Kemppi KempCool 40 User Manual

KempCool

40

Operating manual

EN

OPERATING MANUAL

English

CONTENTS

1. Introduction ......................................................................................................................... 3

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

1.2 About the product ................................................................................................................. 3

1.3 Properties .................................................................................................................................. 4

2. Installation ............................................................................................................................. 6

2.1 Connecting the cooling system ........................................................................................ 6

2.2 Electrical connection ............................................................................................................. 6

3. Taking the machine into use .................................................................................... 6

3.1 Service and maintenance .................................................................................................... 6

3.2 Troubleshooting .....................................................................................................................7

3.3 Water quality ............................................................................................................................ 7

3.4 Temperature control PJ 33 .................................................................................................. 8

3.5 Disposal of the machine ...................................................................................................... 9

EN

4. Ordering numbers ........................................................................................................... 9

5. Technical data ..................................................................................................................... 9

6. Main circuit diagram ....................................................................................................10

2

KempCool 40

1. INTRODUCTION

1.1 General

Congratulations on choosing the KempCool 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 ans 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.

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

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

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

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

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.

EN

1.2 About the product

KempCool 40 is an ecient water cooling device designed for use with Kemppi's tandem
robotic welding equipment, KempArc Pulse TCS. It can be used for water cooling of two
welding guns, operating in a tandem welding environment. KempArc Pulse TCS can also be
used with other mechanised welding equipments, when extremely high ability of cooling is
demanded.

KempCool 40 is equipped with three water ow circuits, one for each contact tip and an
optional circuit for cooling the gas nozzle. Each water ow circuit has its own ow control, and
the low-pressure alarm can be adjusted to the desired level.

Range of application

The KempCool 40 cooling unit is designed to be used with Kemppi's KempArc welding
equipments.

© Kemppi Oy / 1204

3

1.3 Properties

Description and operation principle

KempCool 40 is an ecient water cooling device. It is equipped with a fan and a radiator using
water or special non-freezing liquid as a coolant. The operating temperature range of the
device is 5…40 °C (plain water) or -20…+40 °C (non-freezing liquid) .

Excess heat is removed from the coolant with a fan. When the temperature of the coolant
rises above a set level, heat exchanger is activated and the fan starts to operate, until
the temperature gets below the set level. The activation level can be adjusted inside the
KempCool 40 cooling unit. See instructions later in this manual.

Cooling capacity

Nominal cooling capacity is 4 kW. The temperature of the coolant is always higher than the
surrounding air by 0 to 8 °C.

NOTE! Whenever the unit is idle for longer periods of time, or if the temperature may occationally

drop below freezing point during storage or transport, empty all water ow circuits to avoid frost
damage, or make sure that the cooling brine is of non-freezing kind.

NOTE! Do not use inammable or explosive liquids.

EN

NOTE! To get special non-freezing cooling brine, please contact Kemppi Oy.

Cooling circuit

The KempCool 40 cooling device is equipped with an eective pump, which makes the
coolant continuously circulate between the heat exchanger and the welding gun. In the
welding end, the coolant absorbs heat, which is transferred to the ambient air in the heat
exchanger.

With the ow control screw you can control the ow of the cooling liquid. The level of coolant
container must be checked regularly and lled if needed.

NOTE! Avoid running the pump dry.

NOTE! Ensure that there is at least 40 cm free space on both sides of the machine for eective

cooling air circulation.

Cooling air

If surrounding air is heavily contaminated with particles of dust, install a lter to clean the
incoming cooling air. The lter is available as an optional accessory. The lter must be regularly
checked and replaced if needed.

Flow control

There is a ow control screw in all return lines of the cooling circuit. With this screw you can
adjust the coolant ow rate. Malfunction is indicated with a signal light in front of the cooling
unit.

Pressure alarm limit

If circulation of the coolant is for some reason weakened due to a fault somewhere in the
cooling circuit, the coolant pressure drops and the red signal light shows alarm.

With the control device located inside the cooling unit, you can set the pressure level where
the alarm is triggered.

4

KempCool 40

Slide block

Hex screw

Alarm limit pointer
(switch-o-point)

Setting the alarm limit for coolant pressure:

1. Attach the water hoses to the cooling water connectors on the front of the unit, and start
the unit from the main switch.

- If the ambient temperature is below 35 °C, only the pump starts.

2. Using the ow adjustment screws on the water hose connectors, set the ow rate to the
same value (e.g. 0.5–1 l/min) on each outgoing water line.

3. Remove the side panel on the left of the unit (looking from the front).

4. Loosen the hex screw on top of the ow controller (see the picture).

5. Move the slide block, until an alarm is given.

- If the unit is connected to a FastMig welding device, the alarm appears as a cooling unit
error on the power source's control panel.

6. Move the slide block a little backwards, until the alarm stops.

7. Lock the slide block in its place by xing the hex screw on the top.

8. Test the alarm by disconnecting one of the water lines. If there's no alarm, the set limit
value is too low, and you should adjust the limit to higher value.

9. When the alarm limit is on desired level, tighten the slide block in its place and replace
the side panel.

NOTE! The cooling fan starts when the temperature of the cooling water rises above 35 °C. The

pump starts to circulate the cooling water as soon as you start the unit from the main switch. The
pump has a thermostatic control, which allows longer maintenance intervals, because the unit
gets less dust inside with the fan not operating.

EN

© Kemppi Oy / 1204

5

2. INSTALLATION

2.1 Connecting the cooling system

Fill the coolant container through the lling tube. When the maximal level is reached, the
built-in mechanical oat switch breaks the water delivery. At the same time, circulation pump
starts to operate for a while to allow automatic ventilation of the system.

NOTE! The transfer pump must be switched on only when the system is completely lled. Running

dry can damage the pump.

If the cooled welding torches are located higher than the radiator, the coolant starts to ow
back when you switch o the pump, and the coolant container may overow. In this case you
can set a check valve (either magnetic or manual) in the ow circuit.

2.2 Electrical connection

All local electrical and electronic regulations must be complied with when making the
electrical connections. Before taking the equipment into use, check that the environment
fulls the following requirements.

EN

Mains voltage

Max. fuse protection

Wire cross section

230 V, 50 Hz

10 A

1.5 mm

3. TAKING THE MACHINE INTO USE

When you have lled the cooling system and made the necessary electrical connections, you
can turn on the heat exchanger group. The pump starts when you switch the device on.

If the desired pressure is not reached, please do as follows:

1. Check the coolant level in the cooling system and ll if necessary.

2. Check all joints.

3. Ventilate the system one more time.

3.1 Service and maintenance

The heat exchanger does not require any special servicing. However, it is recommended to
check regularly the hoses and connections for leaks.

NOTE! Always ensure that the voltage is switched o when carrying out any kind of maintenance

or service work on the KempCool 40 cooling device.

NOTE! Do not change electronic connections or make any technical modications on the machine.

For repair work, contact authorised Kemppi service workshop.

6

KempCool 40

3.2 Troubleshooting

Problem Cause Action

Insufficient cooling
capacity

Pump does not start

Flow alarm is on (the
red warning light on the
front panel)

The heat exchanger and/or air lter is
dirty. Clean the components.

Cooling air temperature is too high. Check the air temperature.

Cooling system is overloaded. Remove any extra cooling consumers.

The coolant temperature is too high
(> 40 °C).

Thermal protection of the pump motor
has gone o.

The coolant level is too low. Check the cooling system for leaks and add more

Clean the components.

Check thermoregulator setting. Replace if
necessary.

Check the fuses.

coolant if needed.

3.3 Water quality

Subject to the equipment to be cooled or heat-balanced, certain requirements have to be met
by the cooling water regarding purity. The degree of the water`s contamination, as well as the
size and construction of the heat-exchanging- or -balancing plant determine the process most
suitable for the application of additives and/or care of the water-supply in question. You can
use normal tap water when lling the tanks.

With deviating water-quality, we recommend using the services of consultants, or to have a
water analysis or water sample sent to us.

Kemppi is not liable for any malfunctions or damages arising from deviating water qualities.
When employing chillers at temperatures below + 8°C, an anti-freeze medium must be added.

EN

© Kemppi Oy / 1204

7

3.4 Temperature control PJ 33

m

u

t

e

When you turn the main switch to position 1, the circulating pump starts. If the temperature
of the coolant is higher than the temperature set at the thermoregulator, the cooling fan
also starts automatically. Otherwise, the desired cooling temperature must be set at the
thermoregulator.

Changing the set point

EN

m

u

t

e

2.

1. Unlock the set point with a long press of the up arrow key (3 s).

2. Increase the set point value by pressing the up arrow key or decrease it by pressing the
down arrow key.

3. When you have set the value, wait until the display returns to its initial state. The new
setting is saved automatically.

You can also use the SET button to return to initial state.

Indicator lights

1.

3.

4.

8

If led 3 shows white, the compressor is in operation.
If led 4 shows red, there is a fault (see the errors list).

KempCool 40

3.5 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.

4. ORDERING NUMBERS

KempCool 40

5. TECHNICAL DATA

KempCool 40

Operating voltage

Connection capacity

Cooling power

Start pressure, max.

Cooling liquid

Tank volume

External dimensions

Weight

Operating temperature range

Storage temperature range

EMC class

Degree of protection

6208400

EN

230 V AC ±10 %

100 % ED 300 W

4.0 kW

0.35 MPa (= 3.5 bar)

20–40 % ethanol+water

8 l

LxWxH 700 x 600 x 600 mm

40 kg

–20…+40 °C (non-freezing liquid)

–40…+60 °C

A

IP23S

© Kemppi Oy / 1204

9

6. MAIN CIRCUIT DIAGRAM

L

3

S1

4

2

EN

PJ Easy
230V
50/60 Hz

N

M1

R1

1

L L

M
~

N N

PE PE

pump

9
10

-N1

fan red white

M2

Kompr.

M
~

2

468

AUX

1 3 14

5711

1 11

B1 -K1

A1 x1 x1

K1

A2 x2 x2

Contact open if fault

H1 H2

10

-K1

B2

KempCool 40

11

14

4K7

15k

1 2 3 4 5 6

female

10k

B1 ow control
M1 pump
M2 fan
N1 temperature controller
R1 temperature sensor
S1 on/o switch
B2 AMP connector (connector to

KempArc power source)
K1 Relais Alarm
H2 power on lamp
H1 alarm lamp

KEMPPI OY

Kempinkatu 1
PL 13
FIN-15801 LAHTI
FINLAND
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www.kemppi.com

Kotimaan myynti:

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myynti.@kemppi.com

KEMPPI SVERIGE AB

Box 717
S-194 27 UPPLANDS VÄSBY
SVERIGE
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[e-mail]

KEMPPI NORGE A/S

Postboks 2151, Postterminalen
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NORGE
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KEMPPI BENELUX B.V.

Postbus 5603
NL-4801 EA BREDA
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KEMPPI (UK) Ltd

Martti Kemppi Building
Fraser Road
Priory Business Park
BEDFORD, MK44 3WH
UNITED KINGDOM
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[e-mail]

KEMPPI FRANCE S.A.S.

65 Avenue de la Couronne des Prés
78681 EPONE CEDEX
FRANCE
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KEMPPI GmbH

Otto-Hahn-Straße 14
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KEMPPI SPÓŁKA Z O.O.

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POLAND
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KEMPPI AUSTRALIA PTY LTD.

13 Cullen Place
P.O. Box 5256, Greystanes NSW 2145
SMITHFIELD NSW 2164
AUSTRALIA
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[e-mail]

OOO KEMPPI

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127018 MOSCOW
RUSSIA
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ООО КЕМППИ

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KEMPPI, TRADING (BEIJING) COMPANY,
LIMITED

Room 420, 3 Zone, Building B,
No.12 Hongda North Street,
Beijing Economic Development Zone,
100176 Beijing
CHINA
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[phone]
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肯倍贸易（北京）有限公司
中国北京经济技术开发区宏达
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[phone]
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www.kemppi.com

1920180

1204