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1. 16 Extension cable for remote control 20 Earth cable 21 welding cable C100C C100D Remote control devices 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 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 repairs and mounting of mains connection cables should be carried out only by an authorised electrician 4 2 POWER SOURCE Note Disconnect the plug of the machine from the mains socket and wait approx 2 minutes capacitor charge before removing the cover plate Check at least every half year Electric connections ofthe 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 eg with a soft brush and vacuum cleaner Also clean the ventilation net behind the front grate Do not use compressed air there is a risk that dirt is packed even more tightly into gaps of cooling profiles Do not use pressure washing device Only authorised electrician shall carry out repairs to the
2. and earth connection X14 Remote control connection 01 Inlet of mains cable X11 01 X13 11 14 KEMPPI OY MASTER 5001 0541 5 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 A 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 cabl
3. 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 1s 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
4. 5 Avenue de la Couronne des Pr s 78681 EPONE CEDEX FRANCE Tel 01 30 90 04 40 Telefax 01 30 90 04 45 e mail sales fr 9 kemppi com KEMPPI GmbH Otto Hahn StraBe 14 D 35510 BUTZBACH DEUTSCHLAND Tel 06033 88 020 Telefax 06033 72 528 e mail sales de 9 kemppi com KEMPPI SP z o o UI Pitsudskiego 2 05 091 ZABKI Poland Tel 48 22 781 6162 Telefax 48 22 781 6505 e mail info pl 9 kemppi com 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 info kemppi com au www kemppi com
5. INE 4 400 40 santet inn 13 ORDER NUMBERS iade iar ie i ede RR exe DL RE DAR D a a n FR RR RR 13 8 TECHNICAL DAT 14 9 TERMS OF GUARANTEE 15 2 MASTER 5001 0541 KEMPPI OY 1 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 i
6. Operation instructions english 1913270E Gebrauchsanweisung deutsch 0541 Gebruiksaanwijzing nederlands Manuel d utilisation francais MASTER 9001 gy Vv The Joy of Welding _ T PREFACE EE 3 LAL INTRODUGTION uniti tia tee m rt ee eden ie d e sted deta edat eed 3 1 2 PRODUCT a 3 1 8 OPERATION SAFE Yoa eire eta t th ct 3 2 INSTALLATION o De ER C VR RR EN C ADR RA EUR RR 4 2T INSTALLATION Ee 4 2 2 SITING TEE MACHINE teen e t tee erit leat e be deg hd tata 6 2 3 CONNECTION TO MAIN 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 3i MAIN SWITCH t et eee tr n n Dette eto teta PH ada 8 3 2 PILOT LAMPS epe rre Ee e RR ue M 8 3 3 LOCAL OR REMOTE CONTROL OF WELDING CURRENT 8 3 4 OPERATION OF COOLING 8 3 5 CONTROL FOR WELDING DYNAMICS seen een 9 4 WMgihyemm 11 AAS CABLES eC 11 4 2 POWER SOURJGE bee iad Aen P abe 11 4 3 MAINTENANCE ae 12 5 OPERATION DISTURBANCES 12 6 DISPOSAL OF THE MACH
7. d in intervals of ca half an hour for a minute s time 8 MASTER 5001 0541 KEMPPI OY 3 5 CONTROL FOR 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 22 23 R22 P21 DYNAMICS f i Sg H aem e R21 521 21 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 521 Selection for local remote control TIG MIG KEMPPI OY MASTER 5001 0541 9 _ 2 2 22222222222222 222 Use of arc powered wire feeder Master 5001 can be connected as power s
8. e is entered into the machine through the inlet ring 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 This equipment s electromagnetic compatibility EMC is designed for use in an industrial environment Class equipment is not intended for use in residential location where the electrical power is provided by the public low voltage supply system 6 MASTER 5001 0541 KEMPPI OY 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 96 Fuses delayed 35A Connection cable mm 4 6 05 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 mm In enclosed table are shown typical load capacities of rubber insulated copper cables when ambient temperature is 25 and lead temperature 1s 85 Cable Duty cycled ed Voltage loss 10 m 100 60 30 50mm 285A 370A 520A 0 35 V 100A 70 mm 355A 460A 650A 0 25 V 100A 95 mm 430A 560A 790A 0 18 V 100A Do not overload we
9. h is marked beside the fuse adapter Damage caused by a wrong type of fuse is not covered by the guarantee Under and overvoltages in the mains supply Primary circuits of machine are protected against sudden transient overvoltages Machine is designed to withstand 3 x 440 V voltage continously See to it that voltage is kept within admissible limits especially when mains supply is taken eg from combustion engine generator If the mains has undervoltage under ca 300 V machine control stops automatically 12 MASTER 5001 0541 KEMPPI OY Loss of a phase in the mains supply Loss of a phase causes noticeably poorer welding properties than normally or the machine doesn t get started at all Loss of a phase can be due to following blowing of mains supply fuse defective mains cable bad connection of mains connection cable on terminal block or plug of machine 6 DISPOSAL OF THE MACHINE Do not dispose of electrical equipment together with normal waste 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 ofthe equipment you should get information on approved collection systems from our local representative By ap
10. 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 KEMPPI OY MASTER 5001 0541 3 e 4 XY s w d w n 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 1s 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 R22 22 23 21 521 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 521 Selection for local remote control TIG MIG 4 MASTER 5001 0541 KEMPPI OY 12 H11 S11 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
11. lding 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 KEMPPI OY MASTER 5001 0541 7 _ 3 OPERATION CONTROL SWITCHES AND POTENTIOMETERS AND THEIR USE 3 1 MAIN SWITCH 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 18 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 15 again ready for welding 3 3 LOCAL OR REMOTE CONTROL OF WELDING CURRENT You can control welding current either from local co
12. machines OY MASTER 5001 0541 11 4 3 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 connectors switches and potentiometers checking of electric connections meter checking checking of mains cable and plug damaged parts of 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 5 OPERATION DISTURBANCES In case of problems contact the Kemppi works in Finland or your Kemppi dealer Check the maintenance objects before the machine is sent to the service repair shop Operation of the overload protection Yellow pilot lamp H12 of thermal protection is lighted when thermostat has operated due to overheating of machine The thermostat of machine will operate if machine is continously loaded over rated values or cooling air circulation is blocked Cooling fan cools down the machine and when the pilot lamp is not lighted the machine is automatically ready for welding Control fuses Fuse F11 1 0 A delayed on the rear wall of machine is as protection for connection of auxiliary devices X14 Use same type and rating of fuse whic
13. ntrol 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 Fanis started for a moment when main switch is placed into position I Fanis 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 starte
14. ource 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 15 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 1s 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 S 21 and arc powered MIG and scratch start contact TIG welding cable arc powered wire feeder Master 5001 Accessoiries and cables R62 C100D R61 R61 C100C Control of welding current R61 reference scale 1 10 C100D Rough control R61 reference scale 1 10 and fine control R62 for MMA welding current 10 MASTER 5001 0541 KEMPPI OY
15. plying this European Directive you will improve the environment and human health 7 ORDER NUMBERS Master 5001 6130512 20 5 m 50mm 6184511 20 5 m 70mm 6184711 21 5 m 50mm 6184501 21 5 m 70 mm 6184701 C100C 6185410 C100D 6185413 16c 10 m 6185451 25 6185452 50 m 6185453 12 6185228 KEMPPI OY MASTER 5001 0541 13 8 TECHNICAL DATA Master 5001 Mains voltage 3 50 60 Hz Rated power 80 ED 100 ED Connection cable Fuse Loading capacity 80 ED 100 ED Control range for welding current Max welding voltage Open circuit voltage Open circuit power Efficiency at nominal values Power factor Storage temperature range Operation temperature range Temperature class Degree of protection External dimensions length without handles width height Weight Voltage supply for auxiliary devices fuse The product meets conformity requirements for CE marking 400 V 10 95 500 25 6 440 A 20 2 4x6S 5m 35 A delayed 500A 40V 440 A 37 6 V 10A 500A 50 V 500A 68 V lt 75 85 0 93 40 60 oC 20 40 oC 180 130 IP23C 530 mm 230 mm 520 mm 48 kg 50 V DC 1 A delayed 14 MASTER 5001 0541 KEMPPI OY VV OT 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
16. proof of purchase and serial number ofthe 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 MASTER 5001 0541 15 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 myynti fi kemppi com KEMPPI SVERIGE AB Box 717 S 194 27 UPPLANDS V SBY SVERIGE Tel 08 59 078 300 Telefax 08 59 082 394 e mail sales se 9 kemppi com KEMPPI NORGE A S Postboks 2151 Postterminalen N 3103 TONSBERG NORGE Tel 33 34 60 00 Telefax 33 34 60 10 e mail sales no kemppi com KEMPPI DANMARK A S Literbuen 11 DK 2740 SKOVLUNDE DANMARK Tel 44 941 677 Telefax 44 941 536 e mail sales dk kemppi com KEMPPI BENELUX B V Postbus 5603 NL 4801 EA BREDA NEDERLAND Tel 076 5717 750 Telefax 076 5716 345 e mail sales nl 9 kemppi com 8 KEMPPI The Joy of Welding KEMPPI UK Ltd Martti Kemppi Building Fraser Road Priory Business Park BEDFORD MK443WH ENGLAND Tel 0845 6444201 Fax 0845 6444202 e mail sales uk kemppi com KEMPPI FRANCE S A S A au capital de 5 000 000 F 6
17. s 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 ofthe welding site Fire extinguishers must always be on site where welding 15 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

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