Kemppi 2200 Master User Manual

MASTER

2200

1913710E

0530

Operation instructions • english
Gebrauchsanweisung • deutsch
Gebruiksaanwijzing • nederlands
Manuel d’utilisation • français

CONTENTS

1. Preface .....� 3

1.1. Introduction ...................................................................................................................... 3

1.2. Product Introduction ........................................................................................................3

1.3. Operation safety ............................................................................................................... 3

2. Installation .............................................................................................................................. .4

2.1. Operation control and connectors .................................................................................... 4

2.2. Siting the machine ............................................................................................................ 5

2.3. Connection to the mains supply .......................................................................................6

2.4. Welding- and return current cables ..................................................................................6

3. Operation control switches and potentiometers and their use .................................................6

3.1. Main switch I/O ...............................................................................................................6

3.2. Local/remote control of welding current .........................................................................7

3.3. Adjustment for MMA dynamics ......................................................................................7

3.4. Electrodes to be welded ...................................................................................................7

3.5. Remote control devices and cables .................................................................................. 7

4. Maintenance ............................................................................................................................8

4.1. Cables ............................................................................................................................... 8

4.2. Power source ....................................................................................................................8

5. Operation disturbances ............................................................................................................ 9

5.1. Operation of the overload protection ............................................................................... 9

5.2. Control fuses .................................................................................................................... 9

6. Disposal of the machine .......................................................................................................... 9

7. Ordering numbers ...................................................................................................................9

8. Technical data ....................................................................................................................... 10

9. Terms of guarantee ................................................................................................................ 11

2 – MASTER 2200/0530 © KEMPPI OY

1. PREFACE

1.1. INTRODUCTION

Congratulations on having purchased this product. Properly installed Kemppi products should
prove to be productive machines requiring maintenance at only regular intervals. This manual
is arranged to give you a good understanding of the equipment and its safe operation. It also
contains maintenance information and technical specifications. Read this manual from front to
back before installing, operating or maintaining the equipment for the first time. For further
information on Kemppi products please contact us or your nearest Kemppi distributor.

The specifications and designs presented in this manual are subject to change without prior
notice.

In this document, for danger to life or injury the following symbol is used:

Read the warning texts carefully and follow the instructions. Please also study the Operation
safety instructions and respect them when installing, operating and servicing the machine.

1.2. PRODUCT INTRODUCTION

MASTER is a MMA DC welding power source which is designed for demanding professional
use.

MASTER-inverter power source is 3-phase 220 A. The MASTER-power source is protected
against overload with overcurrent protections and thermal releases. Operation of a thermal
release is indicated with a signal lamp on the front wall of the machine.

To delivery equipment of the MASTER MMA welding power source belong carrying strap,
connection cable and a 4-pole cable without plug.

Using comfort of MASTER can be added with remote control units which can be delivered
as an accessory.

1.3. OPERATION SAFETY

Never watch the arc without a face shield designed for arc welding!

The arc damages unprotected eyes! The arc burns unprotected skin!

Protect yourself and the surroundings against the arc and hot spray!

Remember general fire safety!

Pay attention to the fire safety regulations. Welding is always classified as a fire risk operation.
Welding where there is flammable or explosive material is strictly forbidden. If it is essential to
weld in such an area remove inflammable material from the immediate vicinity of the welding
site. Fire extinguishers must always be on site where welding is taking place.

Note! Sparks may cause ignition many hours after completion of welding.

Watch the mains voltage!

Take care of the cables - the connection cable must not be compressed, touch sharp edges or
hot work pieces. Faulty cables are always a fire risk and highly dangerous. Do not locate the
welding machine on wet surfaces. Do not take the welding machine inside the work piece (i.e.
in containers, cars etc.)

Ensure that neither you nor gas bottles or electricial equipment are in contact with live wires
or connections!

Do not use faulty welding cables. Isolate yourself by using dry and not worn out protective clot­hes. Do not weld on wet ground. Do not place the welding cables on the power source or other
electricial equipment.

MASTER 2200/0530 – 3© KEMPPI OY

H11

H12

X13

S12

R11

Watch the welding fumes!

Ensure that there is sufficient ventilation. Follow special safety measures when you weld metals
which contain lead, cadmium, zinc, mercury and beryllium.

Note the danger caused by special welding jobs!

Watch the fire and explosion danger when welding container type work pieces.

2. INSTALLATION

2.1. OPERATION CONTROL AND CONNECTORS

H11 Signal lamp I/O

H12 Warning lamp for thermal shield

R11 Adjustement of welding current

R12 Adjustment of MMA welding dynamics

S11 Main switch I/O

S12 Selection for local/remote control

X11, X12 Welding and return current connections

X13 Connection for remote control

01 Inlet of mains cable

4 – MASTER 2200/0530

© KEMPPI OY

S11

X11

X12

01

R12

2.2. SITING THE MACHINE

By siting of the machine you should take into attention the following:

- Site the machine on a fixed dry base, from which there doesn’t come any dust etc. into
suction air. See to that the machine is positioned away from the line of particle spray, created by
grinding tools etc. Preferably site machine somewhat higher above the floor level.

- See to that in front of the machine as well as at the rear of the machine there is at least 20 cm
(8.0 inches) free distance to allow good circulation of the cooling air through the machine.

- Protect the machine against hard rain and in hot circumstances against direct sunshine. Ensure
the free circulation of the cooling air.

MASTER 2200/0530 – 5

© KEMPPI OY

MASTER 2200

2.3. CONNECTION TO THE MAINS SUPPLY

Connection of the main s cable and mounting and change of the plug should only be carried
out by a competent electrician.

For the time of the mounting of the mains cable remove handle and casing plate of the machine

MASTER 2200 is delivered equipped with a mains cable without a plug. By change of the mains
cable take into attention the following:

The cable is entered into the machine through the inlet ring on the rear panel of the machine and
fastened with a cable clamp (21). The phase leads of the cable are coupled to connections L!, L2
and L3. The earth protection coloured green-yellow is coupled to connection .

Sizes of the mains cable and fuse ratings for the machine at 100 % duty cycle are specified
in the table below:

Rated voltage 380 V 3 ~

Mains voltage range 380 V -10 % … 415 V +6 %

Fuses 10 A delayed

Connection cable 4 x 1,5 mm² S*)

*) In cables of S type there is a protective grounding conductor coloured green-yellow.

This equipment’s electromagnetic compatibility (EMC) is designed for use in an
industrial environment. Class A equipment is not intended for use in residential location
where the electrical power is provided by the public low-voltage supply system.

2.4. WELDING- AND RETURN CURRENT CABLES

Use only copper cables 25 mm².

Don’t use thinner cables!

Fasten the earthing press of the return current cable carefully, preferably direct onto the
piece of the press should always be as large as possible.

Clean the fastening surface from paint and rust!

3. OPERATION CONTROL SWITCHES AND POTENTIOMETERS
AND THEIR USE

3.1. MAIN SWITCH I/O

When you turn the switch into the I-position, the “ON” pilot lamp H11 on the front panel is
ignited and the machine is ready for use. The cooling fan of the MASTER gets started only
when welding

6 – MASTER 2200/0530 © KEMPPI OY

R61

R62

R61

3.2. LOCAL/REMOTE CONTROL OF WELDING CURRENT

You can control the welding current either from local control R11 of the machine or from a
control which is connected to the remote control unit, the switch S12 should be in the remote
control units: C 100C, and C 100D, see page 3

Pilot lamps

The pilot lamps of the machine report about the electric operation:

The green pilot lamp H11 for readiness for use is always on, when the machine is
connected to mains supply and the main switch is in I-position.

The yellow pilot lamp H12 of the thermal shield is on, when the thermostat has released
due to overheating of the machine. The cooling fan is cooling down the machine and by
blacking out of the pilot lamp the readiness for welding is automatically returned.

3.3. ADJUSTMENT FOR MMA DYNAMICS

On the rear of the MASTER there is a tool-controlled adjustment for MMA dynamics. With this
control you can adjust behaviour of the arc according to electrode type and your own likings.

The adjustment has influence on behaviour of the machine in drop short circuits.

Adjustment in minimum: Welding at its softest, arc pressure low

Adjustment in maximum: Welding at its roughest, arc pressure high

Recommendable initial adjustment is in the middle of the scale

3.4. ELECTRODES TO BE WELDED

By the MASTER power sources you can use all electrodes designed for DC or AC welding
within the current limits of the machine in question.

The MASTER power sources are not suitable for carbon arc gouging or cutting.

3.5. REMOTE CONTROL DEVICES AND CABLES

C 100C

Control of MMA/TIG welding current (R61), memory scale 1-10.

C 100D

Rough control (R61), memory scale 1-10, and fine control +/- (R62) for MMA/TIG welding
current.

16c Extension cable for remote control 4 poles

20 Return current cable

21 Cable for MMA welding

C 100C, C 100D Remote control devices, see also pages 3 and 6

MASTER 2200/0530 – 7

© KEMPPI OY

4. MAINTENANCE

the amount of use and the working environment should be taken into consideration when plan­ning the frequency of maintenance of the machine. Careful use and preventive maintenance will
help to ensure trouble-free operation.

4.1. CABLES

Check the condition of welding and connection cables daily. Do not use faulty cables! Make sure
that the mains connection cables in use are safe and according to laid down regulations.

The repair of the mains connection cables must be carried out only by an authorised electrician.

4.2. POWER SOURCE

Note! Isolate the plug of the machine from the mains socket and wait approx. 2 minutes
(capacitor charging) before removing the casing plate.

Check at least every half year:

- Electric connections of the machine - clean the oxidized parts and tighten the loosened ones.
Note! You must know correct tension torques before starting the reparation of the joints.

- Clean the inner parts of the machine from dust and dirt e.g. with a soft brush and vacuum­cleaner. Do not use compressed air, there is a risk that dirt is packed even more tightly into
gaps of cooling profiles!

Only authorised electrician must carry out repairs to the machines.

Regular maintenance

KEMPPI-service repair shops make regular maintenance according to agreement.

The major points in the maintenance procedure are listed as follows:

- Cleaning of the machine

- Checking and maintenance of the welding tools

- Checking of switches and potentiometers

- Checking of electric connections

- Checking of mains cable and plug

- Damaged parts in bad connection are replaced by new ones

- Maintenance testing. Operation and performance values of the machine are checked, and
adjusted when necessary by means of test equipment

8 – MASTER 2200/0530 © KEMPPI OY

5. OPERATION DISTURBANCES

In case of problems contact the KEMPPI works or your KEMPPI dealer.

Check the maintenance objects before the machine is sent to the service repair shop

5.1. OPERATION OF THE OVERLOAD PROTECTION

The overload protections (thermal protections) of the machine operate, if the machine is
continuously loaded above the rated values or the circulation of the cooling air is blocked.

The machine is automatically returned into operation, after it has cooled down t a lower
temperature.

5.2. CONTROL FUSES

As the machine protection there is on control card an 1,0 A slow-blow cartridge fuse in the
safety voltage circuit.

- Reason for burning of a fuse might be a damaged control card.

Use same type and rating of fuse which is marked beside the fuse adapter.

Damage caused by a wrong type fuse, is not covered by the guarantee.

6. DISPOSAL OF THE MACHINE

Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic

Equipment and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and returned to an
environmentally compatible recycling facility. As the owner of the equipment, you should
get information on approved collection systems from our local representative.

By applying this European Directive you will improve the environment and human
health!

7. ORDERING NUMBERS

C 100C 6185410

C 100D 6185413

16c /10 m 6185451

/25 m 6185452

/50 m 6185453

20 /5 m - 25 mm² 6184211

/10 m - 25 mm² 6184212

21 /5 m - 25 mm² 6184201

/10 m - 25 mm² 6184202

T110 Transport unit 6185251

MASTER 2200/0530 – 9© KEMPPI OY

8. TECHNICAL DATA

MASTER 2200

Mains voltage 3~, 50/60 Hz 380 V -10 % … 415 V +6 %

Rated power 25 % ED 220 A / 8,4 kVA

60 % ED 145 A / 5,5 kVA

100 % ED 110 A / 3,5 kVA

Connection cable/fuses 4 x 1,5S / 10 A delayed

Welding current range MMA 15 A / 20,5 V … 220 A / 28,8 V

Electrode sizes to be welded ø 1,5 … 4,0 (5,0) mm

Welding current control stepless

Open circuit voltage 80 V

Efficiency 82 % (220 A / 28,8 V)

Power factor 0,9 (220 A / 28,8 V)

Open circuit power approx. 10 W

Storage temperature range -40 … +60°C

Operation temperature range -20 … +40°C

Temperature class H (180°C) / B (130°C)

Degree of protection IP 23C

External dimensions: length 472 mm

width 152 mm

height 302 mm

Weight 12,5 kg

Suitable accessories: remote control units C 100C, C 100D

The product meets conformity requirements for CE marking.

10 – MASTER 2200/0530 © KEMPPI OY

9. TERMS OF GUARANTEE

Kemppi Oy provides a guarantee for products manufactured and sold by them if defects in
manufacture and materials occur. Guarantee repairs must be carried out only by an Authorised
Kemppi Service Agent. Packing, freight and insurance costs to be paid by orderer. The guarantee is
effected on the date of purchase. Verbal promises which do not comply with the terms of guarantee
are not binding on guarantor.

Limitations on guarantee

The following conditions are not covered under the terms of guarantee: defects due to natural wear
and tear, non-compliance with operating and maintenance instructions, connection to incorrect or
faulty supply voltage (including voltage surges outside equipment spec.), incorrect gas pressure,
overloading, transport or storage damage, fire of damage due to natural causes i.e. lightning or
flooding.

This guarantee does not cover direct or indirect travelling costs, daily allowances or accommodation.
Note: Under the terms of guarantee, welding torches and their consumables, feeder drive rolls and
feeder guide tubes are not covered. Direct or indirect damage due to a defective product is not
covered under the guarantee. The guarantee is void if changes are made to the product without
approval of the manufacturer, or if repairs are carried out using non-approved spare parts.

The guarantee is also void if repairs are carried out by non-authorised agents.

Undertaking guarantee repairs

Guarantee defects must be informed to Kemppi or authorised Kemppi Service Agents within the
guarantee period. Before any guarantee work is undertaken, the customer must provide proof of
guarantee or proof of purchase, and serial number of the equipment in order to validate the guarantee.
The parts replaced under the terns of guarantee remain the property of Kemppi.

Following the guarantee repair, the guarantee of the machine or equipment, repaired or replaced,
will be continued to the end of the original guarantee period.

MASTER 2200/0530 – 11© KEMPPI OY

KEMPPI OY
PL 13
FIN – 15801 LAHTI
FINLAND
Tel [phone]
Telefax [phone]
www.kemppi.com

KEMPPIKONEET OY
PL 13
FIN – 15801 LAHTI
FINLAND
Tel [phone]
Telefax [phone]
e-mail: myynti.fi @kemppi.com

KEMPPI SVERIGE AB
Box 717
S – 194 27 UPPLANDS VÄSBY
SVERIGE
Tel [phone]
Telefax (08) 59 082 394
e-mail: [e-mail]

KEMPPI NORGE A/S
Postboks 2151, Postterminalen
N – 3103 TØNSBERG
NORGE
Tel [phone]
Telefax 33 34 60 10
e-mail: [e-mail]

KEMPPI DANMARK A/S
Literbuen 11
DK – 2740 SKOVLUNDE
DANMARK
Tel [phone]
Telefax 44 941 536
e-mail:[e-mail]

KEMPPI BENELUX B.V.
Postbus 5603
NL – 4801 EA BREDA
NEDERLAND
Tel [phone]
Telefax [phone]
e-mail: [e-mail]

KEMPPI (UK) Ltd
Martti Kemppi Building
Fraser Road
Priory Business Park
BEDFORD, MK443WH
ENGLAND
Tel [phone]
Fax [phone]
e-mail: [e-mail]

KEMPPI FRANCE S.A.
S.A. au capital de 5 000 000 F.
65 Avenue de la Couronne des Prés
78681 EPONE CEDEX
FRANCE
Tel [phone]
Telefax (01) 30 90 04 45
e-mail: [e-mail]

KEMPPI GmbH
Otto – Hahn – Straße 14
D – 35510 BUTZBACH
DEUTSCHLAND
Tel [phone]
Telefax (06033) 72 528
e-mail:[e-mail]

KEMPPI SP. z o.o.
Ul. Piłsudskiego 2
05-091 ZA¸BKI
Poland
Tel [phone]
Telefax [phone]
e-mail: [e-mail]

KEMPPI WELDING
MACHINES AUSTRALIA PTY LTD
P.O. Box 404 (2/58 Lancaster Street)
Ingleburn NSW 2565, Australia
Tel. [phone]
Telefax [phone]
e-mail: [e-mail]

Ver. 8

www.kemppi.com