Kemppi Master 5001 User manual

MASTER

5001

1913270E

0541

Operation instructions • english

Gebrauchsanweisung • deutsch

Gebruiksaanwijzing • nederlands

Manuel d’utilisation • français

– MASTER 5001/0541 © KEMPPI OY
CONTENTS
PREFACE ...................................................................................................................... 3
1. INTRODUCTION ......................................................................................................... 3
2. PRODUCT INTRODUCTION ...................................................................................... 3
3. OPERATION SAFETY ................................................................................................. 3
INSTALLATION .............................................................................................................. 4
1. INSTALLATION ........................................................................................................... 4
2. SITING THE MACHINE ............................................................................................... 6
3. CONNECTION TO MAIN SUPPLY .............................................................................. 6
4. WELDING AND EARTH CABLES ............................................................................... 7
5. MOUNTING OF POWER UNIT TO TRANSPORT CARRIAGE .................................. 7
OPERATION CONTROL SWITCHES AND POTENTIOMETERS AND THEIR USE .... 8
1. MAIN SWITCH I/O ....................................................................................................... 8
2. PILOT LAMPS ............................................................................................................. 8
3. LOCAL OR REMOTE CONTROL OF WELDING CURRENT ..................................... 8
4. OPERATION OF COOLING FAN ................................................................................ 8
5. CONTROL FOR MMA WELDING DYNAMICS ........................................................... 9
MAINTENANCE ............................................................................................................11
1. CABLES .....................................................................................................................11
2. POWER SOURCE......................................................................................................11
3. REGULAR MAINTENANCE ...................................................................................... 12
OPERATION DISTURBANCES ................................................................................... 12
DISPOSAL OF THE MACHINE ................................................................................... 13
ORDER NUMBERS ..................................................................................................... 13
TECHNICAL DATA ...................................................................................................... 14
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

6 – MASTER 5001/0541 © KEMPPI OY

2.2. SITING THE MACHINE

Site the machine on a stationary, horizontal, dry base from which there does not come any dust

etc. into cooling air (front grate).

– Preferably site the 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 free distance to allow good circulation of the cooling air through the machine.

– Protect the machine against heavy rain and in hot circumstances against direct sunshine.

Ensure free circulation of the cooling air.

Degree of protection of machine IP23 allows at its maximum the water jet coming in

60° angle to hit machine´s outer covering.

See to that the machine is positioned away from the line of particle spray, created by grinding

tools etc.

2.3. CONNECTION TO MAIN SUPPLY

Master 5001 power source is delivered equipped with 5 m mains cable without plug. If local

electricity regulations of operating country are stating otherwise, the mains cable should be replaced

in conformity with them.

Connection of the mains cable and mounting of the plug should only be carried out by

a competent electrician.

Remove machine´s right side plate for the time you are mounting mains cable.

By change of the mains cable pay attention to 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. The phase conductors of the cable are coupled to connectors L1, L2

and L3. The earth protection coloured green-yellow is coupled to connector.

If you are using 5-lead cable, you must connect neutral conductor with terminal N.

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.

MASTER 5001/0541 – 7

Sizes of the mains cables and fuseratings for the machine at 100 % dury cycle are speciﬁed in the

table below:

Master 5001

Rated voltage 3~ 400 V

Mains voltage range 400 V ± 10 %

Fuses, delayed 35 A

Connection cable mm² 4 x 6,0 S

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

2.4. WELDING AND EARTH CABLES

Use only copper cables with cross-sectional area of at least 50 …95 mm².

In enclosed table are shown typical load capacities of rubber insulated copper cables, when ambient

temperature is 25ºC and lead temperature is 85 ºC.

Cable Duty cycled ed Voltage loss /10 m

100% 60% 30%

50mm² 285 A 370 A 520 A 0,35 V/ 100 A

70 mm² 355 A 460 A 650 A 0,25 V/ 100 A

95 mm² 430 A 560 A 790 A 0,18 V/ 100 A

Do not overload welding cables due to voltage losses and heating.

Fasten the earthing press of the return current cable carefully, preferably direct onto the piece to

be welded. The contact surface of the press should always be as large as possible.

Clean the fastening surface from paint and rust.

2.5. MOUNTING OF POWER UNIT TO TRANSPORT CARRIAGE

Read mounting instructions for Master 5001 power source delivered with carriage T12. Fasten

power source carefully of that the equipment should withstand lifting with lifting device.

8 – MASTER 5001/0541 © KEMPPI OY

3. OPERATION CONTROL SWITCHES AND

POTENTIOMETERS AND THEIR USE

3.1. MAIN SWITCH I/O

When you use the switch into I-position, pilot lamp H11 on the front wall is lighted and the machine

is ready for use.

Always start and switch off the machine with the main switch, never use the mains plug as a

switch.

3.2. PILOT LAMPS

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

The green pilot lamp H11 for readiness for use is always lighted, when the machine

is connected to mains supply and the main switch is in I-position.

Yellow pilot lamp H12 of thermal protection is lighted when thermostat has released

due to overheating of machine. The cooling fan is cooling down the machine and when

the pilot lamp is switched off, the machine is again ready for welding.

3.3. LOCAL OR REMOTE CONTROL OF WELDING CURRENT

You can control welding current either from local control unit R21 of the machine or from remote

control unit C100C which is connected to remote control connector X14. When you are using the

remote control unit, the switch S21 must be in remote control position:

During the control, the set value of welding current can be seen on current meter display P21

and at the same time the no-load voltage of the machine can be seen on voltage display. During

welding the current meter P21 and the voltage meter P22 show welding current respectively

welding voltage.

Note! Voltage which can be seen during welding on display P22, is terminal voltage of machine,

which is voltage between terminals X11 and X13.

Accuracy of digital meter is as follows:

Accuracy of current true value in respect to real value is ±2,5%, ±2A.

Accuracy of voltage true value in respect to real value is ±2,5 %, ±0,2 V.

Depending on welding cable length and copper cross-section, real arc voltage and meter display

might differ many volts from each other. Error will increase when current is growing. See table in

paragraph “welding and earthing cables”. In current measurement the same error won´t appear.

3.4. OPERATION OF COOLING FAN

In Master 5001 there are two simultaneously operating fans.

– Fan is started for a moment, when main switch is placed into position I.

– Fan is started after welding start after machine has been heated and runs still for 1…10 min

time after welding stop.

– On no-load fan is started in intervals of ca. half an hour for a minute´s time.

MASTER 5001/0541 – 9

S21

R21

P21

P22 P23 R22

3.5. CONTROL FOR MMA WELDING DYNAMICS

MMA welding dynamics is controlled with potentiometer R22. The potentiometer R22 has the

reference scale -9…0…9 can be seen also on the V display P22, which otherwise is showing no-

load/welding voltage. Setups for dynamics remain on the display still for approx. 3 s after you

have ﬁnished the control.

With control of MMA dynamics you can inﬂuence on arc in different situations. When you make

the arc harder, blow and at the same time spatter is increased.

-9…-1 Softer arc. Object: minimizing spatter in welding at upper end of recommended currents

for electrode.

0 Factory setup. Normal setting for all electrode types.

1…9 Harder arc. Object: eg cellulose covered electrodes (9) and thin stainless electrodes in welding

at lower end of recommended currents for electrode.

P21 Current meter

P22 Voltage meter

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

R21 Adjustment of welding current

R22 Adjustment of MMA welding dynamics

S21 Selection for local/remote control/TIG/MIG

10 – MASTER 5001/0541 © KEMPPI OY

C100C C100D

R61

R62

S 21

welding cable arc powered

wire feeder

C100C

Control of MMA welding current (R61), reference scale 1…10

C100D

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

Accessoiries and cables

MMA and arc powered MIG

MMA and scratch-start/contact TIG

Use of arc powered wire feeder

Master 5001 can be connected as power source to an arc powered wire feeder. In that case set

switch S21 of control panel to centre position. Power source operates then on constant voltage

characteristic curves (cv), which provides the best welding properties for arc powered units. Set

voltage is set with potentiometer or with remote control unit, if installed.

Scratch-start/contact TIG

Master 5001 can be used in TIG welding by switching the jumpers of control card to position TIG

(see jumper settings below). TIG welding is selected by setting switch S21 to centre position. Set

value of TIG is selected with control panel or with remote control unit, if installed. When TIG

electrode touches work piece welding current is on so called pilot current, which is 25 A. Current

is raised or reduced to actual welding current by pulling the electrode away from work piece. Note

that there is always voltage in the electrode when unit is set on TIG welding.

Jumpers

Jumpers on card A001:

Jumper 2 MIG/TIG

Jumpers 5 - 7 not in use

Jumpers 1, 3, 4 reserved (to be left open)

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