Kemppi fastmig kms 400 mvu Operating Instructions Manual

1905300

0647

Operating instructions • english
Bruksanvisning • norsk

FASTMIG™

KMS 400 MVU

2 – Fastmig™ Kms 400 mVU / 0647 © Kemppi oy

CONTENTS

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

1.1. INTRODUCTION .........................................................................................................

3

1.2. PRODUCT INTRODUCTION ...................................................................................... 3

1.2.1. OPERATION CONTROL AND CONNECTORS ............................................. 3

1.3. ACCESSORIES ........................................................................................................... 4

1.3.1. REMOTE CONTROL DEVICES ..................................................................... 4

1.3.2. CABLES ......................................................................................................... 4

1.4. OPERATION SAFETY ................................................................................................. 5

2. INSTALLATION .............................................................................................................. 6

2.1. SITING THE MACHINE ...............................................................................................

6

2.2. CONNECTION TO THE MAINS SUPPLY ................................................................... 6

2.3. WELDING AND EARTH CABLES ............................................................................... 7

3. OPERATION CONTROL SWITCHES AND POTENTIOMETERS AND THEIR USE ....

7

3.1. MAIN SWITCH I/O .......................................................................................................

7

3.2. PILOT LAMPS ............................................................................................................. 7

3.3. OPERATION OF COOLING FAN ................................................................................ 8

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

8

5. MAINTENANCE .............................................................................................................

8

5.1. CABLES ...................................................................................................................... 8

5.2. POWER SOURCE....................................................................................................... 8

5.3. REGULAR MAINTENANCE ........................................................................................ 8

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

9

6.1. OPERATION OF THE OVERLOAD PROTECTION ....................................................

9

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

10. TERMS OF GUARANTEE .........................................................................................

12

Fastmig™ Kms 400 mVU / 0647 – 3

© Kemppi oy

H12

H11

S11

X11

X12

X14

X13

X15

01

F11

1. PREFACE

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 FastMig™ equipment and its safe

operation. It also contains maintenance information and technical specications. Read this manual
from front to back before installing, operating or maintaining the equipment for the rst time. For

further information on Kemppi products please contact us or your nearest Kemppi distributor.

The specications 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

FastMig™ KMS 400 MVU is a multi-operator and multi voltage power source designed for
demanding professional use. It is suitable for MMA and MIG welding in DC.

1.2.1. Operation control and connectors

F11 Fuse for connection for control table 6,3 A delayed

H11 Signal lamp I/O

H12 Warning lamp for thermal protection

S11 Main switch I/O

X11, Welding connection parallel
X13 Welding connection
X12 Earth connection
X14, Connection for control cable parallel
X15 Connection for control cable
01 Inlet of mains cable

4 – Fastmig™ Kms 400 mVU / 0647 © Kemppi oy

1.3. ACCESSORIES

1.3.1. Remote control devices

R10

R20

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.

1.3.2. Cables

FastMig™ KMS 400 MVU

16d Extension cable for remote control

20 Earth cable

21 MMA welding cable
R10, Remote control devices
R20

Wire feed adjustment,
electrode current adjustment

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

Voltage adjustment

Fastmig™ Kms 400 mVU / 0647 – 5

© Kemppi oy

1.4. OPERATION SAFETY

Please study these Operation safety instructions and respect them when installing, operating and

servicing the machine.

Welding arc and spatters

Welding arc hurts unprotected eyes. Be careful also with reecting arc ash. Welding arc and

spatter burn unprotected skin. Use safety gloves and protective clothing.

Danger for re or explosion

Pay attention to re safety regulations. Remove ammable or explosive materials from welding
place. Always ensure that you have sufcient re ghting equipment available where you are
welding. Be prepared for hazards in special welding jobs, eg. for the danger of re or explosion
when welding container type work pieces. Note! Fire can break out from sparks even several hours
after the welding work has been nished!

Mains voltage

Never take welding machine inside a work piece (eg. container or truck). Do not place welding
machine on a wet surface. Always check cables before operating the machine. Change damaged
cables without delay. Damaged cables may cause an injury or set out a re. Connection cable must
not be crushed, it must not touch sharp edges or hot work pieces.

Welding power circuit

Isolate yourself by using proper protective clothing, do not wear wet clothing. Never work on a
wet surface or use defect cables. Do not put the MIG-gun or welding cables on welding machine
or on other electric equipment. Do not press the MIG-gun switch, if the gun is not directed towards
a work piece.

Welding fumes

Take care that there is sufcient ventilation during welding. Take special safety precautions when
welding metal, which contain lead, cadmium, zinc, mercury or beryllium.

This equipment’s electromagnetic compatibility (EMC) is designed for use in an
industrial environment. Class A equipment is not intended for use in residential location
where the electrical power is provided by the public low-voltage supply system.

6 – Fastmig™ Kms 400 mVU / 0647 © Kemppi oy

60º

max. 15º

2. INSTALLATION

2.1. SITING THE MACHINE

Site the machine on a stationary, horizontal, dry base in a position that does NOT allow

dust, dirt or metal particles to enter the machines cooling air ow.

2.2. 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 400 MVU power source can be connected to the mains supply of 230 V 3~ or 400 V 3~.
Power source recognizes the mains voltage automatically. For fuse and cable sizes, see the technical

data in the end of this document.

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.

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

rain water

– Preferably site the machine somewhat higher above

the oor level.

– Ensure that the front as well as 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 the
free circulation of the cooling air.

Degree of protection of machine IP23S allows at
its maximum the water spray coming in 60º 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.

Fastmig™ Kms 400 mVU / 0647 – 7

© Kemppi oy

Sizes of the mains cables and fuse ratings for the KMS 400 MVU machine at 100 % duty cycle
are specied in the table below:

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

2.3. WELDING AND EARTH CABLES

Recommended copper cables with cross-sectional area are as follows:

FastMig™ KMS 400 MVU 70 ... 90 mm²

In enclosed table are shown typical load capacities of rubber insulated copper cables, when ambient

temperature is 25 ºC and lead temperature is 85 ºC.

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 AND THEIR USE

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.

Always turn the machine on and off 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
off 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.

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

400 V 3~ 35 A H07RN-F 4G10 (10 mm

²)

230 V

3~ 50 A H07RN-F 4G10 (10 mm²)

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

8 – Fastmig™ Kms 400 mVU / 0647 © Kemppi oy

4. MANUAL METAL ARC WELDING

The FastMig™ power source can be used in electrode welding by connecting a FastMig™
MSF 53, MSF 55 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.

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.

Fastmig™ Kms 400 mVU / 0647 – 9

© Kemppi oy

6. OPERATION DISTURBANCES

In case of problems contact the Kemppi works in Lahti, Finland, 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.

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.

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 or 3 x 230 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 or overvoltage 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 together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical equipment

that has reached the end of its life must be collected separately and returned to an

environmentally compatible recycling facility. As the owner of the equipment, you should

get information on approved collection systems from our local representative.

By applying this European Directive you will improve the environment and human
health!

10 – Fastmig™ Kms 400 mVU / 0647 © Kemppi oy

8. ORDERING NUMBERS

FastMig™ KMS 400 MVU 605400003

SF 51 200 mm, LED 6085100

SF 52 200 mm, LED 6085200

SF 53 300 mm, LED 6085300

SF 54 300 mm, LED 6085400

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

Transport unit PM 500 6185291

Gun holder GH 30 6256030

Fastmig™ Kms 400 mVU / 0647 – 11

© Kemppi oy

FastMig™ KMS 400 MVU

400 V 230 V

Mains voltage 3~50/60 Hz 400 V

-15 %...+20 % 230 V -10 %...+10 %

Rated power 19 kVA 20 kVA
Primary current

MIG 80%ED I

1max

27A 48A

MIG 100%ED I

1

26A 45A

MMA 80%ED I

1max

29A 50A

MMA 100%ED I

1

27A 47A

Connection cable H07RN-F 4G10 (10 mm²) H07RN-F 4G10 (10 mm²)
Fuse delayed 35 A 50 A

Load capacity 40 ˚C

80 % ED 400 A/36 V

100 % ED 380 A/35 V

Welding range

MIG 10 ... 39 V

Max. welding voltage 46 V
Open circuit voltage

MIG 55 ... 69 V

MMA 50 V

Open circuit power 30 W
Efciency MMA/MIG 100% ED 87 %

Power factor at max current 0,8
Storage temperature range -40 ... +60 ºC
Operating temperature range -20 ... +40 ºC
Degree of protection IP 23 S
External dimensions

length 590 mm

width 230 mm

height 580 mm

Weight

49 kg

Voltage supply for auxiliary devices 24 V DC

9. TECHNICAL DATA

12 – Fastmig™ Kms 400 mVU / 0647 © Kemppi oy

10. TERMS OF GUARANTEE

Kemppi Oy provides a guarantee for products manufactured and sold by them if defects in

manufacture and materials occur. Guarantee repairs must be carried out only by an Authorised
Kemppi Service Agent. Packing, freight and insurance costs to be paid by orderer. The guarantee is

effected on the date of purchase. Verbal promises which do not comply with the terms of guarantee

are not binding on guarantor.

Limitations on guarantee

The following conditions are not covered under the terms of guarantee: defects due to natural wear
and tear, non-compliance with operating and maintenance instructions, connection to incorrect or
faulty supply voltage (including voltage surges outside equipment spec.), incorrect gas pressure,
overloading, transport or storage damage, re of damage due to natural causes i.e. lightning or
ooding.
This guarantee does not cover direct or indirect travelling costs, daily allowances or accommodation.
Note: Under the terms of guarantee, welding torches and their consumables, feeder drive rolls and
feeder guide tubes are not covered. Direct or indirect damage due to a defective product is not
covered under the guarantee. The guarantee is void if changes are made to the product without

approval of the manufacturer, or if repairs are carried out using non-approved spare parts.
The guarantee is also void if repairs are carried out by non-authorised agents.

Undertaking guarantee repairs

Guarantee defects must be informed to Kemppi or authorised Kemppi Service Agents within the
guarantee period. Before any guarantee work is undertaken, the customer must provide proof of

guarantee or proof of purchase, and serial number of the equipment in order to validate the guarantee.
The parts replaced under the terns of guarantee remain the property of Kemppi.

Following the guarantee repair, the guarantee of the machine or equipment, repaired or replaced,
will be continued to the end of the original guarantee period.

KEMPPI OY
PL 13
FIN – 15801 LAHTI
FINLAND
Tel [phone]
Telefax [phone]
www.kemppi.com

KEMPPIKONEET OY
PL 13
FIN – 15801 LAHTI
FINLAND
Tel [phone]
Telefax [phone]
e-mail: myynti.fi @kemppi.com

KEMPPI SVERIGE AB
Box 717
S – 194 27 UPPLANDS VÄSBY
SVERIGE
Tel [phone]
Telefax [phone] 94
e-mail: [e-mail]

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

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

KEMPPI BENELUX B.V.
Postbus 5603
NL – 4801 EA BREDA
NEDERLAND
Tel [phone]
Telefax [phone]
e-mail: [e-mail]

KEMPPI (UK) Ltd
Martti Kemppi Building
Fraser Road
Priory Business Park
BEDFORD, MK443WH
ENGLAND
Tel [phone]
Fax [phone]
e-mail: [e-mail]

KEMPPI FRANCE S.A.
65 Avenue de la Couronne des Prés
78681 EPONE CEDEX
FRANCE
Tel [phone]
Telefax (01) 30 90 04 45
e-mail: [e-mail]

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

KEMPPI SP. z o.o.
Ul. Piłsudskiego 2
05-091 ZA¸BKI
Poland
Tel [phone]
Telefax [phone]
e-mail: [e-mail]

KEMPPI WELDING
MACHINES AUSTRALIA PTY LTD
P.O. Box 404 (2/58 Lancaster Street)
Ingleburn NSW 2565, Australia
Tel. [phone]
Telefax [phone]
e-mail: [e-mail]

OOO KEMPPI
127018 Moscow, Polkovaya str. 1,
Building 6
e-mail: [e-mail]

ООО КЕМППИ
127018 Москва, ул. Полковая 1,
строение 6

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