Kemppi FastMig Pulse 450 Operating Manual

ZH
FastMig Pulse
350, 450
EN
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DE
ES
FR
IT
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NO
PL
PT
RU
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Operating manual
Brugsanvisning
Gebrauchsanweisung
Manual de instrucciones
Käyttöohje
Manuel d’utilisation
Manuale d’uso
Gebruiksaanwijzing
Bruksanvisning
Instrukcja obsługi
Manual de utilização
Инструкции по эксплуатации
Bruksanvisning
操作手册
CHANNEL
MENU
P65
OPERATING MANUAL
English
FastMig Pulse 350, 450
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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 Liquid cooled system: FastMig Pulse + MXF + FastCool 10 .......................................... 6
2.5.2 Air 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 ....................................................................................... 9
3.1 Main switch I/O ....................................................................................................................... 9
3.2 Pilot lamps ................................................................................................................................. 9
3.3 Operation of cooling fan ..................................................................................................... 9
3.4 Manual Metal Arc Welding ................................................................................................. 9
4. Control panel P 65 .................................................................................... 10
4.1 Layout and button functions ...........................................................................................10
4.2 Using the menus ...................................................................................................................11
4.2.1 Selecting the interface language .................................................................................11
4.2.2 About memory channels ..............................................................................................11
4.2.3 Creating the rst memory channel ..............................................................................12
4.2.4 Creating the rst MMA memory channel .....................................................................12
4.2.5 Creating and modifying memory channels .................................................................12
4.3 Welding parameters and functions ...............................................................................13
4.3.1 Welding parameters ......................................................................................................13
4.3.2 Welding functions .........................................................................................................15
4.3.3 Welding software delivery prole ................................................................................18
5. Basic Troubleshooting ............................................................................. 21
6. Operation disturbances .......................................................................... 22
6.1 Operation of the overload protection ..........................................................................22
6.2 Control fuses ..........................................................................................................................22
6.3 Under and over voltages in the mains supply ...........................................................22
6.4 Loss of a phase in the mains supply ..............................................................................22
7. Maintenance .............................................................................................. 22
7.1 Daily maintenance ...............................................................................................................22
7.2 Periodic maintenance .........................................................................................................23
7.3 Service shop maintenance ...............................................................................................23
8. Disposal of the machine ......................................................................... 23
9. Ordering numbers .................................................................................... 24
10. Technical data ............................................................................................ 26
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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 operating manual and the safety instructions booklet 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.
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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 Ssc 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.
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2.3 Machine introduction
CHANNEL
6,3A
1.
2.
3.
4.
8.
10.
5.
7.
9.
6.
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.
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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 Liquid cooled system: FastMig Pulse + MXF + FastCool 10
1.
4.
8.
2.
3.
9.
5.
6.
7.
1. MXF wire feed unit
2. FastMig Pulse power source
3. FastCool liquid 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
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2.5.2 Air cooled system: FastMig Pulse + MXF
1.
4.
5.
6.
8.
2.
3.
7.
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.
05
*)
L3
L2
L1
*) In cables of S type there is a protective grounding conductor coloured green-yellow.
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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.
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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.
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.
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4. CONTROL PANEL P 65
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.
The following information details control panel layout, button functions, operation and set-up. The menu options and their descriptions are listed for each menu command.
4.1 Layout and button functions
CHANNEL
CHANNEL INFO
USER
WF #
MENU
F1 F2 F3
P 65
W003989
1. 4.
5.6.
2. 7. 3.
8.
1. ON/OFF button
• Short press returns the panel to default initial view (channel information).
• Long press (>5 sec) turns P 65 panel and wire feeder panel PF 63/65 ON or OFF.
• Keeping this button pressed while turning the machine ON restores to factory settings. The
panel asks for a conrmation before restoring to defaults.
• If P 65 panel is OFF and a wire feeder panel PF 63/65 is turned ON, the P 65 panel will also be turned ON and linked automatically to this wire feeder panel.
NOTE! This button connects power to the control panel. Use the main switch on the front of the
power source to switch the power source on or o.
2. Welding channel selection buttons
FastMig Pulse oers 100 memory channels (10 for each user) for storing frequently used welding jobs.
• To browse memory channels, press + and – buttons.
• To store a new welding job to an empty channel, press the soft key under the display
text NEW.
3. MENU button
This button takes you to the main menu list. Proceed following the instructions on screen.
P 65 main menu list Edit Channel
Make changes to existing welding channel
User Identification
Select one user out of ten
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Weld Data
Check out the values of the last weld
System Config Menu
Show device conguration and information
Language
Select your menu language
Select Feeder (WF#)
Select another parallel wire feeder as a setup target
MMA On/Off
Activate MMA welding
4. Adjustment knob
Turn the knob to change the value of the selected parameter. In MMA mode when the panel is in default initial view (channel information), knob can be used to adjust current.
5. Menu browsing buttons
Use up and down arrows to move the selection up and down in the menu structure. In MMA mode when the panel is in default initial view (channel information), Up/Down buttons can be used to adjust Arcforce.
6. Menu shortcut buttons
• F1 (CHANNEL INFO) Displays the basic data recorded to the displayed channel. Pressing F1 multiple times gives more information of the selected memory channel. Keeping F1 pressed while turning the machine ON restores the menu language to English.
• F2 (USER) Browses and selects users: 1…10, Administrator. When MMA is selected, only Administrator is allowed.
• F3 (WF#) Selects another wire feeder as a setup target. Panel allows selecting only those WF numbers that are found connected on the system.
NOTE! FastMig Pulse allows up to 4 wire feeders to be connected to one power source. Only one
wire feeder can be active at a time and must be selected before it will operate.
7. LCD menu display
8. Soft key buttons for menu selection
Use these buttons to select menu items. Their functions depend on selected menu items. The function is shown on the display.
4.2 Using the menus
4.2.1 Selecting the interface language
The default menu language is English. If you want to select another menu language, do the following:
1. Connect the mains power and switch on the power source at the main switch.
• If this is the initial system activation (if SYSTEM OFF text is in the display), you may
need to press and hold the POWER ON button in the top left corner of the P 65 control panel. Hold the button down for 5 seconds.
2. Press the MENU button to display the main menu, which includes 7 menu items.
• You can move around in the menu list by pressing the up and down arrow buttons.
• As you browse the menu item list, the currently selected item is shown at the bottom
of the display, marked as 1/7, 2/7, 3/7 etc.
• The selected menu item is marked with a black arrow-shaped cursor.
3. Browse to the menu item LANGUAGE (5/7) and press the SELECT soft key button.
4. Browse to your language and press the SELECT/SAVE soft key button. Your language choice is now conrmed and will remain selected unless you change it later.
4.2.2 About memory channels
You can have several setups of welding parameter values for use in various welding applications. These setups (or welding jobs) are stored on a memory chip in the wire feeder.
Up to 10 user proles can be dened in one FastMig Pulse unit, and each of them are assigned up to 10 memory channels. So, you have maximum of 100 memory channels to store your frequently used welding jobs. In addition to them, there are 10 memory channels available for MMA use.
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To dene a new welding job, you need to make the necessary welding parameter selections and then save them to a memory channel of your choice.
When you want to use these settings, you simply select the corresponding memory channel number on the power source or wire feeder control panel and start welding. Only the most often used controls are available in the wire feeder control panel, making welding easy and convenient.
You can use and update any memory channel, unless it is locked via the four-digit administrator pin code lock.
4.2.3 Creating the rst memory channel
If you are starting a new FastMig Pulse that contains no memory channels, follow these steps to create the rst memory channel.
1. Power on the machine from the main switch. You may need to press the control panel's Power On button for 5 seconds to activate the P 65 control panel.
2. An empty memory channel appears. Press the NEW soft key.
3. With Create New selected, press SELECT soft key.
4. Select the desired welding process and other welding parameters.
• Use up and down arrow buttons to move around in the menus
• Approve selections by pressing the SELECT soft key.
5. When you have made all settings , press SAVE soft key to store the settings in the active memory channel.
4.2.4 Creating the rst MMA memory channel
If you are starting a new FastMig Pulse that contains no MMA memory channels, follow these steps to create the rst MMA memory channel.
1. Press MENU button to display the main menu.
2. With up and down arrows, browse to MMA On/O and press SELECT.
• MMA Mode view appears
3. With the adjustment knob, select ON and press SELECT.
• An empty MMA memory channel appears.
4. When an empty MMA memory channel appears, press NEW soft key.
5. With Create New selected, press SELECT soft key.
6. Select MMA and other parameters.
7. When you have made all settings, press SAVE soft key to store the settings in the active memory channel.
4.2.5 Creating and modifying memory channels
1. Press MENU button to display the main menu.
2. With Edit Channel selected, press SELECT.
3. Select the channel number to be changed and press SELECT.
• Use up and down arrow buttons to browse the displayed channel numbers.
• Use Channel Info (F1) button to see the show the settings of the displayed channel.
• To create a new channel, select a channel that is marked (Empty).
4. Browse the menu to select the desired options and parameters.
• Use up and down arrow buttons to move around in the menus.
• Approve selections by pressing the SELECT soft key.
• See the welding parameters and functions section of this manual.
5. When you have made all settings, press SAVE soft key to store the settings in the selected memory channel number.
When you have created a memory channel, the system is ready to weld. You select the desired memory channel number on wire feeder's control panel, set the welding power and arc length and start welding.
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4.3 Welding parameters and functions
4.3.1 Welding parameters
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
8.0 – 50.0V 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.
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
-9.0 ... +9.0 Factory setting is 0.0
( = curve point)
0.5 steps
Adjusts the arc voltage of the curve within certain limits. In other words, it adjusts the length of the arc within certain limits
FineTuningMax
-9.0 ... +9.0 0.5 steps Set the limit for maximum arc length
FineTuningMin
-9.0 ... +9.0 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
-9.0 ... +9.0 Factory setting is 0.0
( = curve point)
0.5 steps
Adjusts the base current of the curve in certain limits. In other words, it adjusts the length of the arc in certain limits.
FineTuningMax
-9.0 ... +9.0 0.5 steps Set the limit for maximum arc length
FineTuningMin
-9.0 ... +9.0 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%.
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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
-9.0 ... +9.0 Factory setting is 0.0 ( = curve point)
0.5 steps
Adjusts the base current of the curve in certain limits. In other words, it adjusts the length of the arc in certain limits.
FineTuningMax
-9.0 ... +9.0 0.5 steps Set the limit for maximum arc length
FineTuningMin
-9.0 ... +9.0 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 program.
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 program.
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 programs 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.
StartPower
-9 ... +9 Factory setting is 0 Adjusts arc ignition
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4.3.2 Welding functions
OTHER PROCESSES
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
0.0 – 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.
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 program).
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
0.0 – 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
FastMig Pulse 350, 450
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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 program).
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
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:
0.0V/100A –
10V/100A, 0,1V 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.
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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.
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 program.
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: Post Gas time is read from the
Welding program.
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.
FastMig Pulse 350, 450
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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.
ADMINISTRATOR MENU
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.
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. The tables below show typical welding programs, but there are more of them available. Please check availability from your supplier. If the delivery specication is focused to a specic project and you wish to update the machine in the future, you can select additional welding software from the Wise & Match software products. 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) minilog function, plus additional base material welding programs and optional panel function.
1. WiseRoot
6265011
2. WiseThin
9991013
3. WisePenetration
9991000
4. WiseFusion
9991014
5. MatchLog
9991017
Kemppi DataStore oers new welding software packages and special enhanced arc performance solutions. Customization of FastMig Pulse systems can make welding more ecient. Solutions oered are designed to meet the needs of wide ranging welding environments.
You can order materials specic welding programs and/or Wise solutions separately through Datastore or via your local supplier.
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ALUMINIUM PACK
Group Material Wire ø (mm) Shielding gas Process Number
Al AlMg5 1.0 Ar Pulse/Double Pulse A01 Al AlMg5 1.2 Ar Pulse/Double Pulse A02 Al AlMg5 1.6 Ar Pulse/Double Pulse A03 Al AlSi5 1.0 Ar Pulse/Double Pulse A11 Al AlSi5 1.2 Ar Pulse/Double Pulse A12 Al AlSi5 1.6 Ar Pulse/Double Pulse A13 Al AlMg5 1.0 Ar 1-MIG A01 Al AlMg5 1.2 Ar 1-MIG A02 Al AlMg5 1.6 Ar 1-MIG A03 Al AlSi5 1.0 Ar 1-MIG A11 Al AlSi5 1.2 Ar 1-MIG A12 Al AlSi5 1.6 Ar 1-MIG A13
STAINLESS STEEL PACK
Group Material Wire ø (mm) Shielding gas Process Number
Ss CrNiMo 19 12 0.8 Ar+2%CO₂ Pulse/Double Pulse S01 Ss CrNiMo 19 12 0.9 Ar+2%CO₂ Pulse/Double Pulse S02 Ss CrNiMo 19 12 1.0 Ar+2%CO₂ Pulse/Double Pulse S06 Soft Ss CrNiMo 19 12 1.2 Ar+2%CO₂ Pulse/Double Pulse S04 Ss CrNiMo 19 12 1.0 Ar+He+CO₂ Pulse/Double Pulse S26 Soft Ss CrNiMo 19 12 1.2 Ar+He+CO₂ Pulse/Double Pulse S24 Ss CrNiMo 19 12 0.8 Ar+2%CO₂ 1-MIG S01 Ss CrNiMo 19 12 0.9 Ar+2%CO₂ 1-MIG S02 Ss CrNiMo 19 12 1.0 Ar+2%CO₂ 1-MIG S03 Ss CrNiMo 19 12 1.2 Ar+2%CO₂ 1-MIG S04 Ss FC-CrNiMo 19 12 1.2 Ar+15–25%CO₂ 1-MIG S84 Ss MC-CrNiMo 19 12 1.2 Ar+2%CO₂ 1-MIG S87
STEEL PACK
Group Material Wire ø (mm) Shielding gas Process Number
Fe Fe 0.8 Ar+15–25%CO₂ 1-MIG F01 Fe Fe 0.9 Ar+15–25%CO₂ 1-MIG F02 Fe Fe 1.0 Ar+15–25%CO₂ 1-MIG F03 Fe Fe 1.2 Ar+15–25%CO₂ 1-MIG F04 Fe Fe 0.8 CO₂ 1-MIG F21 Fe Fe 0.9 CO₂ 1-MIG F22 Fe Fe 1.0 CO₂ 1-MIG F23 Fe Fe 1.2 CO₂ 1-MIG F24 Fe Fe Metal 1.2 Ar+15–25%CO₂ 1-MIG M04 Fe Fe Metal 1.2 CO₂ 1-MIG M24 Fe Fe Rutil 1.2 Ar+15–25%CO₂ 1-MIG R04 Fe Fe Rutil 1.2 CO₂ 1-MIG R14
FastMig Pulse 350, 450
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WORK PACK
Group Material Wire ø (mm) Shielding gas Process Number
Al AlMg5 1.2 Ar Pulse/Double Pulse A02 Al AlSi5 1.2 Ar Pulse/Double Pulse A12 Fe Fe 1.0 Ar+15–25%CO₂ Pulse/Double Pulse F03 Fe Fe 1.2 Ar+15–25%CO₂ Pulse/Double Pulse F04 Ss CrNiMo 19 12 1.0 Ar+2%CO₂ Pulse/Double Pulse S06 Ss CrNiMo 19 12 1.2 Ar+2%CO₂ Pulse/Double Pulse S04 Al AlMg5 1.2 Ar 1-MIG A02 Al AlSi5 1.2 Ar 1-MIG A12 Fe Fe 0.9 Ar+15–25%CO₂ 1-MIG F02 Fe Fe 1.0 Ar+15–25%CO₂ 1-MIG F03 Fe Fe 1.2 Ar+15–25%CO₂ 1-MIG F04 Fe Fe 0.9 CO₂ 1-MIG F22 Fe Fe 1.0 CO₂ 1-MIG F23 Fe Fe 1.2 CO₂ 1-MIG F24 Fe Fe Metal 1.2 Ar+15–25%CO₂ 1-MIG M04 Fe Fe Metal 1.2 CO₂ 1-MIG M24 Fe Fe Rutil 1.2 Ar+15–25%CO₂ 1-MIG R04 Fe Fe Rutil 1.2 CO₂ 1-MIG R14 Ss CrNiMo 19 12 1.0 Ar+2%CO₂ 1-MIG S03 Ss CrNiMo 19 12 1.2 Ar+2%CO₂ 1-MIG S04 Ss FC-CrNiMo 19 12 1.2 Ar+15–25%CO₂ 1-MIG S84
More welding programs are available by purchasing MatchCurve and MatchCustom products. You can also order welding program packs together with WiseFusion function.
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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 program 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 program 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.
FastMig Pulse 350, 450
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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 permissible 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.
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7.2 Periodic maintenance
NOTE! Periodic 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.
FastMig Pulse 350, 450
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9. ORDERING NUMBERS
FastMig Pulse 350 power source
P 65 control panel included 6150400
FastMig Pulse 450 power source
P 65 control panel included 6150500
FastMig Pulse 350 power source
No control panel 6150400C1
FastMig Pulse 450 power source
No control panel 6150500C1
Remote P 65 control panel
6150600
FastMig MXF 63 EL wire feeder 200 mm
Work pack prole 6152300EL
FastMig MXF 65 EL wire feeder 300 mm
Work pack prole 6152100EL
FastMig MXF 67 EL 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
For MXF 63 wire feeders 6155200
PF 65 wire feeder panel
For MXF 65 and MXF 67 wire feeders 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, liquid cooled
1.8 m 6260410
Interconnection cable, liquid cooled
10 m 6260334
Interconnection cable, liquid cooled
15 m 6260335
Interconnection cable, liquid cooled
20 m 6260337
Interconnection cable, liquid cooled
30 m 6260340
Other lengths available
Remote control unit R10
5 m 6185409
Remote control unit R10
10 m 618540901
Remote control unit R20
5 m 6185419
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
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© Kemppi Oy / 1515
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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
FastMig Pulse 350, 450
26
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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
sc
of
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
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