Kemppi DT400 User Manual

1920130 0808

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Bruksanvisning • Svenska

Bruksanvisning • Norsk

Brugsanvisning • Dansk

Operating manual • English

Gebrauchsanweisung • Deutsch

KEMPARC™

Gebruiksaanwijzing • Nederlands

Manuel d’utilisation • Français

Manual de instrucciones • Español

Instrukcja obsługi • Polski

Инструкции по эксплуатации • По-русски

SYN 300

SYN 400

SYN 500

DT 400

KempArc SYN 300, 400, 500 / © Kemppi Oy / 0808

OPERATING MANUAL

English

CONTENTS

KempArc SYN 300, 400, 500 / © Kemppi Oy / 0808

1. PREFACE ......................................................................................

1.1 General .................................................................................................................................................................3

1.2 Safety Instructions .......................................................................................................................................3

1.3 Introduction .....................................................................................................................................................5

2. USE ...............................................................................................6

2.1 Power source

2.1.1 Power source components ...............................................................................................................6

2.1.2 Locating the power source ...............................................................................................................6

2.1.3 Connecting the power source to the electric network ...........................................................7

2.1.4 Connecting the cables ........................................................................................................................8

2.1.5 Installing the eld bus card ..............................................................................................................9

2.1.6 Starting the power source..............................................................................................................10

2.1.7 Power source indicators ..................................................................................................................10

2.2 Control panel

2.2.1 Control panel parts ...........................................................................................................................10

2.2.2 Adjusting MIG dynamics (Arc Force) ..........................................................................................11

2.2.3 Gas test ..................................................................................................................................................11

2.2.4 Wire feed test ...................................................................................................................................... 11

2.2.5 Selection of liquid- or gas-cooled MIG gun .............................................................................12

2.2.6 Retrieving weld data ........................................................................................................................12

2.2.7 Selecting the welding process .....................................................................................................12

2.2.8 Additional MIG features included in the standard delivery ............................................... 12

2.2.9 Optional additional MIG features ................................................................................................14

2.2.10 Memory features (MEMORY button) ..........................................................................................14

2.2.11 Synergetic 1-MIG welding and AAA-MIG welding ................................................................15

2.2.12 SETUP features of the control panel ........................................................................................... 17

2.3 Wire feeder ..................................................................................................................................................... 18

...................................................................................................................................................6

................................................................................................................................................10

3. MAINTENANCE .........................................................................19

3.1 Cables .................................................................................................................................................................19

3.2 Power source ................................................................................................................................................20

3.2.1. DuraTorque™ 400, 4-wheel wire feeder mechanism ............................................................20

3.3 Regular maintenance .............................................................................................................................21

3.4 Disposal of the machine .......................................................................................................................21

4. TROUBLESHOOTING ................................................................21

4.1 Overload (yellow indicator lit)

4.2 Control cable connector fuse

4.3 Electric network overvoltage or undervoltage ...................................................................21

4.4 Missing phase in the electric network

4.5 Error codes

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

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

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

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

5. ORDERING NUMBERS .............................................................. 23

6. TECHNICAL DATA ..................................................................... 23

7. WARRANTY POLICY ..................................................................25

1. PREFACE

1.1 GENERAL

Congratulations on your choice of the Kemparc™ SYN-series welding system. Reliable and durable, Kemppi products are aordable to maintain, and they increase your work productivity.

This user manual contains important information on the use, maintenance and safety of your Kemppi product. The technical specications of the device can be found at the end of the manual. Please read the manual carefully before using the equipment for the rst time. For your 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.

NOTE! Items in the manual that require particular attention in order to minimise damage and

personal harm are indicated with this symbol. Read these sections carefully and follow their instructions.

1.2 SAFETY INSTRUCTIONS

Kemppi welding devices conform to international safety standards. Safety is an important issue in equipment design and manufacturing. Therefore, Kemppi welding solutions are unparalleled in safety. There are, however, always certain hazards involved in using welding equipment. Therefore, to ensure your personal safety and the safety of your working environment, carefully read the safety instructions below and respect them.

Use of personal protective equipment

• The arc and its reecting radiation damage unprotected eyes. Shield your eyes and face appropriately before you start welding or observe welding. Also note the dierent requirements for the darkness of the screen in the mask as the welding current changes.

• The arc radiation and spatters burn unprotected skin. Always wear protective gloves, clothing and footwear when welding.

• Always wear hearing protection if the ambient noise level exceeds the allowable limit (e.g., 85 dB).

General operating safety

• Exercise caution when handling parts heated in welding. For example, the tip of the welding torch, the end of the welding rod and the work piece will heat during gouging to a burning temperature.

• Never wear the device on the shoulder during welding and never suspend it by the carrying strap during welding.

• Do not expose the machine to high temperatures, as this may cause damage to the machine.

• Keep the torch cable and earthing cable as close to each other as possible throughout their length. Straighten any loops in the cables. This minimises your exposure to harmful magnetic elds, which may interfere with a pacemaker, for example.

• Do not wrap the cables around the body.

• In environments classied as dangerous, only use S-marked welding devices with a safe idle voltage level. These work environments include, for example, humid, hot or small spaces where the user may be directly exposed to the surrounding conductive pieces.

Spatter and re safety

• Welding is always classied as hot work, so pay attention to re safety regulations during welding and after it.

• Remember that re can break out from sparks even several hours after the welding work is completed.

KempArc SYN 300, 400, 500 / © Kemppi Oy / 0808

• Protect the environment from welding spatter. Remove ammable materials, such as ammable uids, from the welding vicinity and supply the welding site with adequate re ghting equipment.

• In special welding jobs, be prepared for hazards such as re or explosion when welding container-type work pieces.

• Never direct the spark spray or cutting spray of a grinder toward the welding machine or ammable materials.

• Beware of hot objects or spatter falling on the machine when working above the machine.

• Welding in ammable or explosive sites is absolutely forbidden.

General electric safety

• Only connect the welding machine to an earthed electric network.

• Note the recommended mains fuse size.

• Do not take the welding machine inside a container, vehicle or similar work piece.

• Do not place the welding machine on a wet surface and do not work on a wet surface.

• Do not allow the mains cable to be directly exposed to water.

• Ensure cables or welding torches are not squashed by heavy objects and that they are not exposed to sharp edges or a hot work piece.

• Make sure that faulty and damaged welding torches are changed immediately as they can be lethal and may cause electrocution or re.

• Remember that the cable, plugs and other electric devices may be installed or replaced only by an electrical contractor or engineer authorised to perform such operations.

• Turn o the welding machine when it is not in use.

Welding power circuit

• Insulate yourself from the welding circuit by using dry and undamaged protective clothing.

• Never touch the work piece and welding rod, welding wire, welding electrode or contact tip at the same time.

• Do not put the welding torch or ground cable on the welding machine or other electric equipment.

Welding fumes

• Ensure proper ventilation and avoid inhaling the fumes.

• Ensure sucient supply of fresh air, particularly in closed spaces. You can also ensure the supply of clean and sucient breathing air by using a fresh-air mask.

• Take extra precautions when working on metals or surface-treated materials containing lead, cadmium, zinc, mercury or beryllium.

Transportation, lifting and suspension

• Never pull or lift the machine by the welding torch or other cables. Always use the lift points or handles designed for that purpose.

• Only use a transport unit designed for the equipment.

• Try to transport the machine in an upright position, if possible.

• Never lift a gas cylinder and the welding machine at the same time. There are separate provisions for gas cylinder transportation.

• Never use a welding machine when suspended unless the suspension device has been designed and approved for that particular purpose.

• Do not exceed the maximum allowed load of suspension beams or the transportation trolley of welding equipment.

• It is recommended that the wire coil be removed during lifting or transportation.

Environment

• Protect welding machines from heavy rain and direct sunshine even if it were suitable for outdoor use.

• Always store the machine in a dry and clean space.

• Protect the machine from sand and dust during use and in storage.

• The recommended operating temperature range is -20 to +40 °C. The machine’s operation eciency decreases and it becomes more prone to damage if used in temperatures in excess of 40 °C.

• Place the machine so that it is not exposed to hot surfaces, sparks or spatter.

• Make sure the airow to and from the machine is unrestricted.

• This electromagnetic compatibility (EMC) of professional equipment is usually designed for industrial use. Such class-A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. The machine may interfere with sensitive home electronic devices.

Gas bottles and pneumatic devices

• Adhere to the instructions for handling pneumatic devices and gas bottles.

• Make sure that gas bottles are used and stored in properly ventilated spaces. A leaking gas bottle may replace the oxygen in the inhaled air, causing suocation.

• Before use, make sure that the gas bottle contains gas suitable for the intended purpose.

• Always x the gas cylinder securely in an upright position, against a cylinder wall rack or purpose-made cylinder cart.

• Never move a protective gas bottle when the ow adjuster is in place. Put the valve cover in place during transportation.

• Close the cylinder valve after use.

1.3 INTRODUCTION

KempArc™ SYN is a product family for welding automation that includes all welding devices needed in robot welding. The KempArc™ SYN welding system includes the following devices:

• KempArc™ SYN 300, SYN 400 and SYN 500 are synergetic welding power sources designed particularly for welding automation that are suitable for MIG welding with direct current. There are three power types of power sources: the 300, 400 and 500 ampere models. For more information on using power sources and their functions, see "Power source".

• RF 59 is a control panel that contains the programs and welding parameters needed in controlling the welding hardware. The panel functions allow the user to control the operation of the welding hardware and adjust its welding settings. The control panel is located in the front panel of the welding power source. For more information on using the control panel and its functions, see "Control panel".

• KempArc™ DT 400 is a wire feeding device that feeds welding wire to the welding robot at the speed it requires at any time. For more information on using the wire feeder and its functions, see "Wire feeder".

This guide presents the functions, operation and technical properties of the above devices. The devices also include the KempArc™ Cool 10 cooler, but its functions and features are presented in a separate guide.

The KempArc™ Synergic hardware is connected to the welding robot control system with the control unit on top of the power source.

2. USE

2.1 POWER SOURCE

2.1.1 Power source components

A3 A2

A11

A10

1 2 3 4

A1 Control panel A2 Main switch A3 Signal light (I/O) A4 Thermal warning light A5 Welding cable connection (parallel) A6 Earthing cable connection A7 Control cable connection (parallel) A8 Mains cable A9 Fuse for control cable connection (6.3 A slow) A10 Fan grill A11 Transportation handles

2.1.2 Locating the power source

Place the machine on a sturdy, level surface that is dry and does not release dust or other impurities to the suction air through the fan grill.

Notes for positioning of the machine

• Preferably, place the machine somewhat above oor level.

• The surface inclination may not exceed 15 degrees.

• 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.

• Ensure the free circulation of the cooling air.

The protection class of the machine, IP23C, allows water spray to hit the machine’s outer covering at a maximum angle of 60 degrees.

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

1 Robot Control 2 Wire Feeder 3 Throughput 4 Analog

2.1.3 Connecting the power source to the electric network

The KempArc™ SYN power source is connected to a 400-V three-phase network. The machine is equipped with a ve-metre mains cable that does not have a plug. Before use, check the mains cable and install a mains plug. If the cable does not comply with the local electrical regulations, replace it with a compliant cable.

NOTE! The mains cable or plug may be installed or replaced by only an electrical contractor or

installer authorised to perform such operations.

Replacement of the mains cable

1. Unscrew the mounting screws on the top and sides of the machine, and remove the case by lifting it.

2. Disconnect the phase leads from connectors L1, L2, and L3, and disconnect the protective earth lead.

3. Pass the cable to the machine through the inlet ring at the rear of the machine, and secure the cable with a cable clamp.

4. Connect the cable’s phase leads to connectors L1, L2, and L3.

5. Connect the yellow-green protective earth lead to its connector .

NOTE! Do not connect the zero lead if you are using a ve-lead cable.

The table below lists the fuse sizes for 100% load in a 400-V three-phase network with 4 x 6-mm² cable for dierent power source models.

Model Fuse

SYN 300 20 A delayed SYN 400 25 A delayed SYN 500 35 A delayed

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