FastMig KM 400 MVU
Contents
1. 2 1 2 2 2 3 INSTALLATION POSITIONING OF THE MACHINE Place the machine on a firm dry and level surface Where possible do not allow dust or other impurities to enter the machines cooling air flow Preferably site the machine above floor 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 IP235 allows for outside preserving and storage only NOTE Never aim metallic grinding spray sparks towards the equipment 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 This equipment complies with IEC 61000 3 12 provided that the short circuit power Ssc is greater than or equal to 4 7 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 ci2. KEMPPI The Joy of Welding FastMig KM 400 MVU MAMAS OUI OO Operating manual English FN Bruksanvisning Norsk NO St0L O ddway o NAW 00 Biwases EN OPERATING MANUAL English FastMig KM 400 MVU Kemppi Oy 1045 EN CONTENTS Ta PREFACE uu 3 14 UM sci a u SH 3 12 WMP TNO a asas ananas necati Ul totu nicae betae need 4 2 INSTALLATION a ua E REESE PEEKR OE oo EERE 5 2 1 Positioning ofthe madii ees uaa aM 5 22 Distribution netwolk Qut Dente rin dde ipd etri 5 2 3 Connection 5 24 Welding and earthing Cables 6 3 MACHINE USE D YES PCR ETIAM RENE 6 3 1 Starting of the power SOC ctione 6 3 2 Front panel indicators tuber 6 3 33 Use of the control 7 331 Starting of the control panel 7 3 3 2 DISDIayS d tpe ep Obere im ina aedis 7 3 3 3 ieri iui iei ee 7 3 3 4 Adjustment of MIG dynamics arc force 8 3 35 et e RE EE HERE EE HERR wide 8 3 3 6 Wire feed test senectt een baths 8 3 3 7 Selection of liquid or gas cooled MIG gun 8 3 3 8 Retrieval of weld data nn nnne 8 3 3 9 Selection of co
3. In the event of a failure of the machine contact an authorised Kemppi service agent Before taking your unit for servicing check the list below OVERLOAD YELLOW INDICATOR LIT Two simultaneously operating fans cool the power source The machine may however overheat if continuously loaded above the rated values or if the circulation of cooling air is prevented The yellow indicator H12 is lit in the event of overheating You then need to stop welding and let the machine cool down The indicator light turns off when welding can be resumed CONTROL CABLE CONNECTOR FUSE The rear wall of the power source contains fuse F11 which protects the control cable connector X15 Using an incorrect fuse may cause damage to the power source It is important that you always use the right kind of fuse The type and size of the fuse are indicated next to the fuse socket 4 3 4 4 4 5 ELECTRIC NETWORK OVERVOLTAGE OR UNDERVOLTAGE If the power source is used in an electric network with insufficient voltage less than 300 V the control features of the device are disabled automatically The primary circuits of the power source are protected against power spikes The product s mains voltage range is broad enough to prevent overvoltage problems at up to 440 V see Section 8 Technical specifications Make sure that the voltage remains within the allowed range especially if the operating power is supplied by a generator set MISSING PHASE I
4. DYNAMICS data GAS TEST WIRE INCH REMOTE LOCAL KEMPPI W001319 P9 P10 P11 P12 3 3 1 Starting of the control panel When you start the power source with the main switch S11 the control panel remains in OFF mode and the wire feeder is not operational The display shows the text OFF When you depress the start button 1 for at least one second the control panel starts The unit is now ready for welding and enters the mode that was active before the power was cut off You can also start the control panel by quickly pressing the welding gun switch three times 3 3 2 Displays When you are adjusting the machine settings the control panel displays show adjustable operation parameters their values and the units of measure During welding display 2 shows the welding current value that is currently in use while display 8 shows the welding voltage 3 3 3 Control knobs The left hand control knob 10 allows adjustment of the speed of wire feeding The selected speed is shown on the display on the left hand side 2 The control knob on the right hand side 11 allows you to adjust the welding voltage The selected voltage is shown on the right hand display 8 These adjusters are used also for selecting the values of the machine s operational parameters such as the MIG mode and set up features A parameter for adjustment is selected with the left hand knob 10 while the value of the parameter is
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6. goes back to the normal state after approximately five seconds from release of the button or immediately when you press the start button Selection of liquid or gas cooled MIG gun You can select a MIG gun cooled with liquid or gas by pressing buttons 3 and 5 simultaneously and holding them down for at least one second When the display reads GAS you can use a gas cooled MIG gun with the equipment When the display reads COOLEr you can use a liquid cooled MIG gun with the equipment You can change the gun selection by pressing buttons 3 and 5 again as above With a liquid cooled gun selected the liquid cooling function is started when the power source is started the next time Retrieval of weld data The weld data function allows you to return to the welding current and voltage used during the previous session with the weld data feature To use the feature press buttons 5 and 7 simultaneously Selection of control panel Button 12 allows you to switch control between the control panels in the power source and wire feeder The indicator shows which of the control panels is in use When the LOCAL light is on the wire feeding speed and welding current are set using knobs 10 and 11 of the power source control panel When the REMOTE light is on the wire feed speed and welding current are set using the control panel of the wire feeder Knobs 10 and 11 of the power source are disabled in this mode 3 3 10 Setti
7. selected with the right hand knob 11 FastMig KM 400 MVU Kemppi Oy 1045 EN FastMig KM 400 MVU Kemppi Oy 1045 EN 3 3 4 3 3 5 3 3 6 3 3 7 3 3 8 3 3 9 Adjustment of MIG dynamics arc force When you press button 3 you can adjust the MIG welding dynamics of the machine by means of the right hand knob 11 The welding dynamics setting affects the properties of the welding arc and the amount of spatter as follows The value 0 is the recommended basic setting Use values 1 9 if you want a softer arc and less spatter Use values 1 9 if yu want a rougher and more stable arc This setting is useful when you are using 10096 CO2 shielding gas when welding steel Gas test The gas test button 5 opens the gas valve without activating the wire feed or power source By default gas flows for 20 seconds The gas flow time remaining is shown on the display The right hand knob 11 allows you to set the default gas flow time between 10 and 60 seconds and store the new default value in the machine s memory To abort the gas test press the start button or gun switch Wire feed test When you press the Wire inch button 6 the wire feeder engine starts but the gas valve does not open and the power source is not activated The default wire feed speed is 5 m min and you can adjust the speed with the right hand knob When the button is released the wire feeding stops The machine automatically
8. stain may become compressed into the grooves of the coolers Do not use a pressure washing device 2 Check the electrical connections of the machine Clean any oxidised connections and tighten the loosened ones Check for the right tension before you start repairing the connections NOTE Remember that the machine may be repaired only by an electrical contractor or installer authorised to perform such operations REGULAR MAINTENANCE Authorised Kemppi service agents perform regular maintenance by agreement Tasks included in regular maintenance Cleaning of equipment Inspection and maintenance of the welding gun Checking of connectors switches and control knobs Checking of electrical connections Checking of the mains cable and plug Replacement of damaged or worn parts Calibration testing with adjustment of the functions and operational values of the machine if necessary 5 4 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 authoritie
9. N THE ELECTRIC NETWORK If a phase is missing from the mains current the welding features will be adversely affected or the machine may have problems starting Loss of a phase can be caused by a e Blown mains fuse Damaged mains cable Poor mains cable connection in the machine s terminal block or mains socket MACHINE ERROR CODES The machine always checks its operation automatically during start up and reports any failures detected If failures are detected during start up they are shown as error codes on the control panel display Power source error codes Err3 Power source overvoltage The machine has stopped the welding because it has detected momentary voltage spikes or continuous overvoltage dangerous to the machine in the electric network Check the quality of the network supply Err4 Power source overheating The power source has overheated The cause might be one of the following The power source has been used for a long time at maximum power The circulation of cooling air to the power source is blocked The cooling system has experienced a failure Remove any obstacle to air circulation and wait until the power source fan has cooled down the machine Err5 Water unit alarm The water circulation is blocked The cause may be one of the following Congestion or disconnection in the cooling pipeline Insufficient cooling liquid e Excessive cooling liquid temperature Check the circulation of t
10. Time PoG Aut 0 1 32 05 Aut Post welding gas time in seconds or automatically according to welding current 15 1004 Aut Creep Start Level CrE 10 170 5096 Initial wire feeding speed as a percentage of the pre set value 10 creep start 100 no creep start 170 rush start Start Power StA 9 49 0 Strength of initial pulse Post Current Time PoC 9 49 0 Post welding current time Remote Switch IS 214 Inc 2t4 Selection of wire feed device Switch operation Calibration Menu CAL Ent Wire feed speed calibration see instructions in sub section 3 4 LongSystem Mode LSy on OFF OFF Select on if you are using long gt 40 m connector cables Restore Factory Settings OFF PAn All OFF Restore factory settings exit the menu by selecting All FastMig KM 400 MVU Kemppi Oy 1045 FastMig KM 400 MVU Kemppi Oy 1045 EN 3 3 12 Calibration of the wire feed speed 4 1 4 2 10 When factory settings are used the wire feed speed can be adjusted to between 4 and 100 without a unit of measurement Only the LED symbol indicates that wire feed speed is the parameter to be set The unit of the wire feed speed m min is shown once the wire feed speed of the device has been calibrated To programmatically calibrate the wire feed speed 1 To prepare the welding equipment for calibrating do the following Connect the wire feeder to the power source with the
11. U Kemppi Oy 1045 EN 2 4 3 1 3 2 WELDING AND EARTHING CABLES The device has a welding cable connection both in the front and in the rear The positions of the welding and earthing cable connections are shown earlier in section Introduction The welding cable type to be used is rubber insulated copper cable The recommended cross surfaces of the cables are as follows Model Cross surface KM 400 70 90 mm The table below shows the typical load capacities of the cables when the ambient temperature is 25 C and the lead temperature is 85 C Cable Duty cyde ED Voltage loss 10 100 96 60 96 3596 20 96 50 mm 285A 316A 371A 458A 0 35V 100A 70 mm 355A 403A 482A 602 0 25V 100A 95 mm 430A 498A 606A 765A 0 18V 100A 120 mm 500A 587A 721A 917A 0 21V 100A NOTE Do not overload the welding cables as an overload may cause voltage loss and overheating 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 MACHINE USE STARTING OF THE POWER SOURCE Start the power source by turning the main switch S11 on the front panel to the l position The standby indicator H11 turns on The control panel and wire feeder are not operational yet and the text OFF is shown on the control panel display NOTE Always turn the device on and off using the main switch not via the mains so
12. ail sales cn kemppi com KEMPPI INDIA PVT LTD LAKSHMI TOWERS New No 2 770 First Main Road KAZURA Gardens Neelangarai CHENNAI 600 041 TAMIL NADU SvOL 005061
13. cket The cooling fan is started for a moment when the main switch is turned to the l position The fan turns off after a while and then restarts during welding when the machine has warmed up sufficiently The fan continues running even after up to 10 minutes of welding depending on the temperature of the machine FRONT PANEL INDICATORS The following indicators can be found on the front panel of the device When the green indicator H11 is on the power source is in standby mode This indicator is on when the machine is connected to the mains supply with the main switch in the I position When the yellow overheating indicator H12 is on the machine has overheated The fan then starts When the indicator turns off the machine can be used again When indicator H12 blinks the machine has experienced a failure Attempt to remedy the problem according to the instructions in Section 4 Troubleshooting If the failure cannot be eliminated turn off the machine and turn it on again If the failure persists write down any fault code that may be shown on the display and contact authorised Kemppi service agent 3 3 USE OF THE CONTROL PANEL The control panel is used for controlling and monitoring the operation of the power source and the wire feeder The buttons are used for adjusting functions The displays and indicators reflect the operating modes of the machine P1 P2 P4 P5 P6 P7 P8 fi A weld 49 MM e lt e
14. control cable Insert the filler wire in the gun and run the wire out of the contact tip Adjust the feeder wheels so that they are sufficiently tight Start the power source and turn on the control panel with the start button 1 2 Depress button 9 SETUP for at least five seconds The set up menu appears on the display 3 Select the calibration menu CAL by rotating the left hand knob and then select the value Enter Ent with the right hand knob Accept your selection by pressing button 12 REMOTE LOCAL briefly 4 Use the right hand knob to select m min as the value of measure for the quantity to be calibrated and accept your selection by briefly pressing button 12 REMOTE LOCAL 5 the left hand knob to set the first calibration point to the desired value e g 2 0 m min 6 Cutthe filler wire at the contact tip end Press the trigger and let the wire run until it stops automatically 7 Measure the length of the loose wire end to an accuracy of 1 cm 8 Enter the measurement with the right hand knob and accept your selection by pressing button 12 REMOTE LOCAL briefly 9 Usetheleft hand knob to set the second calibration point to an appropriate value e g 18 0 m min 10 Repeat steps 6 8 11 The message cES appears on the display to indicate that calibration has ended successfully At the same time the device exits calibration mode and returns to basic operation mode TROUBLESHOOTING
15. ds Check the trigger s leads Other error codes The machine can show codes not listed here In the event of an unlisted code appearing contact an authorised Kemppi service agent and report the error code shown SERVICE The utilisation level of the power source and its working environment should be taken into consideration in planning the frequency of maintenance of the machine Appropriate use and preventive maintenance guarantee the trouble freest use of the equipment This allows you to avoid interruptions in use and increases the productivity of the machine CABLES Check the condition of welding and mains cables daily Do not use damaged cables Also make sure that all extension cables used in the mains connection are in proper condition and compliant with regulations NOTE The mains cables may be repaired and installed only by electrical contractors and installers authorised to perform such operations POWER SOURCE Before cleaning the interior of the machine you need to remove the case by unscrewing the mounting screws at the top and sides of the machine NOTE To prevent damage wait approximately two minutes after disconnecting the mains cable before removing the machine s case Perform the following cleaning and maintenance at least every six months 1 Clean the interior of the machine and the fan grill s net of any dust and stains for example with a soft brush and vacuum cleaner Do not use pressurised air The
16. he cooling liquid and the air circulation of the water unit Err23 Power source overvoltage warning The power source has detected voltage spikes in the electric network Short power spikes can be managed They do not lead to interruptions in welding but may decrease the welding quality Check the quality of the supply network Err61 The water unit is not found The water unit is not connected to the equipment or the connection has failed Set the machine to gas cooling 3 3 7 if you are using a gas cooled welding gun or connect a water unit Err155 Warning of the wire feed unit overheating The voltage level of the wire feeding engine has increased The cause may be a stained wire lead or a gun cable that is twisted at a sharp angle Check the state of the gun and clean the wire line if this is necessary 11 FastMig KM 400 MVU Kemppi Oy 1045 EN FastMig KM 400 MVU Kemppi Oy 1045 EN 5 1 5 2 5 3 12 Err154 Overloading of the wire feed motor The welding has been interrupted because the wire feeding engine power has risen to a high level The cause may be congestion in the wire line Check the wire lead contact tip and feed rollers Err201 Use of PMT gun is prevented The machine is intended for use with MMT guns When a PMT gun is used the gun s jumpers must be set to FU This error code may appear also if the contacts of the gun trigger are stained or there are problems with the trigger lea
17. me For your 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 specifications 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 VOTE notation Read these sections carefully and follow their instructions FastMig KM 400 MVU Kemppi Oy 1045 EN INTRODUCTION The FastMig KM series power source 400 is a MIG power source designed for demanding professional use in the three phase network The power source has a control panel that allows ready control of the functions of the power source and the wire feeder FastMig KM 400 MVU Kemppi Oy 1045 EN Overview of the power source C C C C C C C C C C Front view Rear view A1 Control panel A2 Main switch I O S11 A3 Signal light I O H11 A4 Thermal warning light H12 A5 Welding cable connection X11 13 A6 Earth connection X12 A7 Control cable connection X15 A8 Mains cable input 01 A9 Fuse for control cable connection 6 3 A slow A10 Fan grills A11 Carrying handles
18. mpany if defects in materials or workmanship occur Warranty repairs are to be carried out only by an authorised Kemppi Service Agent Packing shipping and insurance are at the orderer s expense The warranty starts on the date of purchase Spoken promises not included in the terms of warranty are not binding on the warrantor Limitations of the warranty The following conditions are not covered under the terms of warranty defects arising from normal wear and tear non compliance with operation and maintenance instructions overloading negligence connection to incorrect or faulty supply voltage including voltage surges outside equipment specifications incorrect gas pressure anomalies or failures in the electric network transport or storage damage and fire or damage due to forces of nature This warranty does not cover direct or indirect travel costs daily allowances or accommodation related to warranty service The warranty does not cover welding torches and their consumables feeder drive rolls and feeder guide tubes Direct or indirect damage caused by a defective product is not covered under the warranty The warranty becomes void if modifications are made to the machine that are not approved by the manufacturer or if non original spare parts are used in repairs The warranty is also voided if repairs are carried out by a repair agent not authorised by Kemppi Undertaking warranty repairs Warranty defects must be reported to Kemp
19. ng of the MIG operating mode Button 9 allows you to set the MIG welding gun to either two sequence or four sequence mode The indicator shows the mode selected In two sequence mode 2T welding is started by pressing the gun switch and stopped by releasing the switch In four sequence mode 4T the following actions take place When you press the gun switch the shielding gas starts to flow When you release the switch welding starts When you press the switch again welding ends When you release the switch again the flow of the shielding gas ends 3 3 11 Setting of operation parameters Button 9 also is used for changing welding parameters as follows Depress button 9 for at least five seconds The set up menu appears on display 2 Select the parameter to adjust with the left hand knob 10 so that the name of the parameter you want to adjust is shown on display 2 Seta value for the parameter by using the right hand knob 11 such that the value you want is shown on display 2 The value you selected is recorded in the control panel memory Exit the set up menu by pressing button 9 again and holding for at least five seconds or by briefly pressing the control panel start button 1 The table below lists the operation parameters and their possible values Name of parameter Name displayed Parameter values Factory setting Description Pre Gas Time PrG 0 0 9 95 0 1 Pre welding gas time in seconds Post Gas
20. ntrol u teer ii ee a dae 8 3 3 10 Setting of the MIG operating mode ssssssseessseenneneneeees 8 3 3 11 Setting of operation parameters 9 3 3 12 Calibration of the wire feed speed sess 10 4 TROUBLESHOOTING 10 41 Overload yellow indicator llt ttt Este 10 42 Control cable connector fuse 10 4 3 Electric network overvoltage or 11 4 4 Missing phase in the electric network 11 4 5 Machine error CODES dpa 11 SERVICE ene 12 12 52 12 53 Regular maintenance 12 5 4 Disposal or the 13 6 ORDERING NUMBERS 13 7 TECHNICAL SPECIFICATIONS 13 8 WARRANTY POLICY 14 1 1 PREFACE GENERAL Congratulations on your choice of the FastMig KM series power source Reliable and durable Kemppi products are affordable to maintain and they increase your work productivity This user manual contains important information on the use maintenance and safety of your Kemppi product The technical specifications of the device can be found at the end of the manual Please read the manual carefully before using the equipment for the first ti
21. pi or an authorised Kemppi Service Agent without delay Before a warranty repair is undertaken the customer must present proof of warranty or otherwise prove the validity of the warranty in writing The proof must indicate the date of purchase and the manufacturing number of the unit to be repaired The parts replaced under the terms of this warranty remain the property of Kemppi and must be returned to Kemppi if requested After a warranty repair the warranty of the machine or equipment repaired or replaced shall be continued to the end of the original warranty period St0L O ddway o NAW 00 WY Biwases EN 15 KEMPPI OY PL13 FIN 15801 LAHTI FINLAND Tel 358 3 899 11 Telefax 358 3 899 428 www kemppi com KEMPPIKONEET OY PL13 FIN 15801 LAHTI FINLAND Tel 358 3 899 11 Telefax 358 3 734 8398 e mail myynti fi kemppi com KEMPPI SVERIGE AB Box 717 194 27 UPPLANDS VASBY SVERIGE Tel 46 8 590 783 00 Telefax 4 46 8 590 823 94 e mail sales se kemppi com KEMPPI NORGE A S Postboks 2151 Postterminalen N 3103 T NSBERG NORGE Tel 47 33 346000 Telefax 47 33 346010 e mail sales no kemppi com KEMPPI DANMARK A S Literbuen 11 DK 2740 SKOVLUNDE DANMARK Tel 45 4494 1677 Telefax 45 4494 1536 e mail sales dk kemppi com KEMPPI BENELUX B V Postbus 5603 NL 4801 EA BREDA NEDERLAND Tel 31 765717750 Telefax 31 765716345 e mail sales nl kemppi com www kemppi com KEMPPI UK Ltd
22. rcuit power Ssc greater than or equal to 4 7 MVA CONNECTION TO MAINS FastMig KM power sources are connected to the 230 V or 400 V three phase network using the mains cable supplied with the machine The machine is equipped with a five metre mains cable that does not have a plug Before use check the mains cable and install a mains plug If the cable does not comply with the local electrical regulations replace it with a compliant cable See Technical specifications NOTE The mains cable or plug may be installed or replaced by only an electrical contractor or installer authorised to perform such operations Replacement of the mains cable 1 Unscrew the mounting screws on the top and sides of the machine and remove the case by lifting it 2 Disconnect the phase leads from connectors L1 L2 and L3 and disconnect the protective earth lead 3 Passthe cable to the machine through the inlet ring at the rear of the machine and secure the cable with a cable clamp 4 Connect the cable s phase leads to connectors L1 L2 and L3 5 Connect the yellow green protective earth lead to its connector NOTE Do not connect the zero lead if you are using a five lead cable The table below lists the fuse sizes for 10096 load in a 400 V three phase network with 4 x 10 mm cable Voltage Fuse slow Cable 400 V 35 HO7RN F 4610 10 mm 230V 50A HO7RN F 4610 10 mm FastMig KM 400 MVU Kemppi Oy 1045 EN FastMig KM 400 MV
23. s or a Kemppi representative By applying this European Directive you will improve the environment and human health 6 ORDERING NUMBERS Item Size Part number FastMig KM 400 MVU 603400003 Earthing cable 5 m 50 mm 6184511 Earthing cable 5 70 mm 6184711 Transport unit 6185291 Gun holder GH 30 6256030 7 TECHNICAL SPECIFICATIONS FastMig KM 400 MVU 400 V 230V Mains voltage 3 50 60 Hz 400 V 15 20 230V 10 10 Rated power 80 ED 19 kVA 20 kVA 100 ED 18 kVA 18 KVA Primary current 80 ED limax 27A 48A 100 ED 26A 45A Connector cable HO7RN F 4610 10 mm 4610 10 mm Fuse slow recommended 35 50 Load capacity at 40 C 80 ED 400A 400A 100 ED 380A 380A Welding voltage range MIG 10 39V 10 39V Max welding voltage 48V 48V Open circuit voltage 65V 65V Idle power 30W 30W Efficiency 8796 8796 Power factor 0 8 0 8 Storage temperature range 40 60 40 60 Operating temperature range 20 40 C 20 40 C Degree of protection IP 235 IP 235 EMC class A A Minimun short circuit power Ssc of supply network 4 7 MVA 4 7 External dimensions Length 590mm 590 mm Width 230mm 230 mm Height 580mm 580 mm Weight 49 kg 49 kg Voltage supply for auxiliary devices 24VDC 24VDC See paragraph 2 2 13 FastMig KM 400 MVU Kemppi Oy 1045 FastMig KM 400 MVU Kemppi Oy 1045 EN 14 WARRANTY POLICY Kemppi Oy provides a warranty for products manufactured and sold by the co
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