Kemppi KMS 300 User manual

Operating manual • English

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FastMig™ KMS 300, 400, 500

OPERATING MANUAL

English

FastMig KMS 300, 400, 500 / © Kemppi Oy / 1110

CONTENTS

1. PREFACE................................................................................................................................ 3

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

1.2 Product introduction ............................................................................................................ 3

1.2.1 Operation control and connectors................................................................................. 4

1.3 Accessories................................................................................................................................ 4

1.3.1 Remote control devices................................................................................................... 4

1.3.2 Cables ............................................................................................................................... 5

2. INSTALLATION................................................................................................................. 5

2.1 Positioning of the machine ................................................................................................ 5

2.2 Distribution network............................................................................................................. 5

2.3 Connection to the mains supply ...................................................................................... 6

2.4 Welding and earth cables.................................................................................................... 7

3. OPERATION CONTROL SWITCHES AND POTENTIOMETERS... 7

3.1 Main switch I/O ....................................................................................................................... 7

3.2 Pilot lamps................................................................................................................................. 7

3.3 Operation of cooling fan ..................................................................................................... 7

4. MANUAL METAL ARC WELDING ...................................................................... 7

5. MAINTENANCE................................................................................................................ 8

5.1 Cables.......................................................................................................................................... 8

5.2 Power source............................................................................................................................ 8

5.3 Regular maintenance............................................................................................................ 8

6. OPERATION DISTURBANCES.............................................................................. 8

6.1 Operation of the overload protection............................................................................ 8

6.2 Control fuses ............................................................................................................................ 9

6.3 Under- and overvoltages in the mains supply............................................................ 9

6.4 Loss of a phase in the mains supply................................................................................ 9

7. DISPOSAL OF THE MACHINE .............................................................................. 9

8. ORDERING NUMBERS .............................................................................................10

9. TECHNICAL DATA........................................................................................................11

FastMig KMS 300, 400, 500 / © Kemppi Oy / 1110

1. PREFACE

1.1 GENERAL

Congratulations on choosing the FastMig 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.

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 PRODUCT INTRODUCTION

FastMig KMS 300, 400 and 500 are multi-operator power sources designed for demanding

professional use. They are suitable for MMA and MIG welding in DC.

FastMig KMS 300, 400, 500 / © Kemppi Oy / 1110

1.2.1 Operation control and connectors

H12

H11

S11

X11

X12

X14

6,3A

X13 X15

F11

F11 Fuse for connection for

control table

6,3 A delayed X12 Earth connection

H11 Signal lamp I/O X14 , X15 Connection for control cable parallel

H12 Warning lamp for

thermal protection

01 Inlet of mains cable

S11 Main switch I/O

X11, X13 Welding connection parallel

1.3 ACCESSORIES

1.3.1 Remote control devices

R10

1. Control of MMA/TIG welding current, reference

scale 1 – 5.

R20

1. 1. Wire feed adjustment, electrode current

adjustment.

2. Voltage adjustment.

MIG-MAG remote control device with controls for wire feed and voltage, memory scales 1 – 5.

You can use control device also for control of MMA current.

FastMig KMS 300, 400, 500 / © Kemppi Oy / 1110

1.3.2 Cables

FastMig KMS 300, FastMig KMS 400, FastMig KMS 500

16d Extension cable for remote control

20 Earth cable

21 MMA welding cable

R10, R20 Remote control devices

2. INSTALLATION

2.1 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.

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

2.2 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.

FastMig KM 500:

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

is greater than or equal to 4.6 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 4.6 MVA.

FastMig KMS 300, 400, 500 / © Kemppi Oy / 1110

FastMig KM 400:

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-circuit power Ssc greater than or equal

to 4.7 MVA.

FastMig KM 300:

WARNING: This equipment does not comply with IEC 61000-3-12. If it is connected to a public

low voltage system, 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 may

be connected.

2.3 CONNECTION TO THE MAINS SUPPLY

FastMig power sources are delivered equipped with 5 m mains cable without plug.

If local electricity regulations of operating country are stating otherwise, the mains cable

should be replaced in conformity with the local regulations.

Connection of the mains cable, mounting and change of the plug should only be carried out

by a competent electrician.

Remove the machine’s right side plate to enable the mounting of a mains cable.

KMS 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 (05). The phase conductors of the cable are coupled to

connectors L1, L2 and L3. The earth protection coloured green-yellow is coupled to connector.

NOTE! If you are using 5-lead cable, do not connect neutral conductor.

Sizes of the mains cables and fuse ratings for the machine at 100 % duty cycle are specied in

the table below:

Rated voltage Mains voltage range Fuses, slow-blow Connection cable *) mm²

KMS 300 400 V 3~ 360V – 440V 20 A 4 x 6.0 S

KMS 400 400 V 3~ 360V – 440V 25 A 4 x 6.0 S

KMS 500 400 V 3~ 360V – 440V 35 A 4 x 6.0 S

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

FastMig KMS 300, 400, 500 / © Kemppi Oy / 1110

2.4 WELDING AND EARTH CABLES

Recommended copper cables with cross-sectional area are as follows:

FastMig KMS 300 50 – 70 mm²

FastMig KMS 400 70 – 90 mm²

FastMig KMS 500 70 – 90 mm²

In enclosed table are shown typical load capacities of rubber insulated copper cables, when

ambient temperature is 25 °C and lead temperature is 85 °C.

Cable Duty cycle ED Voltage loss / 10 m

100 % 60 % 30 %

50 mm² 285 A 370 A 520 A 0.35V / 100 A

70 mm² 355 A 460 A 650 A 0.25V / 100 A

95 mm² 430 A 560 A 790 A 0.18V / 100 A

Do not overload welding cables due to voltage losses and heating.

Fasten the earth clamp of the return current cable carefully, preferably direct onto the piece to

be welded. The contact surface of the earth clamp should always be as large as possible.

Clean the fastening surface from paint and rust.

3. OPERATION CONTROL SWITCHES AND POTENTIOMETERS

3.1 MAIN SWITCH I/O

When you turn the switch into I-position, pilot lamp H11 on the front face is illuminated and

the machine is ready for use.

NOTE! Always turn the machine on and o with the mains switch, never use the mains plugs as a

switch.

3.2 PILOT LAMPS

The pilot lamps of the machine report the electric operation:

The green pilot lamp H11 when lit indicates that the machine is on and ready for use and it is

connected to the mains supply with the main switch in the I-position.

H12 indicates when lit that the thermal protection of the machine has been activated due to

over heating. The cooling fan will continue to run and cool the machine down and when the

lamp is o the machine is ready to weld.

3.3 OPERATION OF COOLING FAN

In FastMig power sources there are two simultaneously operating fans.

• The fan is started for a moment when main switch is placed into position I.

• The fan will start during welding as the machine heats up and it will run for 1 to 10

minutes after the welding has stopped.

4. MANUAL METAL ARC WELDING

The FastMig power source can be used in electrode welding by connecting a FastMig

MFS 53, MFS 55 or MSF 57 wire feeder to it. The power source can be made suitable for

electrode welding without a wire feeder by connecting an R10 or R20 remote control to the

X14 or X15 terminal at the back of the power source for welding current adjustment, and the

welding power cable connected to the power source’s (+) connector X11 or X12.

FastMig KMS 300, 400, 500 / © Kemppi Oy / 1110

5. MAINTENANCE

The amount of use and the working environment should be taken into consideration

when planning the frequency of maintenance of the machine. Careful use and preventive

maintenance will help to ensure trouble-free operation.

5.1 CABLES

Check the condition of welding and connection cables daily. Do not use damaged cables.

Make sure that the mains cables in use are safe and according to laid down regulations.

The repair and mounting of a mains connection cable should be carried out only by an

authorised electrician.

5.2 POWER SOURCE

NOTE! Disconnect the plug of the machine from the mains socket and wait approx. 2 minutes

(capacitor charge) before removing the cover plate.

Check at least every half year:

• Electric connectors of the machine – clean the oxidised parts and tighten the loosened

ones.

NOTE! You must know correction tension torques before starting the reparation of the joints.

• Clean the inner parts of the machine from dust and dirt e.g. with a soft brush and

vacuum cleaner. Also clean the ventilation net behind the front grate.

• Do not use compressed air, there is a risk that dirt is packed even more tightly into gaps

of cooling proles.

• Do not use pressure washing device.

• Only authorised electrician shall carry out repairs to the machines.

5.3 REGULAR MAINTENANCE

Kemppi Service Workshops make regular maintenance according to agreement.

The major points in the maintenance procedure are listed as follows:

• Cleaning of the machine

• Checking and maintenance of the welding tools

• Checking of connectors, switches and potentiometers

• Checking of electric connections

• Checking of mains cable and plug

• Damaged parts or parts in bad connection are replaced by new ones

• Maintenance testing. Operation and performance values of the machine are checked,

and adjusted when necessary by means of test equipment.

6. OPERATION DISTURBANCES

In the event of a failure of the machine, contact an authorised Kemppi service agent or your

local Kemppi dealer.

Check the maintenance objects before the machine is sent to the Service Workshop.

6.1 OPERATION OF THE OVERLOAD PROTECTION

Yellow pilot lamp H12 of thermal protection is lit when thermostat has operated due to

overheating of machine.

The thermostat of machine will operate, if machine is continuously loaded over rated values or

cooling air circulation is blocked.

Cooling fan cools down the machine and when the pilot lamp is not lit the machine is

automatically ready for welding.

FastMig KMS 300, 400, 500 / © Kemppi Oy / 1110

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