Kemppi 5001 Master User Manual

MASTER

5001

1913270E

0541

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

2 – MASTER 5001/0541 © KEMPPI OY

CONTENTS

1. PREFACE ...................................................................................................................... 3

1.1. INTRODUCTION ......................................................................................................... 3

1.2. PRODUCT INTRODUCTION ...................................................................................... 3

1.3. OPERATION SAFETY ................................................................................................. 3

2. INSTALLATION .............................................................................................................. 4

2.1. INSTALLATION ........................................................................................................... 4

2.2. SITING THE MACHINE ............................................................................................... 6

2.3. CONNECTION TO MAIN SUPPLY .............................................................................. 6

2.4. WELDING AND EARTH CABLES ............................................................................... 7

2.5. MOUNTING OF POWER UNIT TO TRANSPORT CARRIAGE .................................. 7

3. OPERATION CONTROL SWITCHES AND POTENTIOMETERS AND THEIR USE .... 8

3.1. MAIN SWITCH I/O ....................................................................................................... 8

3.2. PILOT LAMPS ............................................................................................................. 8

3.3. LOCAL OR REMOTE CONTROL OF WELDING CURRENT ..................................... 8

3.4. OPERATION OF COOLING FAN ................................................................................ 8

3.5. CONTROL FOR MMA WELDING DYNAMICS ........................................................... 9

4. MAINTENANCE ............................................................................................................11

4.1. CABLES .....................................................................................................................11

4.2. POWER SOURCE......................................................................................................11

4.3. REGULAR MAINTENANCE ...................................................................................... 12

5. OPERATION DISTURBANCES ................................................................................... 12

6. DISPOSAL OF THE MACHINE ................................................................................... 13

7. ORDER NUMBERS ..................................................................................................... 13

8. TECHNICAL DATA ...................................................................................................... 14

9. TERMS OF GUARANTEE ........................................................................................... 15

MASTER 5001/0541 – 3

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 5001 is a 3-phase inverter power source for demanding professional use. Master 5001 is suitable for MMA welding and carbon arc gouging. It is also suitable as power source for arc powered wire feeders. Master 5001 can also be used as power source for scratch-start/contact TIG. Due to its high effect and excellent welding properties as well as due to its small size and light weight it is very suitable for site welding as well as for repair and production welding.

In order to enable a good following of welding current the machine is equipped with well-visible displays for welding current and welding voltage. Properties of Master 5001 can be improved with remote control units and transport carts which are delivered as 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!

4 – MASTER 5001/0541 © KEMPPI OY

P21

P22

P23

R22

S21

R21

P21 Current meter

P22 Voltage meter

P23 Display for adjustment value of MMA welding dynamics -9..0...9

R21 Ajustment of welding current

R22 Adjustment of MMA welding dynamics

S21 Selection for local/remote control/TIG/MIG

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.

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. INSTALLATION

MASTER 5001/0541 – 5

H12

H11

S11

X11

X13

X14

F11

F11 Fuse for remote control connection 1,0 A delayed

H11 Signal lamp I/O

H12 Warning lamp for thermal shield

S11 Main switch I/O

X11 Welding and earth connection

X 13 Welding and earth connection

X14 Remote control connection

01 Inlet of mains cable

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