Kemppi Pulse 350 User Manual

Pulse 350, 450

KempArc™

DT 400

Operating manual • English

Käyttöohje • Suomi

Bruksanvisning • Svenska

Bruksanvisning • Norsk

Brugsanvisning • Dansk

Gebrauchsanweisung • Deutsch

Gebruiksaanwijzing • Nederlands

Manuel d’utilisation • Français

Manual de instrucciones • Español

Instrukcja obsługi • Polski

Инструкции по эксплуатации • По-русски

操作手册 • 中文

Manual de utilização • Português

OPERATING MANUAL

English

KempArc Pulse 350, 450 / © Kemppi Oy / 1044

CONTENTS

KempArc Pulse 350, 450 / © Kemppi Oy / 1044

1. INTRODUCTION

1.1 General

1.2 About KempArc Pulse products

................................................................................................................................................................. 3

..................................................................................................................................3

........................................................................................................ 3

2. INSTALLATION ...................................................................................................................................... 4

2.1 Before use ..........................................................................................................................................................4

2.2 Machine introduction ............................................................................................................................... 4

2.3 Positioning of the machine ...................................................................................................................5

2.4 Distribution network .................................................................................................................................5

2.5 Connecting cables ....................................................................................................................................... 6

3. OPERATION CONTROL ...............................................................................................................9

3.1 Main switch I/O

3.2 Pilot lamps ......................................................................................................................................................... 9

3.3 Operation of cooling fan

.............................................................................................................................................. 9

......................................................................................................................... 9

4. USING THE MACHINE ................................................................................................................10

4.1 setup panel K 60 – layout .................................................................................................................... 10

4.2 Setup panel K 60 ........................................................................................................................................ 10

4.3 Welding parametres and functions .............................................................................................12

4.4 KF 62 panel overview ............................................................................................................................. 19

5. KF 62 PANEL BUTTON FUNCTIONS ........................................................................ 20

5.1 ON / OFF Button

5.2 Dynamics Button ....................................................................................................................................... 21

5.3 Gas Test Button

5.4 Wire Inch Button ........................................................................................................................................21

5.5 Channel -..........................................................................................................................................................21

5.6 Channel +

5.7 Save Button .................................................................................................................................................... 22

5.8 Extra functions Button

5.9 Control display ............................................................................................................................................22

5.10 Power encoder potentiometer ........................................................................................................ 22

5.11 Arc length/voltage/adjustment potentiometer

5.12 Getting started ............................................................................................................................................ 23

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

......................................................................................................................................... 20

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

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

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

6. BASIC TROUBLESHOOTING .............................................................................................. 25

7. OPERATION DISTURBANCES .......................................................................................... 26

7.1 Operation of the overload protection

7.2 Control fuses

7.3 Under and over voltages in the mains supply

7.4 Loss of a phase in the mains supply ........................................................................................... 26

................................................................................................................................................. 26

........................................................................................26

..................................................................... 26

8. MAINTENANCE .................................................................................................................................. 26

8.1 Daily maintenance .................................................................................................................................... 26

8.2 Period maintenance ................................................................................................................................27

8.3 Service shop maintenance ................................................................................................................. 27

9. DISPOSAL OF THE MACHINE ..........................................................................................27

10. ORDERING NUMBERS ...............................................................................................................28

11. TECHNICAL DATA ........................................................................................................................... 29

1. INTRODUCTION

1.1 GENERAL

Congratulations on choosing the KempArc™ 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 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.

1.2 ABOUT KEMPARC PULSE PRODUCTS

KempArc 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 and basic MIG/MAG. K 60 setup panel is included in the delivery for selecting, setting and managing the welding system prior to and during system use.

KempArc 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.

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

KempArc Pulse 350, 450 / © Kemppi Oy / 1044

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.

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 MACHINE INTRODUCTION

KempArc Pulse 350, 450 / © Kemppi Oy / 1044

11. 12. 13. 14.

10.

6,3A

1. Setup panel K 60

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

11. Robot control connection

12. Wire feeder connection

13. Through put connection

14. Analog connection

2.3 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.

KempArc Pulse 350, 450 / © Kemppi Oy / 1044

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

2.4 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.

KempArc Pulse 350 and 450:

This equipment complies with IEC 61000-3-12 provided that the short-circuit power S 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.

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 Water cooled system: KempArc Pulse + DT 400 + KempCool 10

KempArc Pulse 350, 450 / © Kemppi Oy / 1044

10.

11.

1. DT 400 wire feed unit

2. KempArc Pulse power source

3. KempCool water cooler and power connection

4. Robot controller

5. Gas supply

6. Liquid cooled welding Gun

7. Power cable

8. Earth return lead and clamp

9. Wire feeder connection

10. Robot control connection

11. KF 62 remote panel (optional)

2.5.2 Gas cooled system: KempArc Pulse + DT 400

1. DT 400 wire feed unit

2. KempArc Pulse power source

3. Gas supply

4. Gas cooled welding Gun

5. Power cable

6. Earth return lead and clamp

7. KF 62 remote panel (optional)

8. Robot controller

2.5.3 Connecting to mains power

KempArc 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. KempArc 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. 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.

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

2.5.4 Connecting welding and earthing cables

The power source has two welding cable and control cable connectors. With them, the welding robot’s welding torch and, if necessary, a manual welding torch for tack welding can be connected to the power source.

Connect the welding and earthing cables as follows.

1. Connect the power source to the electric network according to the instructions above.

2. Connect the earthing cable to the earthing connector .

3. Connect the welding cable to the welding current connector.

NOTE! Do not overload the welding cables, as an overload may cause voltage loss and

overheating.

You can conect the control cables of manual welding wire feeders or the control cable of a remote controller to the control cable connectors.

Before starting the welding, connect the earth clamp directly to the work piece in such a way as to maximise the contact surface of the clamp. The point of connection must be unpainted and free of corrosion.

2.5.5 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.

• KempArc Pulse 350: 70 to 90 mm²

• KempArc 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 %

70 mm² 95 mm²

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.

355 A 460 A 650 A 0.25 V / 100 A

430 A 560 A 790 A 0.18 V / 100 A

2.5.6 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:

2.4.1 and 2.4.2

NOTE! KempArc Pulse 350/450 power sources are designed to be used ONLY with DT 400 wire feed

unit and KF 62 control panel.

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

KempArc 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.

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