KempArc SYN 300, 400, 500 DT 400 Operating manual • English Käyttöohje • Suomi EN FI Bruksanvisning • Svenska SV Bruksanvisning • Norsk NO Brugsanvisning • Dansk DA Gebrauchsanweisung • Deutsch DE Gebruiksaanwijzing • Nederlands NL Manuel d’utilisation • Français FR Manual de instrucciones • Español ES Instrukcja obsługi • Polski PL Инструкции по эксплуатации • По-русски RU Manual de utilização • Português PT
OPERATING MANUAL English KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117
KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117 CONTENTS 1. PREFACE. ........................................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General. ............................................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREFACE 1.1 GENERAL Congratulations on your choice of the Kemparc SYN-series welding system. 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 time.
KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117 2. USE 2.1 POWER SOURCE 2.1.1 Power source components 1 2 3 4 A12 A1 A9 A3 A2 A11 A10 A5 A8 A4 A7 A6 EN 1 Robot Control 2 Wire Feeder A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 3 Throughput 4 Analog Control panel Main switch Signal light (I/O) Thermal warning light Welding cable connection (parallel) Earthing cable connection Control cable connection (parallel) Cooling unit Mains cable Fuse for control cable connection (6.
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 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.
KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117 2.1.5 Connecting the cables A D C DT 400 B B control Wire feeder + SYN 300/400/500 Analog + Robot H KempArc F KempCool 10 G E A. B. C. D. E. F. G. H. EN air hose shield gas hose air blow intermediate cable earthing cable cooling liquid hoses robot controller cooling unit control cable Welding and earthing cables The welding and earthing cables are rubber-insulated copper cables.
KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117 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 A6. 3.
KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117 2.1.7 Starting the power source Start the power source by turning the main switch A2 on the front panel to the I position. The standby indicator A3 turns on. NOTE! Always turn the device on and off using the main switch, not via the mains socket. The cooling fan is started for a moment when the main switch is turned to the ‘I’ position. The fan turns off after a while and then restarts during welding when the machine has warmed up sufficiently.
Use the Esc button to move to the previous menu level. Displays • The control panel displays show adjustable operation parameters, their values, and the units of measure. • During welding, display P2 shows the welding current value that is currently in use, while display P6 shows the welding voltage. Control knobs • The left-hand control knob P11 allows the adjustment of the speed of wire feeding. The selected speed is shown on the display on the left-hand side.
KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117 You can change the gun selection by pressing buttons P3 and P4 again, as above. With a liquid-cooled gun selected, the liquid cooling function is started when the power source is started the next time. 2.2.6 Retrieving 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 P4 and P5 simultaneously. 2.2.
To set the values of the functional parameters for additional MIG features, use either the SETUP feature in the control panel (see 2.2.12 "SETUP functions in the control panel") or the QUICK SETUP feature, which you can activate by pressing the QUICK SETUP button, P8. Select the parameter to adjust using the left-hand side control knob P11 or the button P10 and then set the parameter value with the right-hand side control know P13. The value you specified is instantly stored in the control panel memory.
KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117 EN 2.2.9 Optional additional MIG features In addition to the additional MIG features included in the standard delivery, it is also possible to acquire optional features that further expand the operating features of the machine. To use the optional features, enter a machine-specific activation code in the machine's control panel as shown below. To purchase an activation code, contact a Kemppi representative. Activating optional additional features 1.
In synergetic 1-MIG welding, the machine selects the optimal welding parameters suitable to the filler wire and shield gas using the programs, or synergetic curves, stored in the control panel. The welder controls the welding by adjusting the welding power and arc length. The synergetic WiseThin process (advanced auto arc) is a synergetic welding process developed for the special needs of robotic welding with weldig characteristics optimised particularly for welding automation.
KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117 1-MIG, SS group EN Program number Wire, mm Material Shield gas 201 0,8 SS-316 202 0,9 SS-316 Ar+2%CO2 Ar+2%CO2 203 1,0 SS-316 204 1,2 SS-316 206 1,6 SS-316 211 0,8 SS-316 212 0,9 SS-316 213 1,0 SS-316 214 1,2 SS-316 216 1,6 SS-316 221 0,8 SS-309 222 0,9 SS-309 223 1,0 SS-309 224 1,2 SS-309 231 0,8 SS-309 232 0,9 SS-309 233 1,0 SS-309 234 1,2 SS-309 242 0,9 FC-316 244 1,2 FC-316 252 0,9
903 904 913 914 1,0 1,2 1,0 1,2 Fe Fe Fe Fe Ar+18%-25%CO2 Ar+18%-25%CO2 CO² CO² 1,0 1,2 1,0 1,2 SS-316 SS-316 SS-316 SS-316 Ar+2%CO2 Ar+2%CO2 Ar+30%He+1%O2 Ar+30%He+1%O2 WiseThin, SS group 923 924 933 934 Using the welding program 5. 6. 7. 8. Select the welding process 1-MIG with the P9 button. Press the SYNERGIC PROGRAM button to display the material group and the welding program number. Make sure that the welding program corresponds to the filler wire and shield gas you use.
KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117 Synergetic MIG welding parameters and their values Name of parameter Name Parameter values Factory setting displayed Description Creep Start Level Cre 10 ... 170 % 50 % Hot Start Level Hot -50 ... 75 % 30 % Crater Fill Level CrL 10 ... 90 % 30 % -9 ...
1. KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117 Threading the wire and adjusting tightness 2. EN 2. 1. 1. 2.
KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117 3. MAINTENANCE 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. Proper use of the machine and regular maintenance help you avoid unnecessary downtime and failures. 3.1 CABLES • Check the condition of welding and mains cables daily. • Make sure to replace damaged cables immediately. Only use original Kemppi spare parts.
KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117 3.2.1 DuraTorque™ 400, 4-wheel wire feeder mechanism Wire guide tubes Ss, Al, Fe, ø 0.6...1.6 mm Mc, Fc ø 2.5/64 mm, W000762, silver, plastic ø 2.5/33 mm, W000956, silver, plastic ø 2.0 mm, W000624, plastic ø 1.6..0.20.4 mm ø 3.5/64 mm, W001430, silver, plastic ø 3.5/33 mm, W001431, silver, plastic ø 3.5 mm, W001389, plastic Fe, Mc, Fc ø 0.6..0.00.8 mm ø 1.0/67 mm, W001432, white, steel ø 2.0/33 mm, W001435, orange, steel ø 2.
KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117 3.4 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 power source has overheated. The cause may 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.
KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117 EN 5. ORDERING NUMBERS Power source/Interface KempArc KempArc Wire feeder Interbus S Interbus S Profibus Devicenet Cooling unit KempCool 10 Cables Intermediate cable Intermediate cable Earthing cable Earthing cable 6.
SYN 300 SYN 400 SYN 500 -20 ... +40 °C -20 ... +40 °C -20 ... +40 °C -40 ... +60 °C -40 ... +60 °C -40 ... +60 °C IP23S IP23S IP23S A A A - 4.7 4.6 590x230x500 mm 590x230x500 mm 590x230x500 mm 35 kg 36 kg 37 kg KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117 KempArc Operating temperature range Storage temperature range Degree of protection EMC class Minimun short circuit power Ssc of supply network * External dimensions LxWxH Weight * See paragraph 2.1.3.
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 KEMPPI (UK) 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 Kotimaan myynti: Tel +358 3 899 11 Telefax +358 3 734 8398 myynti.fi@kemppi.com KEMPPI FRANCE S.A.S.
