KempGouge ARC 800
Contents
1. KEMPPI The Joy of Welding KempGouge ARC 800 Operating manual English K ytt ohje Suomi Bruksanvisning Svenska Bruksanvisning Norsk Brugsanvisning Dansk Gebrauchsanweisung Deutsch Gebruiksaanwijzing Nederlands Manuel d utilisation Francais Manual de instrucciones Espa ol Instrukcja obstugi Polski VIHCTPyKLIMU no kcnnyarauMw Tlo pycckn EN FI SV NO DA DE NL FR ES PL RU ZLLL O ddway 008 2uv ebnoodwuay OPERATING MANUAL English KempGouge ARC 800 Kemppi Oy 1117 EN CONTENTS i PREFACE aa uM E A MEME 3 i Rls 3 1 2 General about carbon arc GOUGING EE 3 1 3 seio O i A NAN 4 ENN A 1 3 2 ere 5 2 INSTALLATION contain O a ton tte ntc 5 2 1 Positioning of the machine 5 22 CONCEBIDO MaS aan 6 23 Distribution network cuoco iiis tid tlbi siso 6 24 Gouging and earthing cables ettet 7 24 1 Connecting the GOUGING cable EEN 7 2 4 2 Connecting the earthing cable ENEE 7 3 USE o uuu IU E E 7 Bel brr 7 3 2 Howto USE the remote Control 8 3 3 Starting of the power soUrCe EEN 8 3 3 1 Automatic function fest 8 3 3 2 Front panel Imndlcators EEN 8 3 4 Control pancia ian 8 3 4 1 Adjusting the gouging current ENEE 8 3 4 3 Actual gouging current and voltage display EEN 9 3 4 3 Restoring factory Settings ciones 9 3 5 Techniques for carbon arc gouging ttes 9 4 TROUBLESHOOTING ttti 9 4 1 Overload yellow indicator lit 9 4 22. Note that a gouged surface is not immediately ready for welding Before welding the surface must be cleaned by grinding for example NOTE You must not exceed the maximum current specified for a gouging carbon as it will accelerate carbon wear The gouging current is too high if the copper coating melts faster than the gouging carbon TROUBLESHOOTING 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 both power sources of the machine The machine may however overheat if continuously loaded above the rated values or if the circulation of cooling air is prevented The yellow indicator A4 is lit in the event of overheating You then must stop gouging and let the machine cool down The indicator light turns off when gouging can be resumed KempGouge ARC 800 Kemppi Oy 1117 EN KempGouge ARC 800 Kemppi Oy 1117 EN 4 2 4 3 4 4 4 5 10 CONTROL CABLE CONNECTOR FUSE The rear wall of the power source contains fuse A9 which protects the control cable connector A7 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 CABLE NETWORK WITH OVER VOLTAGE OR UNDER VOLTAGE If the power source is used in an e
3. INTRODUCTION KempGouge ARC 800 is a solution for all arc gouging needs An 800 A power source with a control panel is included in the package The gouging carbon and carbon holder must be acquired separately Power source Al A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A10 A5 A10 Front view Rear view Control panel Main switch Signal light I O Thermal warning light Gouging cable connection Earth connection Remote control and service connection Connection cable input Fuse for control cable connection 6 3 A slow Fan grill Accessory box 1 3 2 Control panel P1 P2 P3 IN Mi KEMPPI KempGouge P4 P5 P1 Left display gouging current or name of adjustable parameter P2 Indicator lights for the current area P3 Right display gouging voltage or value of adjustable parameter P4 Setup button P5 Control knob gouging current adjustment factory reset 2 INSTALLATION 2 1 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 Prot
4. Ltd Martti Kemppi Building Fraser Road Priory Business Park BEDFORD MK44 3WH UNITED KINGDOM Tel 44 0 845 6444201 Telefax 44 0 845 6444202 sales uk kemppi com KEMPPI FRANCE S A S 65 Avenue de la Couronne des Pr s 78681 EPONE CEDEX FRANCE Tel 33 1 3090 04 40 Telefax 33 1 30 90 04 45 sales fr kemppi com KEMPPI GmbH Otto Hahn StraBe 14 D 35510 BUTZBACH DEUTSCHLAND Tel 49 6033 88 020 Telefax 49 6033 72 528 sales de kemppi com KEMPPI SPOLKA Z 0 0 UI Borzymowska 32 03 565 WARSZAWA POLAND Tel 48 22 7816162 Telefax 48 22 7816505 info pl kemppi com KEMPPI AUSTRALIA PTY LTD 13 Cullen Place PO Box 5256 Greystanes NSW 2145 SMITHFIELD NSW 2164 AUSTRALIA Tel 61 2 9605 9500 Telefax 61 2 9605 5999 info au kemppi com 000 KEMPPI Polkovaya str 1 Building 6 127018 MOSCOW RUSSIA Tel 7 495 739 4304 Telefax 7 495 739 4305 info ru kemppi com 000 KEMTITIM yn MonkoBaa 1 crpoenue 6 127018 MockBa Tel 7 495 739 4304 Telefax 7 495 739 4305 info ru kemppi com KEMPPI TRADING BEIJING COMPANY LIMITED Room 420 3 Zone Building B No 12 Hongda North Street Beijing Economic Development Zone 100176 Beijing CHINA Tel 86 10 6787 6064 86 10 6787 1282 Telefax 86 10 6787 5259 sales cn kemppi com FARS dr ARAA HGRA RAR AK SALES fil Bt KBR X420 100176 FIG 86 10 6787 6064 86 10 6787 1282 f E 86 10 6787 5259 sales cn kemppi com KEMPPI INDIA PVT LTD LAK
5. plate NOTE Do not connect the zero lead if you are using a five lead cable L1 red L2 black L3 grey L4 yellow green 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 7 6 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 7 6 MVA 2 4 2 4 1 2 4 2 3 1 GOUGING AND EARTHING CABLES Connecting the gouging cable The gouging cable is connected to the power source with a 120 mm DIX connector The cable is connected either to the positive or negative connector of the power source depending on the metal that is to be worked The power source has one negative connector and two positive connectors For information on the connector locations see Introduction Connect the gouging cable as follows Work metal Gouging cable connection Steel Positive Cast iron Negative Non iron metal The gouging cable is rubber insulated copper cable The table below sho
6. the indicator turns off the machine can be used again When indicator A4 blinks the machine has encountered a failure For instructions see Troubleshooting CONTROL PANEL FUNCTIONS The control panel allows the user to control and monitor the operation of the machine The buttons and the control knob are used to adjust the current used in gouging and other machine parameters The current and voltage values are shown on the control panel displays while working Adjusting the gouging current The required gouging current is set with the control knob in the control panel The accuracy of adjustment is 10 A which means that turning the control knob one notch increases or decreases the current by 10 amperes If you turn the control knob quickly you can quickly adjust the gouging current in increments of 100 A for each notch 3 4 2 3 4 3 3 5 4 1 The adjustment value of the gouging current is shown on the display when you turn the control knob The adjustment value is shown at the accuracy of 1 A The indicator light A is shown on the display The values you use are stored in the control panel memory and will be used when you start the machine again Actual gouging current and voltage display While gouging the control panel display shows the actual current and voltage values The gouging current is shown in amperes at the accuracy of 1 A while the voltage is shown in volts at the accuracy of 0 1 V Restoring factory setti
7. 0 m 95 mm 5 m DIX120 95 mm 10 m DIX120 120 mm 5m 120 mm 10 m TECHNICAL SPECIFICATIONS 3 50 60 Hz 50 ED 100 ED 50 ED I max 100 EDI HO7RN F 50 ED 100 ED Length Width Height Weight 6284000 W000869 W003408 61840951 61840952 61841201 61841202 6185409 400 V 15 20 44 KVA 35 kVA 65A 51A 4616 16 mm 63 A delayed 120W 0 90 0 90 800 A 44V 600 A 44V 20 A 800 A 50V max size 13 mm 500 700 kPa 5 7 bar 40 C 60 C 20 C 40 C A 7 6 MVA 1P235 590 700 mm 230 660 mm 885 1 400 mm 94 115 kg 200 kg ZLLL AQ ddway 008 2uv ebnoodwuay EN 13 KEMPPI OY Hennalankatu 39 PL 13 FIN 15801 LAHTI FINLAND Tel 358 3 899 11 Telefax 358 3 899 428 export kemppi com www kemppi com Kotimaan myynti Tel 358 3 899 11 Telefax 358 3 734 8398 myynti fi kemppi com KEMPPI SVERIGE AB Box 717 5 194 27 UPPLANDS V SBY SVERIGE Tel 46 8 590 783 00 Telefax 46 8 590 823 94 sales se kemppi com KEMPPI NORGE A S Postboks 2151 Postterminalen N 3103 TONSBERG NORGE Tel 47 33 346000 Telefax 47 33 346010 sales no kemppi com KEMPPI DANMARK A S Literbuen 11 DK 2740 SKOVLUNDE DANMARK Tel 45 4494 1677 Telefax 45 4494 1536 sales dk kemppi com KEMPPI BENELUX B V Postbus 5603 NL 4801 EA BREDA NEDERLAND Tel 31 765717750 Telefax 31 765716345 sales nl kemppi com www kemppi com KEMPPI UK
8. Control cable connector fuse eterne tts 10 4 3 Cable network with over voltage or under voltage 10 4 4 Missing phase in the electric network ttt 10 4 5 Machine error codes mormona india 10 B E e E 11 Lil lean 11 5 2 POWer nens onmia patebant anand feda ieiunia rae 11 5 3 MRegularrrgihitendlfte pisa mes den mnm pai Delta 11 5 4 Disposal of the machine aria 11 6 ORDERINGNUMBERS ttti 12 7 TECHNICAL SPECIFICATIONS EE 12 1 1 1 2 PREFACE GENERAL Congratulations on your choice of KempGouge ARC 800 carbon arc gouging solution Used correctly Kemppi products can significantly 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 specifications of the equipment can be found at the end of the manual Please read the manual carefully before using the equipment for the first 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 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
9. SHMI TOWERS New No 2 770 First Main Road KAZURA Gardens Neelangarai CHENNAI 600 041 TAMIL NADU Tel 91 44 4567 1200 Telefax 91 44 4567 1234 sales india kemppi com ZLLL 0078761
10. VOTE notation Read these sections carefully and follow their instructions Disclaimer While every effort 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 specification 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 GENERAL ABOUT CARBON ARC GOUGING Carbon arc gouging refers to a method where metal is removed by melting it with a welding arc and blowing the melted metal away with compressed air Carbon arc gouging can be used with the majority of metals such as steel stainless steel cast iron nickel copper magnesium and aluminium The equipment used in carbon arc gouging comprises the gouging power source a carbon holder and its cables and the gouging carbon which can be round or flat Also a sufficient compressed air supply must be available Around gouging carbon can be used in opening a root weld opening faulty welds and cracks manufacturing welding grooves cutting metal e making holes A flat carbon can be used in arc grading of surface errors in roller slabs cleaning steel casts opening faulty casts arc grading of weld caps KempGouge ARC 800 Kemppi Oy 1117 EN KempGouge ARC 800 Kemppi Oy 1117 EN 1 3 1 3 1
11. ect 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 NOTE Never aim metallic grinding spray sparks towards the equipment KempGouge ARC 800 Kemppi Oy 1117 KempGouge ARC 800 Kemppi Oy 1117 EN 2 2 2 3 CONNECTION TO MAINS The KempGouge ARC 800 gouging power source is connected to a 400 V three phase network The machine is delivered without a connection cable The cable can be ordered separately in lenght of 5 or 10 metres see Ordering numbers Before use check the connection cable and install a mains plug If the cable does not comply with the local electrical regulations replace it with a compliant cable For more information see the section Technical specifications NOTE The connection cable or plug may be installed or replaced by only an electrical contractor or installer authorised to perform such operations Connecting the connection cable 1 Remove the right side plate Be carefull when you unscrew the mounting screws of the plastic edge cause retaining nuts come out easily 2 Passthe cable to the machine through the inlet ring at the rear of the machine and secure the cable with a cable clamp Remember to use isolation between the cabel and the cable clamp 3 Connect the leads to the connectors as seen in the picture 4 Fasten the side
12. 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 11 KempGouge ARC 800 Kemppi Oy 1117 EN KempGouge ARC 800 Kemppi Oy 1117 EN 6 7 12 ORDERING NUMBERS KempGouge ARC 800 incl transport unit Connector cable Connector cable Earthing cable Earthing cable Earthing cable Earthing cable Remote control R10 KempGouge ARC 800 Connection voltage Rated power Primary current Connection cable Fuse recommended Idle power Efficiency Power factor Load capacity at 40 C Current adjustment range Open circuit voltage Gouging carbon Recommended pressure of the compressed air Storage temperature range Operating temperature range EMC class Minimun short circuit power Ssc of supply network Degree of protection Dimensions without with transport unit Maximum load of lifting lug See paragraph 2 3 4X16 mm 5 m 4X 16 mm 1
13. he 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 connection cable before removing the machines 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 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 Checkfor 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 carbon holder Checking of connectors switches and adjusters Checking of electrical connections Checking of the connection cable and plug Replacement of damaged or worn parts Calibration testing with adjustment of the functions and operational values of the machine if necessary DISPOSAL OF THE MACHINE Do not dispose of electrical
14. lectric network with insufficient voltage less than 300 V the control features of the device are automatically disabled The primary circuits of the power source are protected against power spikes The product s mains voltage range is broad enough to prevent over voltage problems at up to 440 V see 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 IN THE ELECTRIC NETWORK If a phase is missing from the mains current the gouging features will be adversely affected or the machine may have problems starting Loss of a phase can be caused by a Blown mains fuse Damaged connection cable Poor connection 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 Err3 Power source overvoltage Gouging has been interrupted because dangerously high temporary voltage surges or a continuous over voltage has been detected in the electric network Check the fuse size and the quality of the supply network Err4 Power source overheating The power source has overheated The cause may be one of the following 1 The power source has been used for a long time at maximum power 2 Thecirculatio
15. n of cooling air to the power source is blocked 3 Thecooling system has experienced a failure Remove any obstacle to air circulation and wait until the power source fan has cooled down the machine 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 gouging but may decrease the quality of the work Check the quality of the supply network 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 5 1 5 2 5 3 5 4 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 gouging and connection 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 connection cables may be repaired and installed only by electrical contractors and installers authorised to perform such operations POWER SOURCE Before cleaning the interior of t
16. ngs The control panel of the gouging power source has only one setting that the user can modify restore factory settings This allows the user to restore the original welding current value and clear the memory To restore the factory settings do this 1 Keep the Setup button in the control panel pressed for at least 5 seconds The display will read Set Up 2 Release the Setup button The display will read FAC OFF 3 Turn the control knob until the display reads FAC ALL 4 Briefly press the Setup button in the control panel to perform factory reset TECHNIQUES FOR CARBON ARC GOUGING In practical carbon arc gouging note the following Before you start working make sure that the equipment is ready to use and that the gouging current and the carbon have been selected according to the work piece The pressure of the compressed air required in carbon arc gouging is 500 700 kPa 5 7 bar Attach the gouging carbon maximum size 13 mm to the holder in such a way that the free length of the carbon is 100 150 mm Open the compressed air valve and take the tip of the carbon to the work piece Ignite the arc by scratching the work piece with the gouging carbon Move the gouging carbon in such a position that the compressed air flow hits the molten material between the gouging carbon and the groove created A suitable angle for gouging carbon is 20 45 If the angle is greater compressed air cannot blow the molten metal away
17. ontinues running up to 10 minutes after gouging depending on the temperature of the machine NOTE Always turn the device on and off using the main switch not via the mains socket Automatic function test During the power source start up the machine automatically performs a function test The test covers the following functions Software version check The left hand side display shows the program version of the control panel for one second The display on the right displays the power source program version e Indicator light and button functionality All indicator lights and display segment LEDs blink System functions If the system encounters a fault a fault code is shown on the display Implementation of factory settings or preset settings If the function test is successful the machine is ready for use and the current and voltage values are shown in the control panel If a fault has been detected in the function test the display flashes the error code and the yellow indicator light in the front panel of the power source blinks For instructions see Troubleshooting Front panel indicators The following indicators can be found on the front panel of the device When the green indicator A3 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 l position When the yellow overheating indicator A4 is on the machine has overheated When
18. ower source and start gouging For more information on the proper way of performing carbon arc gouging see Gouging techniques The currents recommended for various gouging carbons Round carbon size 5 32 3 2 1 4 5 16 3 8 1 2 4 0 mm 5 0mm 6 35 mm 8 0 mm 10 0 mm 13 0 mm Current A 80 150 110 200 170 330 230 450 300 550 460 900 Voltage V 38 41 39 42 43 46 44 48 46 50 46 50 KempGouge ARC 800 Kemppi Oy 1117 EN KempGouge ARC 800 Kemppi Oy 1117 EN 3 2 3 3 3 3 1 3 3 2 3 4 3 4 1 HOW TO USE THE REMOTE CONTROL 1 Connect the R10 remote control unit to the service connection A7 Power source detects the new device automatically and the reference value of the remote control unit appears on the display 2 Set the desired gouging current with the remote control adjusting knob 3 Tostop using the remote control disconnect it from the power source The display starts to show the gouging current that was used before connecting the remote control unit and the current control returns to the control panel STARTING OF THE POWER SOURCE Start the power source by turning the main switch A2 on the front panel to the position The standby indicator A3 turns on The cooling fan is started for a moment when the main switch is turned to the 1 position The fan turns off after a while and then restarts during gouging when the machine has warmed up sufficiently The fan c
19. ws 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 m 100 96 60 96 3596 2096 50mm 285A 316A 371A 458A 0 35V 100A 70 mm 355 A 403 A 482 A 602 A 0 25V 100A 95 mm 430A 498 A 606 A 765A 0 18V 100A 120mm 500A 587A 721A 917A 0 21V 100A NOTE Do not overload the gouging cables as an overload may cause voltage loss and overheating Connecting the earthing cable The earthing cable is connected to the negative or positive connector in the power source depending on the connector used for the gouging cable see Connecting the gouging cable The recommended cross sections of the cable are listed in the table above Connect the earthing 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 USE BEFORE YOU START Before you start carbon arc gouging do the following Select a gouging carbon suitable for the work piece and attach it to the carbon holder Connect the gouging cable to the positive or negative connector depending on the type of metal to be worked For more information see Connecting the gouging cable Adjust the gouging current to a suitable level By default the machine uses the adjustment of the last time the machine was used For more information on the gouging current see the table below Start the p
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