Related Manuals for Kemppi Master M 205
Summary of Contents for Kemppi Master M 205
- Page 1 Master M 205, 323 Operating manual - EN Master M 205, 323 © Kemppi 1922130 / 2313...
-
Page 2: Table Of Contents
Master M 205, 323 Operating manual - EN CONTENTS 1. General 1.1 Equipment description 1.2 Master M 205 and 323 devices 1.2.1 Wire feed mechanism 1.3 Master Cooler 05M cooling unit (optional) 2. Installation 2.1 Installing power source mains plug 2.2 Installing cooling unit (optional) - Page 3 Master M 205, 323 Operating manual - EN 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 5. Technical data 5.1 Master M devices 5.2 Master Cooler 05M cooling unit...
-
Page 4: General
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). -
Page 5: Equipment Description
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 •... -
Page 6: Master M 205 And 323 Devices
>> For locking on top of the cooling unit or on the cart Welding cable euro connector Wire feed cabinet hatch. Rear Master M 205 on the left and Master M 323 on the right. © Kemppi 1922130 / 2313... -
Page 7: Wire Feed Mechanism
Master M 205, 323 Operating manual - EN Shielding gas hose connector Power switch Mains cable Rear locking interface >> For locking on top of the cooling unit or on the cart. Inside wire feed cabinet Gas regulating valve for measuring and adjusting gas flow (Master M 323 only) >>... -
Page 8: Master Cooler 05M Cooling Unit (Optional)
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 Front locking interface >> For locking to the power source... -
Page 9: Installation
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. -
Page 10: Installing Power Source Mains Plug
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. -
Page 11: Installing Cooling Unit (Optional)
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: Remove the small connector cover in the rear of the power source. - Page 12 Master M 205, 323 Operating manual - EN Fix the units together with two screws (M5x12) in the front. Connect the cooling unit cables. Replace the small connector cover. © Kemppi 1922130 / 2313...
-
Page 13: Installing Equipment On Cart (Optional)
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). - Page 14 Master M 205, 323 Operating manual - EN 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: Install the cooling unit on the cart.
- Page 15 Master M 205, 323 Operating manual - EN Fix the cooling unit to the cart with two screws (M5x12) in the front. Install the Master M device on top of the cooling unit. Refer to "Installing cooling unit (optional)" on page 11 for installation details.
- Page 16 Master M 205, 323 Operating manual - EN For lifting the Master M equipment, refer to "Lifting Master M equipment" on page 51. © Kemppi 1922130 / 2313...
-
Page 17: Connecting Welding Gun
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. -
Page 18: Connecting Earth Return Cable
Master M 205, 323 Operating manual - EN 2.5 Connecting earth return cable Connect the earth return cable to the Master M machine. © Kemppi 1922130 / 2313... -
Page 19: 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)"... - Page 20 Master M 205, 323 Operating manual - EN If needed, adjust the spool braking force by turning the spool hub fastener. 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 21 Master M 205, 323 Operating manual - EN Release the pressure handle. Guide the filler wire through the inlet guide tube (1) and into the outlet guide tube (2), 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 22 Master M 205, 323 Operating manual - EN Close the pressure handle so that the filler wire is locked between the feed rolls. Adjust the pressure of the feed roll with the pressure adjustment wheel. The graduated scales on the pressure arm indicate the pressure applied to the feed rolls. Adjust the pressure of the feed rolls according to the table below.
- Page 23 Master M 205, 323 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 1922130 / 2313...
-
Page 24: Installing And Changing Wire (100 Mm Spool)
Master M 205, 323 Operating manual - EN 2.7 Installing and changing wire (100 mm spool) This section describes how to install and change a 100 mm spool. For instructions on installing and changing a 200 mm spool, refer to "Installing and changing wire (200 mm spool)" on page 19. - Page 25 Master M 205, 323 Operating manual - EN If needed, adjust the spool braking force by turning the spool hub fastener. To install the filler wire, refer to "Installing and changing wire (200 mm spool)" on page 19. © Kemppi 1922130 / 2313...
-
Page 26: Installing And Replacing Feed Rolls
Master M 205, 323 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 69. - Page 27 Master M 205, 323 Operating manual - EN Remove the feed rolls. Follow the previous steps in reverse to install the wire feed rolls. Align the cut on the drive roll's bottom with the pin on the drive shaft. Reattach the mounting cap and mounting pin to lock the drive roll and pressure roll into their places.
-
Page 28: Installing And Replacing Wire Guide Tubes
Master M 205, 323 Operating manual - EN 2.9 Installing and replacing wire guide tubes The wire feed mechanism includes two 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 69. -
Page 29: Installing Gas Bottle And Testing Gas Flow
- Install the welding gun to the welding device before installing and testing the gas 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 30 Master M 205, 323 Operating manual - EN Open the gas bottle valve. If the filler wire is installed, release the pressure arm of the wire feed mechanism to prevent wire feeding. Start gas flow by pressing the welding gun trigger.
-
Page 31: Operation
Master M 205, 323 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 32: Preparing Welding System For Use
If the machine is left unused for a longer period, detach the mains plug to disconnect it from the mains. Preparing cooler Fill the coolant container inside the cooler with Kemppi cooling liquid and bleed the cooler before use. For instructions on filling and bleeding the cooler, refer to "Preparing cooler" on the next page. -
Page 33: Preparing Cooler
Operating manual - EN 3.1.1 Preparing cooler To fill the cooler: Fill the cooler with 20-40 % coolant solution, for example, Kemppi cooling liquid. Open the cooler cap. Fill the cooler with coolant. Do not fill over the max. marking. - Page 34 Master M 205, 323 Operating manual - EN 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. Complete the coolant circulation operation after each time you change the welding gun.
-
Page 35: Calibrating Welding Cable
Master M 205, 323 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. -
Page 36: Using Control Panel
Master M 205, 323 Operating manual - EN 3.3 Using control panel The Master M control panel includes features and functions for MIG welding with the options to use Master M also for TIG and MMA welding. General Settings display... -
Page 37: Control Panel: Main View
Master M 205, 323 Operating manual - EN Indicators Symbol Description General notification There is a problem that requires attention. Service / repair Power source Cooling unit High temperature indicator (overheating) VRD (Voltage Reduction Device): White VRD symbol is on = VRD is on Red VRD symbol is blinking = There is a fault with VRD that prevents welding. - Page 38 Master M 205, 323 Operating manual - EN Memory channel (and filler wire and shielding gas settings, if defined) 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...
-
Page 39: Control Panel: Memory Channels
3.3.3 Control panel: Welding process Welding process is selected in the Welding process view. For more information on welding processes, refer to "Addi- tional guidance to functions and features" on page 47. Pulse welding is possible with Master M 205. © Kemppi 1922130 / 2313... -
Page 40: Control Panel: Trigger Logic
Master M 205, 323 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 are not defined, then only manual MIG process is available. -
Page 41: Control Panel: Weld Assist
Master M 205, 323 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 42: Control Panel: Welding Parameters
Master M 205, 323 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 43 Master M 205, 323 Operating manual - EN Welding parameters Manual MIG and 1-MIG welding parameters The parameters listed here are available for adjustment with the manual MIG and 1-MIG processes. Parameter Parameter value Description Post current -30 ... +30...
-
Page 44: Control Panel: System Settings
ON/OFF welding. Pulse welding parameters (Master M 205 only) The parameters listed here are available for adjustment with the pulse welding process in addition to the MIG and 1-MIG weld- ing parameters. For more information on the processes, refer to "Additional guidance to functions and features" on page 47. -
Page 45: Control Panel: Weld Data
Master M 205, 323 Operating manual - EN Cable calibration Start/Cancel Calibration information on the previous (MIG only) calibration is also shown. Refer to "Cal- ibrating welding cable" on page 35 for cable calibration. Water cooler OFF/Auto/ON When ON is selected, the coolant is cir-... - Page 46 Master M 205, 323 Operating manual - EN © Kemppi 1922130 / 2313...
-
Page 47: Additional Guidance To Functions And Features
The voltage is calculated based on the welding program in use. The process is suitable for all materials, shielding gases and welding positions. 3.4.2 Pulse welding Pulse welding is possible with the Master M 205 machine (220...240 V). Pulse Pulse is an automatic MIG/MAG welding process where the current is pulsed between the base current and the pulse cur- rent. -
Page 48: Trigger Logic Functions
Master M 205, 323 Operating manual - EN 3.4.4 Trigger logic functions Switch between the 2T and 4T trigger logic by pressing the control panel's trigger logic button. In 2T, pressing the trigger ignites the arc. Releasing the trigger switches the arc off. -
Page 49: Changing Welding Polarity
Master M 205, 323 Operating manual - EN 3.5 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 50 Master M 205, 323 Operating manual - EN Remove the terminal tightening bolts and washers. Connect the cables to the polarity terminals according to the polarity recommendation. Replace the washers and bolts. Tighten to 17 Nm torque. Replace the protective rubber covers.
-
Page 51: Lifting Master M Equipment
Master M 205, 323 Operating manual - EN 3.6 Lifting Master M equipment If a gas bottle is installed on cart, DO NOT attempt to lift the cart with the gas bottle in place. Transportation handle: The transportation handle can be used for mechanical lifting (for moving only, not for hanging) when the device is not mounted on a cooling unit or cart. - Page 52 Master M 205, 323 Operating manual - EN 2-wheel cart: Ensure that the welding equipment is properly secured to the cart. Connect the hoist hook to the lifting handle on the cart. Do not lift the device when it is installed on the T32A cart.
-
Page 53: Maintenance
Master M 205, 323 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 1922130 / 2313... -
Page 55: Periodic Maintenance
Master M 205, 323 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
Master M 205, 323 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 •... -
Page 57: Troubleshooting
Master M 205, 323 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 Master M 205, 323 Operating manual - EN Weld quality: Problem Recommended actions 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.
-
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 Master M 205, 323 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.
-
Page 61: Installing And Cleaning Power Source Air Filter (Optional)
Master M 205, 323 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: 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 63: Technical Data
Master M 205, 323 Operating manual - EN 5. TECHNICAL DATA Technical data: • For Master M device technical data, refer to "Master M devices" on the next page. • For Master M Cooler cooling unit technical data, refer to "Master Cooler 05M cooling unit" on page 68. -
Page 64: Master M Devices
Master M 205, 323 Operating manual - EN 5.1 Master M devices Master M 205 GM Master M 205 205 GM Feature Value Mains connection voltage 1~50/60 Hz 110...130 V ±10 % 220...240 V ±10 % 2.5 mm² Mains connection cable... - Page 65 Master M 205, 323 Operating manual - EN Efficiency at rated maximum @ 400 V η 84 % current Operating temperature range -20…+40 °C Storage temperature range -40…+60 °C EMC class Minimum short-circuit power of supply network Gun connection Euro...
- Page 66 Master M 205, 323 Operating manual - EN Master M 323 GM Master M 323 323 GM Feature Value Mains connection voltage 3~50/60 Hz 220...230 V ±10 % 380...460 V ±10 % 2.5 mm² Mains connection cable HO7RN-F 13 kVA...
- Page 67 Master M 205, 323 Operating manual - EN Operating temperature range -20…+40 °C Storage temperature range -40…+60 °C EMC class Minimum short-circuit power 1.6 MVA of supply network Euro Gun connection 2-roll, single-motor Wire feed mechanism Diameter of feed rolls...
-
Page 68: Master Cooler 05M Cooling Unit
Master M 205, 323 Operating manual - EN 5.2 Master Cooler 05M cooling unit Master Cooler 05M Feature Value Supply voltage 220...230 V +/- 10 % 380...460 V +/- 10 % 1.0 A Maximum supply current @ 220...230 V 1max 0.7 A... -
Page 69: 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 70 Master M 205, 323 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) V-groove 0.8−0.9...
-
Page 71: Master M Ordering Info
Master M 205, 323 Operating manual - EN 5.4 Master M ordering info For Master M ordering information and optional accessories, refer to Kemppi.com. © Kemppi 1922130 / 2313... -
Page 72: Welding Program Work Packs
5.5 Welding program work packs Welding program work packs include a set of standard welding programs to allow welding with e.g. automatic 1-MIG and pulse processes. For more information, contact your local Kemppi dealer or go to Kemppi.com. 1-MIG work pack:... - Page 73 Master M 205, 323 Operating manual - EN Pulse work pack (Master M 205, 220...240 V only): The Pulse work pack includes also all 1-MIG work pack welding programs. Welding program Process Wire material Wire diameter Shielding gas Description Pulse...