Using Remote Control
MasterMig 353, 355 Operating manual- EN 3.5 Using remote control Remote control HR43 To adjust the wire feed speed, turn the knob on the remote control. To change the memory channel instead of the wire feed speed with the remote, change the setting in the control panel settings ("Control panel: System settings"... -
Page 51: Changing Welding Polarity
MasterMig 353, 355 Operating manual- EN 3.6 Changing welding polarity Welding polarity needs to changed for TIG welding. Also, some filler wires require changing the welding polarity. Check the recommended welding polarity on the filler wire package. Before handling electrical parts, ensure the welding device is disconnected from the mains. -
Page 52: Lifting Mastermig Equipment
MasterMig 353, 355 Operating manual- EN 3.7 Lifting MasterMig equipment If a gas bottle is installed on cart, DO NOT attempt to lift the cart with the gas bottle in place. 4-wheel cart: Ensure that the welding equipment is properly secured to the cart. -
Page 53: Maintenance
MasterMig 353, 355 Operating manual- EN 4. MAINTENANCE When considering and planning routine maintenance, consider the operating frequency of the welding system and the working environment. Correct operating of the welding machine and regular maintenance helps you avoid unnecessary downtime and equip- ment failure. -
Page 54: Daily Maintenance
Check the wire feed rolls and the pressure handle. Clean and lubricate with a small quantity of light machine oil if needed. For repairs, contact Kemppi at www.kemppi.com or your dealer. Welding gun maintenance For Flexlite GX MIG gun instructions, refer to userdoc.kemppi.com. © Kemppi 1921960 / 2217... -
Page 55: Periodic Maintenance
MasterMig 353, 355 Operating manual- EN 4.2 Periodic maintenance Only qualified service personnel is allowed to carry out periodic maintenance. Only an authorized electrician is allowed to carry out electrical work. Before removing the cover plate, disconnect the power source from the mains and wait for about 2 minutes before discharging the capacitor. -
Page 56: Service Workshops
MasterMig 353, 355 Operating manual- EN 4.3 Service workshops Kemppi Service Workshops complete the welding system maintenance according to the Kemppi service agreement. The main aspects in the service workshop maintenance procedure are: • Cleanup of the machine • Maintenance of the welding tools •... -
Page 57: Troubleshooting
MasterMig 353, 355 Operating manual- EN 4.4 Troubleshooting The problems listed and the possible causes are not definitive, but suggest some typical situations that may turn up during normal use of the welding system. Welding device: Problem Recommended actions The welding device does not power up Check that the mains cable is plugged in properly. - Page 58 MasterMig 353, 355 Operating manual- EN Dirty and/or poor quality weld Check that the shielding gas has not run out. Check that the shielding gas flow is unobstructed. Check that the gas type is correct for the application. Check the polarity of the gun/electrode.
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Page 59: Error Codes
Too long welding session with high power. Do not shut down, let the fans cool the machine. If overheated fans are not running, contact Kemppi service Internal 24V Power source contains an inoperative 24V Restart the power source. If problem persists, contact voltage is too power supply unit . - Page 60 MasterMig 353, 355 Operating manual- EN VRD error Open circuit voltage exceeds the VRD limit. Restart the power source. If problem persists, contact Kemppi service. High current in There may be too much pressure in the Adjust the feed roll pressure. Clean the wire line.
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Page 61: Installing And Cleaning Power Source Air Filter (Optional)
MasterMig 353, 355 Operating manual- EN 4.6 Installing and cleaning power source air filter (optional) An optional power source air filter can be purchased separately. The air filter comes with a fixed casing designed to be mounted directly onto the power source air intake. - Page 62 MasterMig 353, 355 Operating manual- EN Cleansing Remove the air filter from the power source by releasing the clips on the edge of the air filter casing. Blow the air filter clean with compressed air. © Kemppi 1921960 / 2217...
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Page 63: Disposal
The owner of the equip- ment is obliged to deliver a decommissioned unit to a regional collection center, as per the instructions of local author- ities or a Kemppi representative. By applying these European Directives you improve the environment and human health. -
Page 64: Technical Data
MasterMig 353, 355 Operating manual- EN 5. TECHNICAL DATA Technical data: • For MasterMig device technical data, refer to "MasterMig devices" on the next page. • For MasterMig Cooler cooling unit technical data, refer to "MasterMig cooling unit" on page 69. -
Page 65: Mastermig Devices
MasterMig 353, 355 Operating manual- EN 5.1 MasterMig devices MasterMig 353 G, 355 G MasterMig 353, 355 353 G, 355 G Feature Value Mains connection voltage 3~50 Hz 380...460 V ±10 % Mains connection cable HO7RN-F 4 mm² Input power at rated maximum cur-... - Page 66 @ 400 V 20 kVA erator power Wired communication type Wireless communication type Standards IEC 60974-1, -10 MasterMig 353 GM, 355 GM MasterMig 353, 355 353 GM, 355 GM Feature Value Mains connection voltage 3~50 Hz 220...230 V ±10 % 380...460 V ±10 %...
- Page 67 MasterMig 353, 355 Operating manual- EN Output at +40 °C 40 % 380...460 V 350 A (MMA 330 A) 220...230 V 300 A (MMA 280 A) 60 % 380...460 V 280 A 220...230 V 240 A 100 % 380...460 V 220 A 220...230 V...
- Page 68 MasterMig 353, 355 Operating manual- EN Recommended minimum gen- @ 400 V 20 kVA erator power Wired communication type Wireless communication type IEC 60974-1, -10 Standards © Kemppi 1921960 / 2217...
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Page 69: Mastermig Cooling Unit
MasterMig 353, 355 Operating manual- EN 5.2 MasterMig cooling unit MasterMig Cooler MasterMig Cooler Feature Value Supply voltage 380...460 V +/- 10 % Maximum supply current @ 380...460 V 0.7 A 1max Cooling power @ 1 l/min 1.0 kW Recommended coolant... -
Page 70: Wire Feeder Consumables
The wire feeder consumables can be ordered in Configurator.kemppi.com. In the tables, standard refers to plastic feed rolls and heavy-duty refers to metal feed rolls. The materials mentioned first refer to primary suitability and the materials mentioned inside brackets refer to secondary suitability. - Page 71 MasterMig 353, 355 Operating manual- EN Feed rolls The table below lists the standard feed rolls available. Feed rolls, standard Filler wire diameter Filler wire material Feed roll profile* Drive roll code Pressure roll code (mm) Fe, Ss, Cu (Al, MC/FC)
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Page 72: Mastermig Ordering Info
MasterMig 353, 355 Operating manual- EN 5.4 MasterMig ordering info For MasterMig ordering information and optional accessories, refer to Kemppi.com. © Kemppi 1921960 / 2217...