Kemppi M315G, Operating Manual

Page 1: ...Master 315 Operating manual EN Master 315 Kemppi 1 1921530 2052 ...

Page 2: ...ontrol 15 2 9 Moving equipment by lifting 18 3 Operation 20 3 1 Operating power source 21 3 2 Operating control panel MTP35X 22 3 2 1 Home view 23 3 2 2 Weld Assist view 25 3 2 3 Memory channels view 27 3 2 4 Pulse view 28 3 2 5 Settings view 29 3 2 6 Info view 32 3 2 7 Screen saver 33 3 3 Remote control 35 4 Maintenance 36 4 1 Disposal 38 5 Troubleshooting 39 5 1 Error codes 40 6 Technical data 4...

Page 3: ...der 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 DISCLAIMER While ever...

Page 4: ...voltage and generator compatible 300 A A dedicated VRD Voltage Reduction Device model version where the VRD function is locked on is also available Control panel MTP35X control panel 7 TFT LCD display panel Equipment 1 Master 315 power source 2 Electrode holder 3 TIG torch Flexlite TX 223GVD13 4 Earth return cable and clamp 5 Remote control wired or wireless 6 Foot pedal remote control wired or wi...

Page 5: ... to the serial number of the product when ordering spare parts or mak ing 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 Ke...

Page 6: ... and fuse rating given in the Technical data on page 41 chapter Do not connect the machine to the mains before the installation is complete Only an authorized electrician is allowed to install the mains cable Distribution network Master 315 Provided that the public low voltage short circuit power at the point of common coupling is higher than or equal to the value stated on the list below this equ...

Page 7: ... 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 power source and site requirements Refer also to Technical data on page 41 for power source specific technical information Kemppi 7 1921530 2052 ...

Page 8: ...nd mount the control panel in place Insert the top of the panel in the slot first and then lower the bottom of the panel down Push the bottom of the panel firmly so that it locks in place 2 Secure the control panel together with the hinged panel cover in place with the screw provided The hinged panel cover and the control panel are secured with the same screw Kemppi 8 1921530 2052 ...

Page 9: ... filter optional The optional particle filter is installed together with an additional filter frame as a pack 1 Place the filter into the filter frame 2 Install the filter pack in front of the air inlet on the rear of the power source Kemppi 9 1921530 2052 ...

Page 10: ...pment securing bracket is attached once the welding equipment is installed on the cart Transport units from left to right P45MT T25MT P43MT 2 Move the unit on top of the cart so that the bar in the rear goes into the rear connection interface and lower the front onto the front connection interface Secure the power source from the front with the screws 2 x M5x12 provided Do not attempt to move the ...

Page 11: ... 315 Operating manual EN With the 2 wheel cart T25MT an additional securing bracket is attached to the power source handle Secure the bracket to the cart with the screws provided M8x16 Kemppi 11 1921530 2052 ...

Page 12: ...o electrical equipment 1 Connect the earth return cable to the power source 2 Ensure the earth return clamp is secured tightly to the work piece or work surface 3 Ensure that the clamp s contact surface is as large as possible In MMA welding the earth return cable can also be connected to the positive connector depending on the applic ation Kemppi 12 1921530 2052 ...

Page 13: ...Connect the earth return cable to the connector on the power source 3 Ensure the earth return clamp is secured tightly to the work piece or work surface 4 Ensure that the clamp s contact surface is as large as possible In MMA welding the cables can also be connected the other way round depending on the welding polarity Kemppi 13 1921530 2052 ...

Page 14: ...h the Master power source use the Flexlite TX 223GVD13 torch 1 Assemble the TIG torch according to the instructions delivered with the torch 2 Connect the TIG torch cable to the power source Tip For Kemppi welding torches refer also to userdoc kemppi com Kemppi 14 1921530 2052 ...

Page 15: ... mode is selected on the control panel and both wireless and wired remotes are connected the wired remote will be used Refer to the and signs on the battery holder and in the remote for the correct positioning of batteries Tools Screwdriver Torx head T15 Wireless hand remote control HR45 1 Take the remote control battery holder out Install the batteries 3 x AAA and put the holder back into the rem...

Page 16: ...mote 4 Once connected the blue LED on the left of the connection button is lit The green LED blinks when the battery is low 5 To enable remote operation select Remote mode in the control panel settings Remote control with cable HR43 FR43 1 Connect the remote control cable to the power source Wireless foot pedal FR45 Refer to the and signs on the battery holder and in the remote for the correct pos...

Page 17: ...ettings refer to Settings view on page 29 3 Keeping the wireless remote close to the power source long press 3 sec the wireless remote pairing button on the foot pedal 4 Once connected the blue LED next to the button is lit The green LED blinks when the battery is low Tip You can set minimum and maximum values for the remote current adjustment in the control panel set tings Kemppi 17 1921530 2052 ...

Page 18: ... the equipment is installed securely on the cart If a gas bottle is installed on the cart DO NOT attempt to lift the cart with the gas bottle in place DO NOT attempt to lift the equipment with a hoist from the handle 4 wheel cart P45MT 1 Ensure that the welding equipment is properly secured to the cart 2 Connect the 4 legged chain or straps from the hoist hook to the four lifting points on the car...

Page 19: ...Master 315 Operating manual EN 2 wheel cart T25MT 1 Ensure that the welding equipment is properly secured to the cart 2 Connect the hoist hook to the lifting handle on the cart Kemppi 19 1921530 2052 ...

Page 20: ...d for a longer period disconnect the mains plug from the mains Do not use the mains plug as a power ON OFF switch Always check before use that all cables are in serviceable condition Ensure that the connectors are correctly fastened Loose connectors can impair welding performance and damage connectors For technical data and general guidance for selecting initial TIG welding parameters refer to TIG...

Page 21: ...power source 1 Turn the power source ON The power switch is located in the rear 2 Wait approximately 15 seconds for the system to start up For control panel operation refer to Operating control panel MTP35X on the next page Kemppi 21 1921530 2052 ...

Page 22: ...e knob center Used to navigate through the control panel views and selections 2 Menu button left function button This is used to access the view menu With certain control panel settings and features this also acts as a back or cancel button 3 Custom function button right function button This button can be used as a user programmable shortcut With certain control panel settings and features this al...

Page 23: ...djusted directly by turning the control knob Home view in MMA Depending on your welding settings the following are shown 1 Welding process 2 Memory channel 3 Weld Assist symbol 4 Hot start 5 Arc force 6 Recommended welding current range for the selected electrode 7 Pulse parameters 8 Wireless remote and its battery status 9 Remote mode ON OFF Warning and notification symbols a General notification...

Page 24: ...atus 7 Remote mode ON OFF Warning and notification symbols a General notification Yellow This is a warning that requires attention Red There is an error that prevents welding Error code is shown below the symbol b Operating temperature Red Welding equipment has overheated c VRD voltage reduction device VRD symbol on VRD is on This is always on in power source models where the VRD function is locke...

Page 25: ...control knob 1 and with the two function buttons 2 3 Tip You can go back step by step in Weld Assist by pressing the left function button 2 Selecting Cancel with the right function button 3 you can cancel Weld Assist recommendations and return to the beginning Using Weld Assist with MMA welding 1 Go to the Weld Assist view and select Start with the control knob button 1 2 Select The electrode type...

Page 26: ...sitive DIX connector All these parameters can still be modified as per normal for the actual welding Using Weld Assist with TIG welding 1 Go to the Weld Assist view and select Start with the control knob button 1 2 Select The material you are about to weld Fe mild steel Ss stainless steel The welded material s thickness 0 5 10 mm The welding joint type butt joint corner joint edge joint lap joint ...

Page 27: ...eld Assist gives you a recommendation for these Shielding gas flow Electrode Diameter Filler if used Material and diameter Number of passes Number and or visualization Travel speed mm min 3 2 3 Memory channels view Memory channel is a place to store predefined welding parameter settings for future use A welding machine can include a number of preset and user defined channels In the Channels view t...

Page 28: ...utomatically selected To save or delete channels 1 Turn the control knob 1 to highlight a channel 2 Open the channel actions menu by pressing the control knob button 1 The available actions are shown Cancel Save changes Save to and Delete 3 Select an action with the control knob 1 3 2 4 Pulse view In the Pulse view the selections are made with the control knob 1 Kemppi 28 1921530 2052 ...

Page 29: ...visibleand adjustable Average current Min Current limit min Max Machine specific Thesevalues depend also on other pulsepara meters Maximum averagecur rent is also lim ited by the machinespe cifications Pulse frequency 0 2 Hz 10 Hz 0 1 Hz step 10 Hz 300 Hz 1 Hz step Default 2 5 Hz Non adjustable parameters Parameter Value Note Pulse ratio 40 Pulse base current 70 Pulse current Adjusted automaticall...

Page 30: ...Parameter Value Note Welding process TIG MMA Default TIG Selecting a welding process changes automatically to the last activechannelfortheselected process Current limit min TIG 2 A MMA 8 A step 1 A Current limit max TIG powersource s nominalvalue MMA powersource s max MMA current step 1 A Remote control mode OFF Remote Default OFF When a remotecontrolis selected thewelding current adjustment on th...

Page 31: ...enabling the longest arc possible System settings Parameter Value Note Brightness 10 100 step 1 Default 100 Weld data time 1 s 10 s step 1 s Default 5 s Screen saver Default Kemppilogo An alternativescreen saverimagecan beused Formore information referto Screen saver on page 33 Date Datesetting DD MM YYYY Time 24h Timesetting HH MM Language Languagesetting Show Weld Assist ON OFF Default ON Factor...

Page 32: ...u can see information about the equipment usage as well as software version for example Included in the Info view Usage counters Error status and error log Latest welds Power source type and model Power source and control panel software versions Kemppi 32 1921530 2052 ...

Page 33: ... download the new screen saver image onto a USB memory stick 3 Detach the control panel from the power source Remove the top screw and panel cover First pull the top of the control panel slightly and then the rest of the panel Do not disconnect the control panel cable The power source and control panel must be turned on 4 Connect the USB memory stick to the USB connector on the rear side of the co...

Page 34: ...ory stick you want to use as a screen saver 6 Remove the USB memory stick and install the control panel back in place Refer to Installing control panel on page 8 for more information To delete a custom screen saver image from the control panel memory or to use the Kemppi logo instead go to Set tings view on page 29 Kemppi 34 1921530 2052 ...

Page 35: ... control To adjust the welding current turn the knob on the remote control Tip The remote control comes equipped with a handy clip for hanging the remote onto your belt Foot pedal remote control To adjust the welding current press the pedal Tip To shift the foot pedal position on the floor use the foot pedal handle Kemppi 35 1921530 2052 ...

Page 36: ...em Check that all covers and components are intact Check all the cables and connectors Do not use them if they are damaged For repairs contact Kemppi at www kemppi com or your dealer Periodic maintenance Only an authorized electrician is allowed to carry out electrical work Only qualified service personnel is allowed to carry out periodic maintenance Before removing the cover plate disconnect the ...

Page 37: ...s Checkup of the connectors and switches Checkup of all electric connections Checkup of the power source mains cable and plug Repair of defective parts and replacement of defective components Maintenance test Test and calibration of operation and performance values when needed Find your closest service workshop at Kemppi website Kemppi 37 1921530 2052 ...

Page 38: ...tronic equipment and their implementation in accordance with national law electrical equipment that has reached the end of its life must be collected separately and taken to an appropriate environmentally responsible recycling facility The owner of the equipment is obliged to deliver a decommissioned unit to a regional collection center as per the instructions of local authorities or a Kemppi repr...

Page 39: ...e of the welding torch If different torch components have separate limits for the maximum current the lower one of these is the maximum current that can be used Make sure you are using original Kemppi consumable and spare parts Incorrect spare part materials may also cause overheating Make sure the connectors are clean undamaged and properly fastened Weld quality Dirty and or poor weld quality Che...

Page 40: ...ins supply 34 Unknown welding load An unknown load con nected to DIX connectors Removeany unintended resistiveload connected to thewelding equip ment and restart thepowersource 35 Too high mains current Current drawn from the mains is too high Reducewelding power 36 DC link under voltage DC link voltageis too low Check themains voltageand orthesupply cable 37 DC link over voltage DC link voltageis...

Page 41: ...Master 315 Operating manual EN 6 TECHNICAL DATA Power source Master 315 on the next page For ordering codes see Ordering codes on page 50 Kemppi 41 1921530 2052 ...

Page 42: ...pecified in the next column 30 TIG 300 A 22 V 400 V 260 A 20 4 V 220 V 40 TIG 300 A 22 V 280 A 21 2 V 400 V 260 A 20 4 V 220 V 60 TIG 260 A 20 4 V 260 A 20 4 V 400 V 230 A 19 2 V 220 V 100 TIG 220 A 18 8 V 220 A 18 8 V 400 V 175 A 17 V 220 V 30 MMA 300 A 32 V 400 V 260 A 30 4 V 220 V 40 MMA 300 A 32 V 280 A 31 2 V 400 V 260 A 30 4 V 220 V 60 MMA 260 A 30 4 V 260 A 30 4 V 400 V 230 A 29 2 V 220 V 1...

Page 43: ... 4 GHz Bluetooth 2400 2483 5 MHz 10 dBm 2 4 GHz Bluetooth 2400 2483 5 MHz 10 dBm Wired communication type Remote Analog Analog CAN BUS KemppiRemote Bus KemppiRemote Bus Stick electrode diameters ø mm 1 6 7 0 mm 1 6 7 0 mm Standards IEC60974 1 3 10 IEC61000 3 12 AS 60974 1 2006 3 GB 15579 1 IEC60974 1 3 10 IEC61000 3 12 GB 15579 1 1 In the AU power source model versions with the Voltage Reduction D...

Page 44: ...ided is based solely on the use of WC20 grey electrode and Argon gas TIG welding DC Welding current range DC Electrode WC20 Gas nozzle Gas flow rate Min A Max A ø mm number ø mm l min Argon 5 80 1 0 4 5 6 5 8 0 5 6 70 140 1 6 4 5 6 6 5 8 0 9 5 6 7 140 230 2 4 6 7 9 5 11 0 7 8 225 330 3 2 7 8 10 11 0 12 5 16 8 10 Kemppi 44 1921530 2052 ...

Page 45: ...evel of the pulse cycle In TIG welding its main tasks are to cool down the weld pool and to maintain the arc D DC TIG Direct current TIG welding process where the polarity of the electrode is either positive or negative throughout the welding process Negative polarity DC allows high penetration whereas positive polarity DC is used only in special applications H Hot start Welding function that uses...

Page 46: ...ode is touching the workpiece Can be used for avoiding MMA electrode getting too hot when it s in contact with the work piece P Pulse current The higher current level of the pulse cycle In TIG welding its main task is to create weld pool or increase the heat of the weld pool Pulse frequency Determines how many pulse cycles is created per second Hz Pulse ratio Determines how big part of the whole p...

Page 47: ...eans the function is off V VRD voltage reduction device A safety device used in welding equipment to reduce the open circuit voltage to maintain below a certain voltage value This reduces the risk of electric shock particularly in dangerous environments such as closed or damp spaces VRD may also be required by law in certain countries or regions W Weld Assist A wizard like utility for easy selecti...

Page 48: ...N 6 4 Symbols used Symbol Description Gas input Gas output TIG TIG HF ignition TIG Contact ignition TIG Gas Cooling MMA Arc break Arc force Pulse Hot Start Upslope Gas test Frequency orWavelength Basecurrent Kemppi 48 1921530 2052 ...

Page 49: ...ontrol Remotecontrolin TIG torch Foot pedal High voltage Low voltage Common symbols used in Kemppi documentation Symbol Description Usermanual CE mark EMCClass A Electricaland electronic waste High voltage warning Protectiveearth Kemppi 49 1921530 2052 ...

Page 50: ...n M315GAU Master 315 GM Power source 300 A generator and multi voltage use M315GM HR43 Wired remote HR43 HR45 Wireless remote HR45 FR43 Wired foot pedal remote FR43 FR45 Wireless foot pedal remote FR45 P43MT Transport unit 4 wheel undercarriage P43MT T25MT Transport unit 2 wheel cart T25MT P45MT Transport unit 4 wheel cart P45MT Particle filter pack SP020952 Kemppi 50 1921530 2052 ...

Page 51: ... Letters with the product model names stand for G gas cooled V gas valve D DIX connection Flexlite TX Product Ordering code 4 m 8 m 16 m Flexlite TX 223GVD13 TX223GVD134 External package dimensions mm L x W x H 590 x 390 x 130 80 Kemppi 51 1921530 2052 ...