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Pulse TCS
User Manual
38 pgs2.12 Mb2

Kemppi Pulse TCS User Manual

KempArc
Pulse TCS
Operating manual
EN
OPERATING MANUAL
English
KempArc Pulse TCS / © Kemppi Oy / 1204
EN
CONTENTS
KempArc Pulse TCS / © Kemppi Oy / 1204
2. INSTALLATION ........................................................................... 4
2.11 Enabling Tandem Control System ................................................................................................ 10
2.12 Interconnection with wire feeders ...............................................................................................10
2.13 Connecting the welding gun ...........................................................................................................11
2.14 Connecting earth return cables ......................................................................................................11
EN
3. USING THE MACHINE .............................................................. 12
3.1 Control from the robot .........................................................................................................................12
3.2 Control from the K 60 panel ..............................................................................................................14
3.3 Layout of control panel K 60 .............................................................................................................14
3.4 menu functions of control panel K 60 ......................................................................................15
3.5 Layout and buttons of remote panel KF 62 ...........................................................................22
3.6 Functions of remote panel KF 62 ...................................................................................................24
3.7 Getting started ............................................................................................................................................ 27
4.1 What is tandem MIG/MAG welding? ...........................................................................................28
4.2 how does it work? ..................................................................................................................................... 29
4.3 The Four operation modes .................................................................................................................29
5. BASIC TROUBLESHOOTING .................................................... 30
6. OPERATION DISTURBANCES ..................................................31
6.1 Operation of the overload protection........................................................................................31
6.2 Control fuses .................................................................................................................................................31
6.3 Under and over voltages in the mains supply .....................................................................31
6.4 Loss of a phase in the mains supply ............................................................................................ 31
7.1 Daily maintenance .................................................................................................................................... 31
7.2 Period maintenance ................................................................................................................................32
7.3 Service shop maintenance ................................................................................................................. 32
8. DISPOSAL OF THE MACHINE .................................................. 32
9. ORDERING NUMBERS ............................................................. 33
10. TECHNICAL DATA .................................................................... 35
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1. INTRODUCTION
1.1 GENERAL
Congratulations on choosing the KempArc™ Pulse TCS 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.
For Kemppi’s standard safety instructions and warranty terms and conditions, please visit our 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.
KempArc Pulse TCS / © Kemppi Oy / 1204
Disclaimer
While every eort has been made to ensure that the information contained in this guide is accurate and complete, no liability can be accepted for any errors or omissions. Kemppi reserves the right to change the specication of the product described at any time without prior notice. Do not copy, record, reproduce or transmit the contents of this guide without prior permission from Kemppi.
1.2 ABOUT KEMPARC PULSE TCS
KempArc Pulse TCS is a dual wire MIG/MAG welding system designed for demanding robotic applications. It is equipped with a Tandem Control System (TCS), which means that it includes two power sources and two control panels, both of them piloting independently their own ller material feeds into the weld pool.
The system consists of two KempArc Pulse 450 A power souces, two DT 400 wire feeders, one for the left side and one for the right side, and a welding gun with two contact tips. The system has a liquid-cooling system managed by the KempCool 40 cooling unit.
With Kemppi's welding software products, such as modied processes and welding programs, you can customize your KempArc Pulse TCS system to suit excactly your special welding needs.
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2. INSTALLATION
2.1 BEFORE USE
KempArc Pulse TCS welding system is delivered in several packages. Product packaging material is recyclable. Check that you have received following components and that they have not been damaged during transportation:
• KempArc Pulse TCS 450 A power source (2 pcs)
• KempCool 40 cooler unit (1 pcs)
• Power source xing plates and their accessories
• DT400 and DT400L wire feeders
• Fieldbus interface card
• TCS cable and interconnection cables (2 pcs)
• Tandem welding torch and its xing bracket
The detailed parts list can be found in the ordering codes section at the end of this operating manual.
KempArc Pulse TCS / © Kemppi Oy / 1204
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.
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2.2 MACHINE INTRODUCTION
1.
2.
7.
10. 11. 12. 13.
14.
3.
6,3A
4.
8.
5.
6.
9.
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1. Control panel K 60
2. Main switch (ON/OFF)
3. Main power indicator light (ON/OFF)
4. Warning indicator 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. Robot control connection
11. Wire feeder connection
12. Throughput connection
13. Analogue connection
14. Connection for KempArc Browser or Tandem
2.3 MAIN SWITCH
When you turn the main switch to position I, the main switch indicator light turnes on and the machine is ready for use.
NOTE! Always start and stop the machine from the main switch, never use the plug as a switch!
2.4 INDICATOR LIGHTS
Indicator lights display the machine’s operational state. When the green indicator is lit, it displays that the machine is switched on and is ready for use, and that it is connected to the mains supply with the power source main switch in position I.
When the orange indicator is lit, it indicates that the thermal protection circuit has been activated due to high working loads that exceed the rated duty cycle. The cooling fan will continue to run and cool the machine down. When the light turns o, the machine is again ready to weld.
KempArc Pulse TCS / © Kemppi Oy / 1204
EN
2.5 OPERATION OF THE COOLING FAN
KempArc Pulse TCS power sources incorporate two simultaneously operating fans.
• The fan starts momentarily, when you turn the machine on from the main switch.
• 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.
2.6 MACHINE ASSEMBLY AND POSITIONING
KempArc Pulse TCS is delivered with a KempCool 40 cooler unit, which also serves as a stand for the two power sources. The cooler unit delivery package contains the xing screws and plates for attaching the power sources on top of the cooler unit.
To assemble the KempArc equipment, do the following:
1. Attach the xing plates to the power sources with the screws delivered in the package.
2. Lift the leading power source onto the cooler unit, and attach the cooler control lead to the connector on the bottom of the power source.
3. Fix with four screws on the facing side and the backside.
4. Lift the other power source onto the cooler unit and x with screws.
NOTE! Remember to attach rst the xing plates to the power sources, then lift the power sources
on the cooler unit.
NOTE! When starting to use the machine, do the following conguration settings in the K 60
control panel menu:
- Set Water Cooling mode to AUTO in the leading machine that is connected to the cooler.
- Set the Water Cooling mode to OFF in the other machine.
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KempArc Pulse TCS / © Kemppi Oy / 1204
EN
If it is necessary to place the power sources elsewhere, use a rm, dry and level surface. Try not to allow dust or other impurities to enter the machines cooling air ow. Preferably site them 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! Do not operate the machine in the rain. The protection class is IP23S, which allows for
outside preserving and storage only.
NOTE! Never aim metallic grinding spray/sparks towards the equipment.
2.7 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 TCS:
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 supply network. It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power Ssc greater than or equal to 5.5 MVA.
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2.8 OVERVIEW OF THE SYSTEM
3.
11.
10.
2.
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13.
1.
7.
6.
5.
8.
4.
13.
KempArc Pulse TCS / © Kemppi Oy / 1204
EN
9.
12.
1. DT 400 wire feeder (right-handed)
2. KempArc Pulse TCS power source, master unit
3. Robot controller
4. DT 400L wire feeder (left-handed)
5. KempArc Pulse TCS, slave unit
6. KempCool 40 cooling unit
7. Shielding gas supply
8. Power cable (3-phase)
9. Power cable for cooling unit (1-phase)
10. KF 62 remote control panel (optional)
11. Robot control connection
12. Liquid cooled tandem welding gun
13. Earth return cable and clamp
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2.9 CONNECTING TO MAINS POWER
NOTE! Always check before use that all cables are in good working condition: the mains cable,
interconnecting cable, shielding gas hose, earth return cable and clamp. Ensure that connectors are correctly fastened. Loose connectors can impair welding performance and damage connectors.
KempArc power sources are delivered as standard with a 5-meter 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 TCS power sources can be connected to the 3-phase mains supply of 400 V.
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
KempArc Pulse TCS / © Kemppi Oy / 1204
and fastened with a cable clamp. The phase conductors of the cable are coupled to supply terminals L1, L2 and L3. If the cable has also a green and yellow coloured protective grounding conductor, it should be coupled to the terminal marked with .
If you are using a 5-lead cable, do not connect the neutral conductor.
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2.10 CONNECTING TO WELDING ROBOT
Select which one of the KempArc Pulse TCS power sources you want to make the leading unit that controls the rst ller wire. In this unit you should install the eldbus card, which connects the KempArc Pulse TCS system to the robot control unit.
It is recommended to install the eldbus card to the same power source unit, which is connected to the KempCool 40 cooling unit.
To install the eldbus card, do the following:
1. Open the cover of the black control unit box located above the power source.
2. Install the eldbus card onto the interface card as shown in the picture. Attach the xing nuts.
3. Connect the welding robot's eldbus cable to the eldbus card's connector.
4. Close the cover of the black control unit box.
Fieldbus cable connector
KempArc Pulse TCS / © Kemppi Oy / 1204
Fixing nuts
Fieldbus card
Interface card
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KempArc Pulse TCS / © Kemppi Oy / 1204
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2.11 ENABLING TANDEM CONTROL SYSTEM
The KempArc Pulse TCS welding system is equipped with a Tandem Control system (TCS), which allows both ller wires to be controlled independently of each other. To enable the control system, you need to connect the two power sources to each other using a tandem control cable.
Connect tandem control cable to BROWSER/TANDEM connections on the back of the control boxes as shown in the picture.
2.12 INTERCONNECTION WITH WIRE FEEDERS
Both power sources are connected to wire feeders with their own interconnection cable sets. Each cable set includes the following parts:
• a welding current cable
• a control cable
• four cooling hoses, two blue ones and two red ones
• a shielding gas hose.
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 cable 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 overview of the system earlier in this operating manual.
2.12.1 Connecting the welding cables
The welding cables are used for delivering the welding power to the robot's tandem welding gun. To connect the welding cables, do the following:
1. Connect the welding cable to the plus pole (+) located on the back of the leading power source that delivers ller wire to the rst contact tip of the tandem welding gun..
2. Attach the other end of the welding cable to the wire feeder, which delivers ller wire to the leading contact tip.
3. Connect the welding cable to the plus pole (+) on the back of the trailing power source that delivers ller wire to the second contact tip of the tandem welding gun..
4. Attach the other end of the welding cable to the wire feeder, which delivers ller wire to the trailing contact tip.
You can also use a manual welding gun for tack welding when necessary. It is connected to the plus pole (+) on the front of the power source.
NOTE! Do not overload the welding cables, as an overload may cause voltage loss and
overheating.
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