Kemppi KMS 300, KMS 400, KMS 500, FastMig KMS 300, FastMig KMS 400 Operating Manual

Operating manual • English

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FastMig™

KMS 300, 400, 500

IT

OPERATING MANUAL

English

FastMig KMS 300, 400, 500 / © Kemppi Oy / 1110

EN

CONTENTS

1. PREFACE ................................................................................................................................ 3

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

1.2 Product introduction ............................................................................................................ 3

1.2.1 Operation control and connectors ................................................................................. 4

1.3 Accessories ................................................................................................................................ 4

1.3.1 Remote control devices ................................................................................................... 4

1.3.2 Cables ............................................................................................................................... 5

2. INSTALLATION ................................................................................................................. 5

2.1 Positioning of the machine ................................................................................................ 5

2.2 Distribution network ............................................................................................................. 5

2.3 Connection to the mains supply ...................................................................................... 6

2.4 Welding and earth cables.................................................................................................... 7

3. OPERATION CONTROL SWITCHES AND POTENTIOMETERS ... 7

3.1 Main switch I/O ....................................................................................................................... 7

3.2 Pilot lamps ................................................................................................................................. 7

3.3 Operation of cooling fan ..................................................................................................... 7

4. MANUAL METAL ARC WELDING ...................................................................... 7

5. MAINTENANCE ................................................................................................................ 8

5.1 Cables .......................................................................................................................................... 8

5.2 Power source ............................................................................................................................ 8

5.3 Regular maintenance ............................................................................................................ 8

6. OPERATION DISTURBANCES .............................................................................. 8

6.1 Operation of the overload protection ............................................................................ 8

6.2 Control fuses ............................................................................................................................ 9

6.3 Under- and overvoltages in the mains supply ............................................................ 9

6.4 Loss of a phase in the mains supply ................................................................................ 9

7. DISPOSAL OF THE MACHINE .............................................................................. 9

8. ORDERING NUMBERS .............................................................................................10

9. TECHNICAL DATA ........................................................................................................11

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FastMig KMS 300, 400, 500 / © Kemppi Oy / 1110

EN

1. PREFACE

1.1 GENERAL

Congratulations on choosing the FastMig 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.

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.

1.2 PRODUCT INTRODUCTION

FastMig KMS 300, 400 and 500 are multi-operator power sources designed for demanding
professional use. They are suitable for MMA and MIG welding in DC.

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FastMig KMS 300, 400, 500 / © Kemppi Oy / 1110

EN

1.2.1 Operation control and connectors

H12

H11

S11

X11

X12

X14

6,3A

X13

X15

01

F11

F11

Fuse for connection for
control table

6,3 A delayed

X12

Earth connection

H11

Signal lamp I/O

X14 , X15

Connection for control cable parallel

H12

Warning lamp for
thermal protection

01

Inlet of mains cable

S11

Main switch I/O

X11, X13

Welding connection parallel

1.3 ACCESSORIES

1.3.1 Remote control devices

R10

1.

1. Control of MMA/TIG welding current, reference
scale 1 – 5.

R20

2.

1.

1. Wire feed adjustment, electrode current
adjustment.

2. Voltage adjustment.

MIG-MAG remote control device with controls for wire feed and voltage, memory scales 1 – 5.
You can use control device also for control of MMA current.

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FastMig KMS 300, 400, 500 / © Kemppi Oy / 1110

EN

1.3.2 Cables

FastMig KMS 300, FastMig KMS 400, FastMig KMS 500

16d

Extension cable for remote control

20

Earth cable

21

MMA welding cable

R10, R20

Remote control devices

2. INSTALLATION

2.1 POSITIONING OF THE MACHINE

Place the machine on a rm, dry and level surface. Where possible, do not allow dust or other
impurities to enter the machines cooling air ow. Preferably site the machine above oor level;
for example on a suitable carriage unit.

Notes for positioning the machine

• The surface inclination should 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 to circulate.

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

NOTE! The machine should not be operated in the rain as the protection class of the machine,

IP23S, allows for outside preserving and storage only.

NOTE! Never aim metallic grinding spray/sparks towards the equipment.

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 KM 500:

This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc
is greater than or equal to 4.6 MVA at the interface point between the user's supply and
the public supply 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 4.6 MVA.

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FastMig KMS 300, 400, 500 / © Kemppi Oy / 1110

EN

FastMig KM 400:

This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc
is greater than or equal to 4.7 MVA at the interface point between the user's supply and
the public supply 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 4.7 MVA.

FastMig KM 300:

WARNING: This equipment does not comply with IEC 61000-3-12. If it is connected to a public
low voltage system, 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 may
be connected.

2.3 CONNECTION TO THE MAINS SUPPLY

FastMig power sources are 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 the local regulations.
Connection of the mains cable, mounting and change of the plug should only be carried out

by a competent electrician.
Remove the machine’s right side plate to enable the mounting of a mains cable.
KMS 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 connector.

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

Sizes of the mains cables and fuse ratings for the machine at 100 % duty cycle are specied in
the table below:

Rated voltage Mains voltage range Fuses, slow-blow Connection cable *) mm²

KMS 300 400 V 3~ 360 V – 440 V 20 A 4 x 6.0 S
KMS 400 400 V 3~ 360 V – 440 V 25 A 4 x 6.0 S
KMS 500 400 V 3~ 360 V – 440 V 35 A 4 x 6.0 S

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

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FastMig KMS 300, 400, 500 / © Kemppi Oy / 1110

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2.4 WELDING AND EARTH CABLES

Recommended copper cables with cross-sectional area are as follows:
FastMig KMS 300 50 – 70 mm²
FastMig KMS 400 70 – 90 mm²
FastMig KMS 500 70 – 90 mm²
In enclosed table are shown typical load capacities of rubber insulated copper cables, when

ambient temperature is 25 °C and lead 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.
Fasten the earth clamp of the return current cable carefully, preferably direct onto the piece to

be welded. The contact surface of the earth clamp should always be as large as possible.
Clean the fastening surface from paint and rust.

3. OPERATION CONTROL SWITCHES AND POTENTIOMETERS

3.1 MAIN SWITCH I/O

When you turn the switch into I-position, pilot lamp H11 on the front face is illuminated and
the machine is ready for use.

NOTE! Always turn the machine on and o with the mains switch, never use the mains plugs as a

switch.

3.2 PILOT LAMPS

The pilot lamps of the machine report the electric operation:
The green pilot lamp H11 when lit indicates that the machine is on and ready for use and it is

connected to the mains supply with the main switch in the I-position.
H12 indicates when lit that the thermal protection of the machine has been activated due to

over heating. The cooling fan will continue to run and cool the machine down and when the
lamp is o the machine is ready to weld.

3.3 OPERATION OF COOLING FAN

In FastMig power sources there are two simultaneously operating fans.

• The fan is started for a moment when main switch is placed into position I.

• The fan will start during welding as the machine heats up and it will run for 1 to 10

minutes after the welding has stopped.

4. MANUAL METAL ARC WELDING

The FastMig power source can be used in electrode welding by connecting a FastMig
MFS 53, MFS 55 or MSF 57 wire feeder to it. The power source can be made suitable for
electrode welding without a wire feeder by connecting an R10 or R20 remote control to the
X14 or X15 terminal at the back of the power source for welding current adjustment, and the
welding power cable connected to the power source’s (+) connector X11 or X12.

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FastMig KMS 300, 400, 500 / © Kemppi Oy / 1110

EN

5. 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 will help to ensure trouble-free operation.

5.1 CABLES

Check the condition of welding and connection cables daily. Do not use damaged cables.
Make sure that the mains cables in use are safe and according to laid down regulations.
The repair and mounting of a mains connection cable should be carried out only by an

authorised electrician.

5.2 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 connectors of the machine – clean the oxidised parts and tighten the loosened
ones.

NOTE! You must know correction 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. 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 proles.

• Do not use pressure washing device.

• Only authorised electrician shall carry out repairs to the machines.

5.3 REGULAR MAINTENANCE

Kemppi Service Workshops 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

• Checking of mains cable and plug

• Damaged parts or 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.

6. OPERATION DISTURBANCES

In the event of a failure of the machine, contact an authorised Kemppi service agent or your
local Kemppi dealer.

Check the maintenance objects before the machine is sent to the Service Workshop.

6.1 OPERATION OF THE OVERLOAD PROTECTION

Yellow pilot lamp H12 of thermal protection is lit when thermostat has operated due to
overheating of machine.

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

Cooling fan cools down the machine and when the pilot lamp is not lit the machine is
automatically ready for welding.

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FastMig KMS 300, 400, 500 / © Kemppi Oy / 1110

EN

6.2 CONTROL FUSES

Fuse F11, 6.3 A delayed, on the rear wall of machine is as protection for connection of auxiliary
devices X14-15.

NOTE! 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.

6.3 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 continuously (see technical data). See to

it that voltage is kept within admissible limits especially when mains supply is taken e.g. from
combustion engine generator.

If the mains has undervoltage (under approx. 300 V) or overvoltage (over approx. 480 V)
machine control stops to operate automatically.

6.4 LOSS OF A PHASE IN THE MAINS SUPPLY

Loss of a phase causes noticeable 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

7. 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.

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FastMig KMS 300, 400, 500 / © Kemppi Oy / 1110

EN

8. ORDERING NUMBERS

FastMig KMS 300

6053000

FastMig KMS 400

6054000

FastMig KMS 500

6055000

Wire feeders
MXF 65

6152100EL

MXF 67

6152200EL

MXF 63

6152300EL

MXF 65

6152100

MXF 67

6152200

MXF 63

6152300

Panels for wire feeders
SF 51

6085100

SF 52W

6085200W

SF 53W

6085300W

SF 54

6085400

Accessories
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

R10

6185409

Remote controlled interconnecting cable

10 m 6185481

Cooling unit FastCool 10

6068100

Transport unit PM 500

6185291

Gun holder GH 30

6256030

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FastMig KMS 300, 400, 500 / © Kemppi Oy / 1110

EN

9. TECHNICAL DATA

FastMig KMS 300 FastMig KMS 400 FastMig KMS 500
Connection voltage
3~, 50/60 Hz

400 V -15 %...+20 % 400 V -15 %...+20 % 400 V -15 %...+20 %

Rated power
60 ED

- - 26.1 kVA

80 % ED

- 19.5 kVA -

100 % ED

13.9 kVA 18.5 kVA 20.3 kVA

Connection cable

H07RN-F 4G6 (5 m) H07RN-F 4G6 (5 m) H07RN-F 4G6 (5 m)

Fuse (delayed)

25 A 35 A 35 A

Output 40 °C
60 % ED

- - 500 A

80 % ED

- 400 A -

100 % ED

300 A 380 A 430 A

Welding current and voltage range
MMA

10 A – 300 A 10 A – 400 A 10 A – 500 A

MIG

10 V – 37 V 10 V – 39 V 10 V – 42 V

Max. welding voltage

46 V 46 V 46 V

Open circuit voltage

50 V 50 V 50 V

Idle power

25 W 25 W 25 W

Efficiency at max. current

87 % 87 % 87 %

Power factor at max. current

0.9 0.9 0.9

Operating temperature range

-20 ... +40 °C -20 ... +40 °C -20 ... +40 °C

Storage temperature range

-40 ... +60 °C -40 ... +60 °C -40 ... +60 °C

Degree of protection

IP23S IP23S IP23S

EMC class

A A A

Minimun short circuit power Ssc
of supply network*

- 4.7 MVA 4.6 MVA

External dimensions
length

590 mm 590 mm 590 mm

width

230 mm 230 mm 230 mm

height

430 mm 430 mm 430 mm

weight

34 kg 35 kg 36 kg

Voltage supply for auxiliary
devices

50 V DC 50 V DC 50 V DC

X14, X15

fuse 6.3 A delayed fuse 6.3 A delayed fuse 6.3 A delayed

Operating voltage
(for cooling unit)

400 V -15 %...+20 % 400 V -15 %...+20 % 400 V -15 %...+20 %

* See paragraph 2.2.

11

FastMig KMS 300, 400, 500 / © Kemppi Oy / 1110

www.kemppi.com

1905310

1110

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