KEMPPI MASTER 2200 TIG Welder Rentals Instruction Manual

KEMPPI MASTER 2200 TIG Welder Rentals

Product Information

Specifications

• Model: MASTER 2200
• Part Number: 1913710E 0530
• Manufacturer: Unknown
• Website: https://manual-hub.com/

Preface

This user manual provides detailed information on the usage and operation of the MASTER 2200 welding machine. It covers installation, operation, maintenance, and troubleshooting instructions.

Introduction

The introduction section provides an overview of the product and its features.

Product Introduction

This section provides a detailed description of the MASTER 2200 welding machine, including its capabilities and applications.

Operation Safety

This section highlights important safety precautions that must be followed while using the welding machine to ensure user safety.

Installation

The installation section provides step-by-step instructions on setting up the welding machine for use.

Operation Control and Connectors

This subsection explains the various control switches and connectors on the welding machine and their functions.

Siting the Machine

This subsection guides users on selecting an appropriate location for the welding machine, considering factors such as ventilation and space requirements.

Connection to the Mains Supply

This subsection provides instructions on how to connect the welding machine to the mains power supply.

Welding and Return Current Cables

This subsection explains the proper connection and usage of welding and return current cables.

Operation Control Switches and Potentiometers and Their Use

This section provides detailed information on the operation of control switches and potentiometers on the welding machine.

Main Switch I/O

This subsection explains the function of the main switch and its operation.

Local/Remote Control of Welding Current

This subsection describes how to switch between local and remote control of welding current.

Adjustment for MMA Dynamics

This subsection provides guidance on adjusting the welding machine for MMA (Manual Metal Arc) dynamics.

Electrodes to be Welded

This subsection specifies the types of electrodes that can be used with the welding machine.

Remote Control Devices and Cables

This subsection explains the compatibility and usage of remote control devices and cables with the welding machine.

Maintenance

The maintenance section provides instructions on how to properly maintain and care for the welding machine.

Cables

This subsection explains how to inspect and maintain the cables used with the welding machine.

Power Source

This subsection provides guidelines for maintaining the power source of the welding machine.

Operation Disturbances

This section addresses common operation disturbances that users may encounter while using the welding machine.

Operation of the Overload Protection

This subsection explains how the overload protection feature of the welding machine operates and what to do in case of an overload.

Control Fuses

This subsection provides information on the control fuses used in the welding machine and how to replace them if needed.

Disposal of the Machine

This section provides guidelines on the proper disposal of the welding machine at the end of its lifecycle.

Ordering Numbers

This section lists the ordering numbers and codes for replacement parts or additional accessories related to the welding machine.

Technical Data

This section presents detailed technical specifications and data for the MASTER 2200 welding machine.

Terms of Guarantee

This section outlines the terms and conditions of the product guarantee provided by the manufacturer.

Product Usage Instructions

Installation

Follow these steps to install the MASTER 2200 welding machine:

1. Ensure you have read and understood all safety precautions mentioned in the user manual.
2. Select a suitable location for the welding machine, considering ventilation and space requirements.
3. Connect the welding machine to the mains power supply using the provided instructions.
4. Properly connect the welding and return current cables as instructed in the user manual.

Operation Control

Learn how to use the control switches and potentiometers on the welding machine:

• To turn on/off the welding machine, use the main switch located on the front panel.
• Switch between local and remote control of welding current as needed.
• Adjust the welding machine for MMA dynamics according to the specific requirements of your welding process.
• Refer to the user manual for information on the types of electrodes that can be used with the welding machine.
• If using remote control devices and cables, ensure compatibility and follow the provided instructions for their usage.

Maintenance

Proper maintenance is essential for the longevity and performance of the welding machine:

• Regularly inspect and maintain the cables used with the welding machine, following the instructions provided in the user manual.
• Follow the guidelines for maintaining the power source of the welding machine to ensure its proper functioning.

Operation Disturbances

If you encounter any operation disturbances while using the welding machine, refer to the following:

• Understand how the overload protection feature operates and take appropriate action in case of an overload.
• If control fuses need replacement, follow the instructions in the user manual to replace them correctly.

Disposal

When it is time to dispose of the welding machine, follow the guidelines provided in the user manual for proper disposal methods.

FAQ

Q: Where can I find replacement parts or additional accessories for the MASTER 2200 welding machine?

A: The ordering numbers and codes for replacement parts or additional accessories can be found in the user manual.

Q: How can I switch between local and remote control of welding current?

A: Refer to section 3.2 of the user manual for instructions on switching between local and remote control.

Q: What should I do if the welding machine experiences an overload?

A: Section 5.1 of the user manual explains the operation of the overload protection feature and provides guidance on what to do in case of an overload.

Q: Can I use any type of electrode with the MASTER 2200 welding machine?

A: Refer to section 3.4 of the user manual for information on the types of electrodes that can be used with the welding machine.

PREFACE

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.

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.

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 your 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 workpieces. 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 workpiece (i.e. in containers, cars etc.)
• Ensure that neither you nor gas bottles or electricial equipment are in contact with live wires or connections!
• 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.
• 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.

INSTALLATION

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

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.

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.

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!

OPERATION CONTROL SWITCHES AND POTENTIOMETERS AND THEIR USE

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

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.

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

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.

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

MAINTENANCE

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

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.

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 vacuum-cleaner. 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

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

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.

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.

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!

ORDERING NUMBERS

TECHNICAL DATA

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.

• KEMPPI OY
  PL 13 FIN – 15801 LAHTI FINLAND
  Tel (03) 899 11
  Telefax (03) 899 428
  www.kemppi.com

• KEMPPIKONEET OY
  PL 13 FIN – 15801 LAHTI FINLAND
  Tel (03) 899 11
  Telefax (03) 7348 398
  e-mail: mynti.fi@kemppi.com

• KEMPPI SVERIGE AB
  Box 717
  S – 194 27 UPPLANDS VÄSBY SVERIGE
  Tel (08) 59 078 300
  Telefax (08) 59 082 394
  e-mail: [email protected]

• KEMPPI NORGE A/S
  Postboks 2151, Postterminalen N – 3103 TØNSBERG NORGE
  Tel 33 34 60 00
  Telefax 33 34 60 10
  e-mail: [email protected]

• KEMPPI DANMARK A/S
  Literbuen 11 DK – 2740 SKOVLUNDE DANMARK
  Tel 44 941 677
  Telefax 44 941 536
  e-mail:[email protected]

• KEMPPI BENELUX B.V.
  Postbus 5603 NL – 4801 EA BREDA NEDERLAND
  Tel (076) 5717 750
  Telefax (076) 5716 345
  e-mail: [email protected]

• KEMPPI (UK) Ltd
  Martti Kemppi Building Fraser Road Priory Business Park BEDFORD, MK443WH ENGLAND
  Tel 0845 6444201
  Fax 0845 6444202
  e-mail: [email protected]

• 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 (01) 30 90 04 40
  Telefax (01) 30 90 04 45
  e-mail: [email protected]

• KEMPPI GmbH
  Otto – Hahn – Straße 14 D – 35510 BUTZBACH DEUTSCHLAND
  Tel (06033) 88 020
  Telefax (06033) 72 528
  e-mail: [email protected]

• KEMPPI SP. z o.o.
  Ul. Piłsudskiego 2 05-091 ZA¸BKI Poland
  Tel +48 22 781 6162
  Telefax +48 22 781 6505
  e-mail: [email protected]

• KEMPPI WELDING
  MACHINES AUSTRALIA PTY LTD P.O. Box 404 (2/58 Lancaster Street) Ingleburn NSW 2565, Australia
  Tel. +61-2-9605 9500
  Telefax +61-2-9605 5999
  e-mail: [email protected]

www.kemppi.com

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