Kemppi 350, 450 Operating Manual

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FastMig Pulse

350, 450

CHANNEL

P65

OPERATING MANUAL

English

FastMig Pulse 350, 450 / © Kemppi Oy / 1110

CONTENTS

1. INTRODUCTION

.............................................................................................................. 3

1.1 General

....................................................................................................................................... 3

1.2 About FastMig Pulse products

.......................................................................................... 3

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

2.1 Before use .................................................................................................................................. 4

2.2 Distribution network ............................................................................................................. 4

2.3 Machine introduction ........................................................................................................... 5

2.4 Positioning of the machine ................................................................................................ 5

2.5 Connecting cables ................................................................................................................. 6

2.5.1 Water cooled system: FastMig Pulse + MXF + FastCool 10 ........................................... 6

2.5.2 Gas cooled system: FastMig Pulse + MXF ......................................................................7

2.5.3 Connecting to mains power ........................................................................................... 7

2.5.4 Welding and earth return cables .................................................................................... 8

2.5.5 Interconnection with wire feeder ................................................................................... 8

3. OPERATION CONTROL.............................................................................................. 8

3.1 Main switch I/O

....................................................................................................................... 8

3.2 Pilot lamps ................................................................................................................................. 8

3.3 Operation of cooling fan

..................................................................................................... 9

3.4 Manual Metal Arc Welding ................................................................................................. 9

4. USING THE MACHINE................................................................................................. 9

4.1 Arc Wizard, setup panel P65 – layout .............................................................................. 9

4.2 Setup panel P65 – quick guide .......................................................................................... 9

4.3 Welding parameters and functions ...............................................................................10

4.3.1 Welding parameters (In Edit Channel menu 2/6) ........................................................10

4.3.2 Welding functions .........................................................................................................12

4.3.3 Welding software delivery prole ................................................................................17

4.4 Getting started ......................................................................................................................18

5. BASIC TROUBLESHOOTING ...............................................................................20

6. OPERATION DISTURBANCES ............................................................................21

6.1 Operation of the overload protection ..........................................................................21

6.2 Control fuses ..........................................................................................................................21

6.3 Under and over voltages in the mains supply ...........................................................21

6.4 Loss of a phase in the mains supply ..............................................................................21

7. MAINTENANCE ..............................................................................................................21

7.1 Daily maintenance

...............................................................................................................21

7.2 Period maintenance

............................................................................................................22

7.3 Service shop maintenance ...............................................................................................22

8. DISPOSAL OF THE MACHINE ............................................................................22

9. ORDERING NUMBERS .............................................................................................23

10. TECHNICAL DATA ........................................................................................................25

FastMig Pulse 350, 450 / © Kemppi Oy / 1110

1. INTRODUCTION

1.1 GENERAL

Congratulations on choosing the FastMig Pulse welding equipment. Used correctly, Kemppi products can signicantly increase the productivity of your welding, and provide years of economical service.

This operating manual contains important information on the use, maintenance and safety of your Kemppi product. The technical specications of the equipment can be found at the end of the manual.

Please read the manual carefully before using the equipment for the rst time. For your own safety and that of your working environment, pay particular attention to the safety instructions in the manual.

For more information on Kemppi products, contact Kemppi Oy, consult an authorised Kemppi dealer, or visit the Kemppi web site at www.kemppi.com.

The specications presented in this manual are subject to change without prior notice.

Important notes

Items in the manual that require particular attention in order to minimise damage and personal harm are indicated with the ’NOTE!’ notation. Read these sections carefully and follow their instructions.

1.2 ABOUT FASTMIG PULSE PRODUCTS

FastMig™ Pulse 350 and 450 are CC/CV welding power sources designed for demanding professional use. They are suitable for synergic Pulsed MIG/MAG, synergic 1-MIG/MAG, basic MIG/MAG and MMA welding in DC current when connected to FastMig MXF wire feeding units. P65 setup panel is included in the delivery for selecting, setting and managing the welding system prior to and during system use.

FastMig Pulse 350/450 product range oers both technical and commercial welding solutions matching a wide range of applications from sheet metal fabrication to heavy industry segments. Innovative distance wire feeding solutions are also available for use with this product, including SuperSnake GT02S/GT02SW.

Disclaimer

While every eort has been made to ensure that the information contained in this guide is accurate and complete, no liability can be accepted for any errors or omissions. Kemppi reserves the right to change the specication of the product described at any time without prior notice. Do not copy, record, reproduce or transmit the contents of this guide without prior permission from Kemppi.

FastMig Pulse 350, 450 / © Kemppi Oy / 1110

2. INSTALLATION

2.1 BEFORE USE

The product is packed in specially designed transport cartons. However, before use always make sure the products have not been damaged during transportation.

Check also that you have received the components you ordered and the instruction manuals needed, as described in the Quick start guide pack. Product packaging material is recyclable.

NOTE! When moving the welding machine, always lift it from the handle, never pull it from the

welding gun or other cables.

Operating environment

This machine is suitable for both indoor and outdoor use. Always make sure that the air ow to the machine is unrestricted. The recommended operating temperature range is

-20 … +40 °C. Please ensure you read the safety instructions concerning operating environments supplied in

this manual.

2.2 DISTRIBUTION NETWORK

All regular electrical devices without special circuits generate harmonic currents into distribution network. High rates of harmonic current may cause losses and disturbance to some equipment.

FastMig™ Pulse 350 and 450:

This equipment complies with IEC 61000-3-12 provided that the short-circuit power S

is greater than or equal to 5.5 MVA at the interface point between the user’s supply and the public suply network. It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power Ssc greater than or equal to 5.5 MVA.

FastMig Pulse 350, 450 / © Kemppi Oy / 1110

2.3 MACHINE INTRODUCTION

CHANNEL

6,3A

10.

1. Setup panel 'Arc Wizard P65'

2. Main switch I/O – On/O

3. Signal lamp I/O – On/O

4. Warning lamp for thermal protection

5. Welding cable connection - negative pole

6. Welding cable connection + positive pole

7. Control cable connection

8. Fuse – 6,3 A delayed

9. Control cable connection

10. Mains power cable

2.4 POSITIONING OF THE MACHINE

Place the machine on a sturdy, level surface that is dry and does not allow dust or other impurities to enter the machines cooling air ow. Preferably site the machine to a suitable carriage unit so it is above oor level.

Notes for positioning the machine

• The surface inclination may not exceed 15 degrees.

• Ensure the free circulation of the cooling air. There must be at least 20 cm of free space in

front of and behind the machine for cooling air circulation.

• Protect the machine against heavy rain and direct sunshine.

The machine is not allowed to be operated in the rain as the protection class of the machine, IP23S, allows preserving and storing outside only.

NOTE! Never aim the spray of sparks from a grinding machine toward the equipment.

FastMig Pulse 350, 450 / © Kemppi Oy / 1110

2.5 CONNECTING CABLES

NOTE! Always check before use that the interconnecting cable, shielding gas hose, earth return

lead/clamp, and mains cable is in a serviceable condition. Ensure that connectors are correctly fastened. Lose connectors can impair welding performance and damage connectors.

2.5.1 Water cooled system: FastMig Pulse + MXF + FastCool 10

1. MXF wire feed unit

2. FastMig Pulse power source

3. FastCool water cooler and power connection

4. Gas supply

5. MMA electrode holder

6. Remote control device

7. Liquid cooled welding Gun

8. Power cable

9. Earth return lead and clamp

FastMig Pulse 350, 450 / © Kemppi Oy / 1110

2.5.2 Gas cooled system: FastMig Pulse + MXF

1. MXF wire feed unit

2. FastMig Pulse power source

3. Gas supply

4. MMA electrode holder

5. Remote control device

6. Air cooled welding Gun

7. Power cable

8. Earth return lead and clamp

2.5.3 Connecting to mains power

FastMig power sources are delivered as standard with 5 meters of mains power cable. No mains plug is tted at the Kemppi factory.

NOTE! If local country based regulations state an alternative power cable is required, the mains

cable must be replaced in conformity with the regulations. Connection and installation of the mains cable and plug, should only be carried out by a suitably qualied person.

Remove the machine cover plate to enable mounting of a mains cable. FastMig Pulse power sources can be connected to the mains supply of 400 V 3~ .

If changing the mains cable take into consideration 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 (05). The phase conductors of the cable are coupled to connectors L1, L2 and L3. The earth protection coloured green-yellow is coupled to the marked connector.

If you are using 5-lead cable, do not connect the neutral conductor.

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

FastMig Pulse 350, 450 / © Kemppi Oy / 1110

2.5.4 Welding and earth return cables

Kemppi always recommend the use of high quality copper cables with a suitable crosssectional area. Cable size should be selected depending on the intended welding application.

50mm Copper welding cables may be used for low duty work in basic or Synergic 1-MIG. However when using Pulse MIG/MAG process, and or longer cables, and or higher welding power, voltage loss increases, and therefore smaller cross sectional interconnecting power and return cables will restrict the welding performance of your machine.

• FastMig Pulse 350 – 70 to 90 mm²

• FastMig Pulse 450 – 70 to 90 mm²

The enclosed table shows typical load capacities of rubber insulated copper cables, when ambient temperature is 25 °C and the cable temperature is 85 °C.

Cable Duty cycle ED Voltage loss / 10 m

100 % 60 % 30 %

50 mm²

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.

NOTE! Always check the serviceability of the earth return cable and clamp. Ensure the metal

surface to which the cable is connected is clean from metal oxide or paint. Check the connector to the power source is fastened correctly.

2.5.5 Interconnection with wire feeder

Kemppi provide a choice of interconnection cable sets for dierent environments. Only materials that meet the demands of Kemppi's international markets are used in their construction.

Used correctly, Kemppi cables sets ensure high welding performance and serviceability. Before use, always ensure the cable set is in good condition and that connectors are correctly

fastened. Loose connections reduce welding performance and may result in damage to connectors due to heating eects.

For correct connection and conguration of cable sets, please refer to schematic drawings:

2.5.1 and 2.5.2

NOTE! FastMig 350/450 power sources are designed to be used ONLY with MXF wire feed units.

3. OPERATION CONTROL

3.1 MAIN SWITCH I/O

When you turn the on/o switch into I -position, the pilot warning lamp is illuminated and the machine is ready for use. Always turn the machine on and o with the power source mains switch. Never use the mains plugs as a switch.

3.2 PILOT LAMPS

The pilot lamps of the machine report its operational state: The green pilot lamp when lit, indicates that the machine is switched on and ready for

use, and that it is connected to the mains supply with the power source main switch in the I-position.

When lit, the orange lamp indicates that the thermal protection circuit has been activated due to higher than normal working loads that exceed the rated duty cycle. The cooling fan will continue to run and cool the machine down. When the lamp is o the machine is again ready to weld.

FastMig Pulse 350, 450 / © Kemppi Oy / 1110

3.3 OPERATION OF COOLING FAN

FastMig Pulse power sources incorporate two simultaneously operating fans.

• The fan is started momentarily when the main switch is placed into position - I.

• The fan will start during welding as the machine reaches operational temperature, and

it will run for 1 to 10 minutes after the welding has stopped, depending on the welding cycle completed.

3.4 MANUAL METAL ARC WELDING

FastMig Pulse power source can be used for MMA electrode welding by connecting the FastMig MXF wire feeding unit and PF function panel. MMA function is optional in FastMig Pulse equipment, and therefore can be activated by purchasing the appropriate licence for the MMA process. Please see ordering number codes. FastMig Pulse power source will not support the MMA process without an MXF wire feeder connected.

4. USING THE MACHINE

Welding applications vary, so the equipment must adapt. FastMig Pulse features Arc Wizard P65 interface, a clear and logical LCD menu display. Arc Wizard menu allows the operator to rene, adapt and manage the arc process and system function before, during and after welding.

4.1 ARC WIZARD, SETUP PANEL P65  LAYOUT

CHANNEL

CHANNEL INFO

USER

WF #

F1 F2 F3

P 65

W003989

1. 4.

5.6.

2. 7. 3.

4.2 SETUP PANEL P65  QUICK GUIDE

The following information details P65 panel operation and set-up. Additional information is also available in the printed 'Quick Guide' for P65 and PF function panels. Quick Guide is included in the delivery package, plus pdf copy recorded to CD.

Introduction to P65 button functions

1. Switch P65 ON/OFF by long pressing on this button (approximately 5 seconds). Also returns channel information display by short press.

NOTE! For true ON/OFF switching of the mains power, use the main switch I/O – ON/OFF located

on the front of the power source.

FastMig Pulse 350, 450 / © Kemppi Oy / 1110

2. Welding channel (job) selection. There are 10 memory channels available per USER channel. There are 10 USER channels . If the channel is empty you can create a new (job) channel by pressing the key below the LCD screen text stating NEW.

3. MENU button for entering the main menu list. Proceed following the LCD screen menu guidance.

P65 main menu list Edit Channel

for making changes to existing welding channel

User Identification

for selecting one user out of ten

Weld Data

for checking out the values of the last weld

System Config Menu

for device conguration and information

Language

for selecting your menu language

Select Feeder (WF#)

for selecting another parallel wire feeder as a setup target

MMA on/off

for activating electrode welding (licence needed)

Buttons in dierent situation (shortcut) include functions depending on menu/task.

4. Potentiometer for making adjustments to selected values

5. Up/down arrow keys for moving vertically in the menu structure

6. Pre-programmed menu shortcut keys

• F1 for displaying channel information

• F2 for selecting the USER

• F3 for selecting another parallel connected wire feeder sub system as a setup target.

7. LCD menu display

8. Soft key buttons. Function according to the menu location/task.

4.3 WELDING PARAMETERS AND FUNCTIONS

4.3.1 Welding parameters (In Edit Channel menu 2/6)

MIG

WFSpeed

0.7 – 25 m/min 0.05 m/min steps when WFSpeed < 5 m/min and

0.1 m/min steps when WFSpeed > 5 m/min

WFS-Max

Set the limit for maximum WFSpeed

WFS-Min

Set the limit for minimum WFSpeed

Voltage

8 – 50V 0.1V steps Controls the length of the arc

VoltageMax

Set the limit for maximum voltage value

VoltageMin

Set the limit for minimum voltage value

Dynamics

-9 ... +9 Factory setting is 0 Controls the short circuit behaviour of the arc. The lower the value the softer the arc is. The higher the value the rougher the arc is.

FastMig Pulse 350, 450 / © Kemppi Oy / 1110

1-MIG

WFSpeed

0.7 – 25 m/min * 0.05 m/min steps when WFSpeed < 5 m/min and

0.1 m/min steps when WFSpeed > 5 m/min

WFS-Max

Set the limit for maximum WFSpeed

WFS-Min

Set the limit for minimum WFSpeed

FineTuning

-9 ... +9 Factory setting is 0 ( = curve point)

Adjusts the arc voltage of the curve within certain limits. In other words, it adjusts the length of the arc within certain limits

FineTuningMax

-9 ... +9 0.5 steps Set the limit for maximum arc length

FineTuningMin

-9 ... +9 0.5 steps Set the limit for minimum arc length

Dynamics

-9 ... +9 Factory setting is 0 Controls the short circuit behaviour of the arc. The lower

the value the softer the arc is. The higher the value the rougher the arc is.

PULSE MIG

WFSpeed

0.7 – 25 m/min * 0.05 m/min steps when WFSpeed < 5 m/min and

0.1 m/min steps when WFSpeed > 5 m/min

WFS-Max

Set the limit for maximum WFSpeed

WFS-Min

Set the limit for minimum WFSpeed

FineTuning

-9 ... +9 Factory setting is 0 ( = curve point)

Adjusts the base current of the curve in certain limits. In other words, it adjusts the length of the arc in certain limits.

FineTuningMax

-9 ... +9 0.5 steps Set the limit for maximum arc length

FineTuningMin

-9 ... +9 0.5 steps Set the limit for minimum arc length

Dynamics

-9 ... +9 Factory setting is 0 Controls the short circuit behaviour of the arc. The lower

the value the softer the arc is. The higher the value the rougher the arc is.

Pulse Current

-10% ... +15% Factory Setting is 0%

Reduces the pulse current of the curve at the maximum 10% and raises it at the maximum 15%.

DOUBLE PULSE MIG

WFSpeed

0.7 – 25 m/min * 0.05 m/min steps when WFSpeed < 5 m/min and

0.1 m/min steps when WFSpeed > 5 m/min

WFS-Max

Set the limit for maximum WFSpeed

WFS-Min

Set the limit for minimum WFSpeed

FineTuning

-9 ... +9 Factory setting is 0 ( = curve point)

Adjusts the base current of the curve in certain limits. In other words, it adjusts the length of the arc in certain limits.

FineTuningMax

-9 ... +9 0.5 steps Set the limit for maximum arc length

FineTuningMin

-9 ... +9 0.5 steps Set the limit for minimum arc length

Dynamics

-9 ... +9 Factory setting is 0 Controls the short circuit behaviour of the arc. The lower

the value the softer the arc is. The higher the value the rougher the arc is.

Pulse Current

-10% ... +15% Factory setting is 0%

Reduces the pulse current of the curve at the maximum 10% and raises it at the maximum 15%

DPulseAmp

0.1 – 3.0 m/min Factory setting is CURVE

Adjusts the amplitude of the WFSpeed in 0.1 m/min steps. Value comes from Welding Curve.

DPulseFreq

0.4 – 8.0 Hz Factory setting is CURVE

Adjusts the frequency of the double pulse in 0.1 Hz steps. Value comes from Welding Curve.

FastMig Pulse 350, 450 / © Kemppi Oy / 1110

WISEROOT / WISETHIN

WFSpeed

0.7 – 14 m/min * 0.05 m/min steps when WFSpeed < 5 m/min and

0.1 m/min steps when WFSpeed > 5 m/min

WFS-Max

Set the limit for maximum WFSpeed

WFS-Min

Set the limit for minimum WFSpeed

BaseCurrent

-50 ... +50 Adjusts the base current of the curve – the arc length – within certain limits.

BaseCurrentMax

-50 ... +50 1% steps Set the limit for maximum “arc length”

BaseCurrentMin

-50 ... +50 1% steps Set the limit for minimum “arc length”

FormingPulse

-30 ... +30 Adjusts the forming pulse current of the curve in certain limits. In other words, it controls arc pressure.

FormingPulseMax

-30 ... +30 1% steps Set the limit for maximum forming pulse current

FormingPulseMin

-30 ... +30 1% steps Set the limit for minimum forming pulse current

StartTime

-9 ... +9 Factory setting is 0 Set how long arc behaves like normal synergic MIG/ MAG prosess after the arc start. It gives heat for the arc start.

StartVoltage

-30 ... +30 Factory setting is 0 Set the arc voltage which is used during StartTime. In other words, it adjusts the length of the arc during StartTime.

* Dierent welding curves may further restrict the value range further.

MMA PROCESSES

Current

14 – 350A/450A Welding current

CurrentMax

14 – 350A/450A Set the limit for maximum current value

CurrentMin

14 – 350A/450A Set the limit for minimum current value

ArcForce

-9 ... +9 Factory setting is 0 Controls the short circuit behaviour of the arc. The lower the value the softer the arc is. The higher the value the rougher the arc is.

4.3.2 Welding functions

OTHER PROCESSES

(In Edit Channel menu 3/6)

2T/4T

2T, 4T, MATCHLOG or USER

Factory setting is USER => USER can freely choose the switching logic

Set switching logic

HotStart

ON, OFF or USER Factory setting is USER =>

USER can freely choose is the HotStart ON or OFF

HotStartLevel

-50 ... +100 % 1 % steps. Factory setting 40%

Hot 2T Time

0 – 9.9 s 0.1 s steps. Factory setting 1.2 s

CraterFill

ON, OFF, USER Factory setting is USER =>

USER can freely choose is the CraterFill ON or OFF

CraterStart

10 – 250% Factory setting is 100% Set the level of the curve where the crater

lling will start

CraterFillEnd

10 – 250 %, not higher than start

1 % steps. Factory setting 30% Set the level of the curve where the crater

lling will end.

FastMig Pulse 350, 450 / © Kemppi Oy / 1110

CraterTime

0.0 – 10.0 s 0.1 s steps. Factory setting 1.0 s CrateFill Slope Time

Crater 4T Timer

On or OFF Factory setting is OFF ON: if 4T is selected crater lling will last

at least time that has been ad-justed by CraterTime or as long as trigger is pressed. OFF: if 4T is selected crater lling will last as long as trigger is pressed.

Creep Start

10 – 99% 1% steps. OFF, CURVE

(OFF = 100%)

Factory setting is CURVE (Creep Start value comes from Welding Curve).

StartPower

-9 ... +9 Factory setting is 0 Adjusts arc ignition

WISEROOT / WISETHIN

2T/4T

2T, 4T, MATCHLOG or USER

Factory setting is USER => USER can freely choose the switching logic

Set switching logic

HotStart

ON, OFF or USER Factory setting is USER =>

USER can freely choose is the HotStart ON or OFF

HotStartLevel

-50 ... +100 % 1 % steps. Factory setting 40%

Hot 2T Time

0 – 9.9 s 0.1 s steps. Factory setting

1.2 s

CraterFill

ON, OFF, USER Factory setting is USER =>

USER can freely choose is the CraterFill ON or OFF

CraterStart

10 – 250% Factory setting is 100% Set the level of the curve where the crater

lling will start.

CraterFillEnd

10 – 250%, not higher than start

1 % steps. Factory setting 30%

CraterTime

0.0 – 10.0 s 0.1 s steps. Factory setting

1. 0 s

Crater 4T Timer

On or OFF Factory setting is OFF ON: if 4T is selected crater lling will last

at least time that has been ad-justed by CraterTime or as long as trigger is pressed. OFF: if 4T is selected crater lling will last as long as trigger is pressed.

Creep Start

10 – 99% 1% steps. OFF, CURVE (OFF =

100%)

Factory setting is CURVE (Creep Start value comes from Welding Curve).

FastMig Pulse 350, 450 / © Kemppi Oy / 1110

ADVANCED FUNCTIONS

WisePenet

ON or OFF Penetration control selection

Penet%(123A)

-30 ... +30 % Factory setting: 0 % Wise penetration percent setting. Set

penetration Current.

WiseFusion

ON or OFF WiseFusion selection

WiseFusion%

10 – 60 % or CURVE

Factory setting is CURVE When WISE FUSION is ON it controls the

amount of short circuits in the arc. The lower the value there will be less short circuits in the arc. The higher the value there will be more short circuits in the arc.

MatchLog Menu —> MinilogLevel

-99 ... +125 Factory setting: 20 % Set the “MiniLog level”

SYSTEM CONFIG MENU (In Main menu 4/7)

Water Cooling

Water Cooler control: OFF / AUTO / ON.

Factory setting: AUTO OFF: Water Cooler always OFF.

AUTO: Water Cooler automatic control ON. Water Cooler starts when welding starts and is turned o after a delay when welding stops. ON: Water Cooler is always ON.

Cable Length

Cable length: 10m – 100m, 5m steps.

Factory Setting: 10m Welding cable loop length setting for

optimising arc control.

FineCalib

Fine Tuning Calibration Point: 0V/100A – 10V/100A, 1V steps.

Factory Setting: 1.0V/100A Compensation for varying cable resistance.

System Clock

System Clock Settings

Device Information

System Device information: DevSW: Unit Software Version. SysSW: System Software Version (Base software version). BootSW: Boot Software Version. SW Item: Software Item Number (IFS number). Serial: Device Serial number. Prog: Programmer name Date: Programming date.

Restore Settings

User 1 (one of ten users) Channel: Selected user can restore to his backup memory channels one by one. Other users’ memory channels remain untouched. Setup settings remain untouched.

User 1 (one of ten users) All Channels: Selected user can restore all of his backup memory channels (0-9) at one time. Other users’ memory channels remain untouched. Setup settings remain untouched.

Restore To Factory: All channels (of all users) are removed. All users’ backup channels are removed. All setup settings are set to defaults.

Licence Menu

Licence Code allows you to enter the licence code:

- Up/Down arrows are used to select the code number position.

- Pulse encoder is used to select the code number (0-255) to be entered.

- Soft key button on the right is used to activate the licence number (after all numbers have been

entered). In case the code was wrong the earlier view will be displayed. Licence Timers allows you to check the remaining time of the time-based Wise features.

FastMig Pulse 350, 450 / © Kemppi Oy / 1110

WeldData Delay

Adjustment Range: 1s – 60s, 1s steps.

Factory Setting: 20s. Denes how long the Weld Data is

displayed after Welding Ends. Weld Data display is also turned o when pulse encoder is turned or any button is pressed.

Display Delay

Adjustment Range: 1 – 20, 1 steps.

Factory Setting: 10 Denes how long time the information is

displayed (like: “Setting Saved” text). This is not always the exact time.

Pre Gas Time

Pre Gas Time setting:

0.0s – 9.9s – CURVE,

0.1s steps.

Factory Settings: CURVE CURVE: Pre Gas time is read from the

Welding Curve.

0.0 – 9.9s: User Pre Gas time setting.

Post Gas Time

Post Gas Time setting:

0.0s – 9.9s – CURVE,

0.1s steps.

Factory Settings: CURVE CURVE: Pre Gas time is read from the

Welding Curve.

0.0 – 9.9s: User Post Gas time setting.

Control

Remote Control Selection: USER / PANEL / REMOTE / GUN.

Factory Settings: USER This setting aects to Welding panel (PF65

panel) remote control unit selection. USER: PF65 user can freely select the Remote control device. PANEL: PF65 user can not select the remote device. Selection is locked to PANEL. REMOTE: Selection is locked to HAND REMOTE device. GUN: Selection is locked to GUN REMOTE device.

RemoteAutoRecog

Remote Auto Recognition: ON / OFF.

Factory Setting: ON ON: Remote control units are recognized.

Welding panel (PF65) jumps to PANEL selection if the selected remote control unit disappears. If PF65 USER selection is allowed (see Control). OFF: Remote control units are not recognized. Remote device selection remains unchanged if the selected remote control unit disappears

MIG CurrentDisp

ON / OFF Factory Setting: OFF ON: Display’s amperage (A) preset values

OFF: Display’s wire feed speed m/min.

WFMotorWarnLev

1.5 – 5.0 A Factory Setting: 3.5A The alarm level of wire feed motor current. Check/service wire feed mechanism, adjustment and gun components.

WF End Step *

ON/OFF Factory Setting: OFF ON: The ller wire steps forward at the end

of the welding cycle. OFF: Filler wire remains static at the end of the welding cycle.

AutoWireInch

ON/OFF Factory Setting: ON Automatic SuperSnake Wire Inch feature.

When ON, the Wire Inch button drives the ller wire automatically up to SuperSnake.

Gas Guard

ON/OFF Factory Setting: OFF Turns the gas guard on and o, provided

that one is installed.

* Enabled only in processes with ller wire.

FastMig Pulse 350, 450 / © Kemppi Oy / 1110

ADMINISTRATOR MENU (In Main menu 2/7, User Identication)

Change PIN Code

Administrator pin code change.

Factory PIN code: 0000

Ask PIN

PIN code inquiry selection: OFF / StartUp / Menu

Factory Setting: OFF OFF: No PIN code inquiry.

StartUp: Setup panel (P65) always asks for the PIN code when the machine is turned on. PF 65 is not aected and always works without PIN. Menu: Setup panel (P65) asks every time for PIN code when MENU button is pressed and when the display is in channel info mode i.e. in start-up view. PIN code inquiry is made only once when entering the menu. After that the menu button can be pressed any time without PIN inquiry.

BUTTON FUNCTIONS

ON / OFF Button

Short Press: Panel returns to default start-up display view (Channel info display). Long Press: When setup panel (P65) is ON => Setup panel and all PF65 panels are turned OFF. When setup panel is OFF => Setup panel and all PF65 panels are turned ON. Pressed while machine is turning ON: Restore to factory shortcut. Panel will ask conrmation to restore factory setting. If Setup panel is OFF and some other PF65 panel is turned ON the Setup Panel turns also ON and will be linked automatically to this PF panel (WF# function).

F1 Button

F1 button gives further information of selected memory channel. Pressed while machine is turned ON: Restore language selection to English.

F2 Button

F2 button can be used to select user. Selections: 1 – 10, Administrator. If Welding Process is MMA only Administrator is allowed.

F3 Button (WF#)

F3 button can be used to select Wire Feeder. Panel allows selecting only those WF numbers that are found connected on the sys-tem.

Channel +/-

Memory channel selection.

Up/Down Button

Moving Up/Down in menu.

Right/Left selection buttons (Soft Keys)

Button function depends on where in menu you are.

FastMig Pulse 350, 450 / © Kemppi Oy / 1110

4.3.3 Welding software delivery prole

FastMig Pulse is designed to allow customer specied welding software choice. Following delivery and installation your machine will include welding software specied at the point of order. Detailed in the table below are typical welding curves available. If the delivery specication is focused to a specic project and you wish to up-date the machine in future, you can select additional welding software from the Wise & Match software menu. Order and load these software products to your machine with Kemppi DataGun eld program device.

Wise and Match products provide optional welding application solutions. Wise and Match products menu includes special weld process for (1) root pass and (2) thin plate welding, (3) auto power regulation and (4) arc length recognition, (5) system lock function, plus additional base material curves and optional panel function. With Wise & Match you can turn something special into something unique.

1. WiseRoot

6265011

2. WiseThin

9991013

3. WisePenetration

9991000

4. WiseFusion

9991014

5. MatchLog

9991017

WORK PACK. The welding table below details Work Pack delivery option. Additional welding software products can be purchased and added later if required.

Group N:o Pulse 1-MIG Wire ø mm Material Gas Alu

A02 X X 1.2 AlMg5/AlMgMn Ar

Alu

A12 X X 1.2 AlSi5/AlSi12 Ar

F03 X X 1 Fe Ar+18–25%CO

F04 X X 1.2 Fe Ar+18–25%CO

S03 X 1 Ss-316/308 Ar+2%CO

S04 X X 1.2 Ss-316/308 Ar+2%CO

S06 X 1 Ss-316/308 Ar+2%CO

R04 X 1.2 FeFC_Rut Ar+18–25%CO

M04 X 1.2 FeMC Ar+18–25%CO

S84 X 1.2 FC-316 Ar+25%CO

More welding curves are available by purchasing Kemppi's MatchCurve and MatchCustom product packages.

Kemppi WISE products are welding process solutions. WiseRoot and WiseThin process group curves are listed below.

Group N:o WiseRoot WiseThin Wire ø mm Material Gas Fe

F01 X 0.8 Fe Ar+18–25%CO

F02 X X 0.9 Fe Ar+18–25%CO

F03 X X 1 Fe Ar+18–25%CO

F04 X X 1.2 Fe Ar+18–25%CO

S03 X X 1 SS-316/308 Ar+2%CO

S04 X X 1.2 SS-316/308 Ar+2%CO

C03 X 1 CuSi3 Ar

C13 X 1 CuAl8 Ar

F21 X 0.8 Fe CO

FastMig Pulse 350, 450 / © Kemppi Oy / 1110

F22 X X 0.9 Fe CO

F23 X X 1 Fe CO

F24 X X 1.2 Fe CO

S01 X 0.8 Ss-316/308 Ar+2%CO

S02 X X 0.9 Ss-316/308 Ar+2%CO

S12 X 0.9 Ss-316/308 Ar+He+CO

S13 X 1 Ss-316/308 Ar+He+CO

S14 X 1.2 Ss-316/308 Ar+He+CO

4.4 GETTING STARTED

Step by step for the rst time user

First select your language

NOTE! The default menu language is English. In the following steps you will be able to select

alternative languages

1. Connect mains power and switch on power source. If this is the initial system activation you may need to press and hold the large orange ON/OFF button on the ARC WIZARD P65 panel. Top left - Long Press (Approximately 5 seconds).

2. Now press button marked ‘MENU’ to display MAIN MENU listing. There are 7 x items in this MAIN MENU list. As you select each item in the list, the reference number (Bottom middle display) will change e.g. 2/7 or 5/7 etc, showing which menu item you have selected. (You can cycle from rst to last or last to rst in a loop in all menu lists, if you wish). A black arrow marks your menu item selected.

3. MENU items are selected via the UP-DOWN buttons marked with orange arrows. These buttons are situated underneath the encoder knob to the right of the panel. Move the ‘black arrow cursor’ up and down the menu lists. Press down arrow button selecting item 5/7 marked LANGUAGE. Press soft key button underneath the word SELECT.

4. Make your language choice as detailed above, and then press the SELECT/SAVE button (righthand button next to MENU button). Your language choice is now conrmed and will remain selected unless you change it later.

New channel job number

FastMig Pulse is designed for production jobs as well as varied specialist operation. Main welding set-up is made through the ARC WIZARD P65 MENU and recorded to a ‘Channel (Job) Number’ of your choice.

When you want to weld you simply select the corresponding channel (Job) number on the wire feed panel PF65 and weld. Only regular needed controls are present on the wire feed unit panel PF65, making welding easy and convenient.

NOTE! If the machine is new and no welding has been completed before, follow these steps.

A. Switch on power source (May require long press of panel ON/OFF button – 5 sec).

1. Press and select NEW button.

2. Create New Channel – Press SELECT button.

3. Choose weld process and press SELECT button.

B. Then follow the steps from item 4 in the list below.

Editing an existing channel (job) number

1. Press button marked ‘MENU’ to show MAIN MENU listing.

2. SELECT ‘Edit Channel’ – Press SELECT button

3. SELECT ‘Select Weld Curve’ - Press SELECT button

4. Choose and SELECT Process. MIG/1-MIG/Pulse MIG/Double Pulse MIG/ or Curve Number List Press SELECT button

5. Choose and SELECT material group – Press SELECT button

6. Choose and SELECT material grade – Press SELECT button

7. Choose and SELECT ller wire diameter – Press SELECT button

FastMig Pulse 350, 450 / © Kemppi Oy / 1110

8. Choose and SELECT shielding Gas – Press SELECT button

9. Choose and SELECT curve – Press SELECT button. (Note: The curve(s) presented in this view are based on your previous selections from items 4 through to 8.)

10. Choose and SAVE memory channel number. Memory channel selections are made using either the White +/- buttons OR Orange UP-DOWN buttons – Press SAVE button

READY TO WELD: Your basic welding selection and set-up is now complete. You are ready to weld, providing you select the corresponding channel ‘Job’ number on the PF65 wire feed unit panel. Set your welding power and arc length and weld.

NOTE! If you SELECT ‘MIG’ (i.e. Basic MIG/MAG selection in the above listing) you will automatically

jump from item 4 to item 9. When you have saved your channel ‘Job’ number selection, you will have access to basic MIG/MAG welding on this channel. Voltage and wire feed speed are then selected in the normal way.

Memory ‘Job’ Channels and User Channels

1. There are 10 x separate MEMORY ‘JOB’ CHANNELS per Active USER channel.

2. There are 10 x USER channel choices.

So there is a maximum of 100 x channels available for a variety of welding ‘Job’s, welding projects or multi-operator environments.

Welding parameters can be quickly saved to MEMORY ‘Job’ CHANNEL Numbers and recalled later or updated later unless ‘locked’ via the four digits ADMINISTRATOR PIN code lock.

USER channels can be activated through either the MAIN MENU or fast function Key F2, marked USER. Selection process is then standard. SELECT USER number, and use pre recorded channel information OR save and record new channel information.

P65 – Fast Function Keys

The fast function keys, F1, F2 and F3 are short cut keys.

• F1 CHANNEL INFO – Display the basic data recorded to the displayed channel.

• F2 USER – Displays the ‘Active’ User and allows a new User channel activation.

• F3 WF# – Displays active and selected wire feed unit and allows a new WFU selection.

FastMig Pulse allows up to 7 x wire feed units to be connected to one power source.

NOTE! Only one wire feed unit can be active at any one time and must be selected before it will

operate.

5. BASIC TROUBLESHOOTING

NOTE! The problems listed and the possible causes are not denitive, but serve to suggest some

standard and typical situations that may present during normal environmental use when using the MIG/MAG process with FastMig Pulse.

Problem Check the following Machine won’t work?

Check mains plug is connected Check mains power distribution is switched on Check the mains fuse and or circuit breaker Check power source 0/I switch is ON Check interconnection cable set and connectors between the power source and wire feed unit are correctly fastened. See the manual schematic Check earth return lead is connected Check function panels are switched on – Orange buttons top left, long press.

Dirty, poor quality weld?

Check shielding gas supply Check and set gas ow rate Check gas type for application Check gun/electrode polarity. Example: Fe solid ller wire: Earth return should be connected to the – pole, wire feed unit to the + pole connector Check correct welding curve selected Check correct Channel (job) number selected on PF65 function panel Check power supply – Phase down?

Variable welding performance?

Check wire feed mechanism is correctly adjusted Check correct drive rolls are tted Check wire spool overrun tension is correctly adjusted Check gun liner is not blocked. Replace if necessary Check correct gun liner is tted for the ller wire size and type Check contact tip for size, type and wear Check gun is not over heating in application Check cable connections and earth return clamp Check welding parameter settings.

Filler wire won’t feed?

Check wire feed mechanism. Pressure arms are closed? Close and adjust Check welding gun switch function. Check euro gun collar is correctly fastened to euro block Check gun liner is not blocked Check contact tip, size, type, wear Check and try alternative gun.

High spatter volume?

Check welding parameter values Check inductance/Dynamics values

•Check cable compensation value if long cables are tted

Check gas type and ow Check welding polarity – cable connections Check ller material selection Check correct welding curve selected Check correct Channel (job) number selection Check ller wire delivery system Check power supply – 3 x phase present?

NOTE! Many of these checks may be carried out by the operator. However certain checks relating to

mains power must be completed by an authorised trained electrician.

6. OPERATION DISTURBANCES

Should you experience a malfunction from your machine, please consult the basic troubleshooting text above rst, and complete some basic checks.

If the machine malfunction cannot be corrected with these measures, contact your KEMPPI maintenance service workshop.

6.1 OPERATION OF THE OVERLOAD PROTECTION

Yellow thermal protection lamp is lit when the thermostat is operating due to loading beyond the stated duty cycle.

The thermostat will operate, if machine is continuously loaded over rated values or cooling air circulation is blocked.

Internal fans will cool the machine, and when the pilot lamp is not lit the machine is automatically ready for welding.

6.2 CONTROL FUSES

Fuse, 6,3 A delayed, on the rear wall of machine provides protection for auxiliary devices. Use the same type and rating of fuse as marked beside the fuse adapter. Damage caused by

incorrect fuse selection is not covered by the guarantee.

6.3 UNDER AND OVER VOLTAGES IN THE MAINS SUPPLY

Primary circuits of the machine are protected against sudden, transient overvoltages. The machine is designed to withstand 3 x 440 V voltage continuously (see technical data). Ensure that voltage is kept within this admissible limit, especially when the mains supply is provided by a combustion engine generator. If the mains has under voltage (under approx. 300 V) or overvoltage (over approx. 480 V) machine control stops operation automatically.

6.4 LOSS OF A PHASE IN THE MAINS SUPPLY

Loss of a main power phase causes noticeably poor welding properties. In some cases the machine won't start at all. Loss of a phase can be due to following:

• Blowing of mains supply fuse

• Defective mains cable

• Bad connection of mains power cable on machine terminal block or plug of machine.

7. MAINTENANCE

When considering and planning routine maintenance, please consider the the frequency of machine use and the working environment.

Correct operation of the machine and regular maintenance will help you avoid unnecessary downtime and equipment failure.

NOTE! Disconnect the machine from the mains before handling the electrical cables.

7.1 DAILY MAINTENANCE

• Check the overall condition of the welding gun. Remove welding spatter from the contact tip and clean the gas nozzle. Replace worn or damaged parts. Only use original Kemppi spare parts.

• Check the condition and connection of the welding circuit components: welding gun, earth return cable and clamp, sockets and connectors.

• Check the condition of the feed rolls, needle bearings and shafts. Clean and lubricate bearings and shafts with a small quantity of light machine oil if necessary. Assemble, adjust and test function.

7.2 PERIOD MAINTENANCE

NOTE! Period maintenance should only be carried out by a suitably qualied person. 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 connectors of the machine – clean any oxidized parts and tighten loose connections.

NOTE! You must know the correct tension torques values before starting the reparation of the loose

joints.

Clean the inner parts of the machine from dust and dirt e.g. with a soft brush and vacuum cleaner. Also clean the ventilation net behind the front grill.

Do not use compressed air, there is a risk that the dirt will compact even more tightly into gaps of cooling proles.

Do not use pressure washing devices. Only an authorized trained electrician should carry out repairs to Kemppi machines.

7.3 SERVICE SHOP MAINTENANCE

Kemppi Service Workshops complete maintenance according to their Kemppi service 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

• Checking of mains cable and plug

• Damaged parts or parts in bad condition are replaced by new ones

• Maintenance testing.

• Operation and performance values of the machine are checked, and when necessary

adjusted by means of software and test equipment.

Software loading

Kemppi Service Workshops can also test and load rm ware and welding software.

8. DISPOSAL OF THE MACHINE

Do not dispose of electrical equipment 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 taken to an appropriate environmentally responsible recycling facility.

The owner of the equipment is obliged to deliver a decommissioned unit to a regional collection centre, per the instructions of local authorities or a Kemppi representative. By applying this European Directive you will improve the environment and human health.

9. ORDERING NUMBERS

FastMig Pulse 350 power source

6150400

FastMig Pulse 450 power source

6150500

FastMig Pulse Setup panel P65

Included with power source 6155300

FastMig MXF 63 wire feeder 200 mm

Work pack prole 6152300EL

FastMig MXF 65 wire feeder 300 mm

Work pack prole 6152100EL

FastMig MXF 67 wire feeder 300 mm

Work pack prole 6152200EL

FastMig MXF 63 wire feeder 200 mm

Project pack custom 6152300

FastMig MXF 65 wire feeder 300 mm

Project pack custom 6152100

FastMig MXF 67 wire feeder 300 mm

Project pack custom 6152200

PF 63 wire feeder panel

6155200

PF 65 wire feeder panel

6155100

Return current cable

5 m, 50 mm² 6184511

Return current cable

5 m, 70 mm² 6184711

Cable for MMA welding

5 m, 50 mm² 6184501

Cable for MMA welding

5 m, 70 mm² 6184701

Interconnection cable

1.8 m 6260401

Interconnection cable

10 m 6260326

Interconnection cable

15 m 6260325

Interconnection cable

20 m 6260327

Interconnection cable

30 m 6260330

Interconnection cable, water cooled

1.8 m 6260410

Interconnection cable, water cooled

10 m 6260334

Interconnection cable, water cooled

15 m 6260335

Interconnection cable, water cooled

20 m 6260337

Interconnection cable, water cooled

30 m 6260340

Other lengths available

R30 DataRemote

5 m 6185420

R30 DataRemote

10 m 618542001

Remote control extension cable

10 m 6185481

Cooling unit FastCool 10

6068100

Software installation device DataGun

6265023

Transport unit PM 500

6185291

KV 200 mounting plate

6185249

Gun holder GH 30

6256030

SuperSnake GT02S sub feeder

10 m 6153100

SuperSnake GT02S sub feeder

15 m 6153150

SuperSnake GT02S sub feeder

20 m 6153200

SuperSnake GT02S sub feeder

25 m 6153250

SuperSnake GT02S W sub feeder

10 m 6154100

SuperSnake GT02S W sub feeder

15 m 6154150

SuperSnake GT02S W sub feeder

20 m 6154200

SuperSnake GT02S W sub feeder

25 m 6154250

SuperSnake GT02S sub feeder synchronization unit for FastMig MXF wire feed units

W004030

WiseFusion welding function

9991014

WisePenetration welding function

9991000

WiseRoot welding process

6265011

WiseThin welding process

9991013

MatchLog

9991017

MMA welding process

9991016

10. TECHNICAL DATA

FastMig™ Pulse 350 450 Connection voltage

3~50/60 Hz 400 V -15 %...+20 % 400 V -15 %...+20 %

Rated power

60 % ED 22.1 kVA

80 % ED 16.0 kVA

100 % ED 15.3 kVA 16.0 kVA

Connection cable

HO7RN-F 4G6 (5 m) 4G6 (5 m)

Fuse (delayed)

25 A 35 A

Output 40 °C

60 % ED 450 A

80 % ED 350 A

100 % ED 330 A 350 A

Welding current and voltage range

MMA 10 A – 350 A 10 A – 450 A

MIG 10 V – 50 V 10 V – 50 V

Max. welding voltage MMA

49 V 53 V

Open circuit voltage

MMA 50 V 50 V

MIG/MAG/Pulse 80 V 80 V

Open circuit power

100 W 100 W

Power factor at max. current

0.85 0.9

Efficiency at max. current

88 % 88 %

Operating temperature range

-20 ... +40 °C -20 ... +40 °C

Storage temperature range

-40 ... +60 °C -40 ... +60 °C

EMC class

A A

Minimun short circuit power S

supply network*

5.5 MVA 5.5 MVA

Degree of protection

IP23S IP23S

External dimensions

L x W x H 590 x 230 x 430 mm 590 x 230 x 430 mm

Weight

36 kg 36 kg

Voltage supply for auxiliary devices

50 V DC / 100 W 50 V DC / 100 W

Fuse (delayed)

6.3 A 6.3 A

Voltage supply for cooling unit

24V DC / 50 VA 24V DC / 50 VA

* See paragraph 2.2.

www.kemppi.com

1923670

1110

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Kemppi 350, 450 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual