Kemppi HiArc M 350A User manual

Operating manual
操作手册
EN
ZH
HiArc
M 350A, M 500A

OPERATING MANUAL
English

EN
CONTENTS
1. Introduction ......................................................................................................................... 3
1.1 General ....................................................................................................................................... 3
1.2 About HiArc product series ................................................................................................ 4
2. Installation............................................................................................................................. 5
2.1 Before use.................................................................................................................................. 5
2.2 Machine introduction........................................................................................................... 5
2.3 Positioning of the machine ................................................................................................ 6
2.4 Distribution network............................................................................................................. 6
2.5 Connecting cables ................................................................................................................. 7
2.5.1 Mains connection ............................................................................................................ 7
2.5.2 Wire feeder connection................................................................................................... 8
2.5.3 Earth return cable connection........................................................................................ 9
2.6 Optional accessories ............................................................................................................. 9
3. Using the machine.........................................................................................................10
3.1 Control panel .........................................................................................................................10
3.2 Starting the machine ..........................................................................................................11
3.3 LED indicators........................................................................................................................11
3.4 Manual and Automatic operating modes...................................................................11
3.4.1 Using Manual operating mode.....................................................................................12
3.4.2 Using Automatic operating mode................................................................................12
3.4.3 Selection for ller wire, diameter and gas....................................................................13
3.4.4 Gas test...........................................................................................................................14
3.4.5 Selection for display of amperes/wire feed speed (automatic mode).......................14
3.4.6 LCD display.....................................................................................................................14
3.4.7 Material thickness and weld shape display .................................................................15
3.5 Crater ll...................................................................................................................................15
3.5.1 Crater ll (wire feed speed or power)...........................................................................15
3.5.2 Crater ll (voltage or arc length)...................................................................................15
3.6 Trigger logic function .........................................................................................................16
3.7 Calibrating wire feed speed..............................................................................................18
4. Troubleshooting..............................................................................................................20
5. Maintenance......................................................................................................................20
5.1 Regular maintenance..........................................................................................................20
5.2 Disposal of the machine ....................................................................................................20
6. Technical data...................................................................................................................21
7. Ordering codes.................................................................................................................22
HiArc M 350A, M 500A
2

EN
1. INTRODUCTION
1.1 General
Congratulations on choosing the HiArc series power source. 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 device can be found at the end of the
manual.
Please read the operating manual and the safety instructions booklet 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.
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.
NOTE! Items in the manual that require particular attention in order to minimise damage and
personal harm are indicated with this symbol. Read these sections carefully and follow their
instructions.
Circuit diagram and spare part lists
If the circuit diagram and the spare parts list are not included in your delivery package, please
request them from your local Kemppi service representative. For more information, please
visit www.kemppi.com.
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.
3
© Kemppi Oy / 1445

EN
1.2 About HiArc product series
Kemppi’s HiArc M 350A/M 500A products are inverter MIG/MAG welding power sources to be
used in a 3-phase mains power supply.
These MIG/MAG power sources can be used with various wire feeders. However, it is
recommended to use Kemppi’s HF10 wire feeder unit, which has been designed especially for
use with your HiArc power source.
The HiArc power sources are equipped with Automatic adjustment features. This means that
you can use either manual mode or Automatic mode when adjusting the welding parameters.
In Automatic mode, the HiArc chooses automatically the suitable preset welding parameters
according to your wire and gas selections.
Enjoy welding with your Kemppi product!
HiArc M 350A, M 500A
4

EN
2. INSTALLATION
2.1 Before use
The product is packed in cartons designed specically for them. However, always make sure
before use that the products have not been damaged during transportation.
Check also that you have received the components you ordered and the instruction manuals
needed. Product packaging material is recyclable.
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 in
the machine is unrestricted. The recommended operating temperature range is -20…+40 °C.
Please read also the Safety Instructions concerning the operating environment.
2.2 Machine introduction
1.
2.
3.
4.
5.
6. 7.
8.
9.
10.
FRONT
1. ON/OFF switch
2. LCD display
3. Fan grill
4. Wire feeder cable connector ( + )
5. Control cable connection
6. Earth return cable connector ( – )
BACK
7. Mains lead connector
8. Power source fuse, 8A
9. Shielding gas heater fuse, 6.3 A
10. Connector for shielding gas heater
5
© Kemppi Oy / 1445

EN
2.3 Positioning of the machine
Place the machine on a sturdy, level surface that is dry and does not allow dust or other
impurities to enter the machines cooling air ow. Preferably site the machine to a suitable
carriage unit so it is above oor level.
Notes for positioning the machine
• The surface inclination may not exceed 15 degrees.
< 15°
• 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 circulation.
• Protect the machine against heavy rain and direct sunshine.
The machine is not allowed to be operated in the rain as the protection class of the machine,
IP23S, allows preserving and storing outside only.
NOTE! Never aim the spray of sparks from a grinding machine toward the equipment.
2.4 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.
HiArc M 350A, M 500A
6

EN
2.5 Connecting cables
On the front side of the machine, there are connectors for the interconnection cable and the
control cable for connecting the power source to the wire feeder.
On the back side of the machine, there is a terminal strip connector, where you connect the
mains cable leads.
2.5.1 Mains connection
HiArc must be connected to a 3-phase power supply using the terminal strip connector in the
backside of the machine. Attach the mains cable leads as shown in the picture below.
L1 L2 L3
To connect the mains cable do the following:
1. Remove the mains lead cover plate.
2. Connect the mains cable’s phase lead connectors to L1, L2, and L3 terminals.
3. Connect the protective earth lead to its terminal.
4. Secure the cable clamp.
Check also that the mains cable complies with the local electrical regulations, and replace the
cable if necessary. See ’Technical specications’.
NOTE! The mains cable or wall plug may be installed or replaced only by an electrical contractor or
installer authorised to perform such operations.
7
© Kemppi Oy / 1445

EN
2.5.2 Wire feeder connection
The HiArc power source is designed to be used with the HF10 wire feed unit.
To connect the HF10 wire feeder unit to the power source, complete the following steps:
1.
2.
3.
1. Attach the HF10 wire feed unit power cable to the + connector of the HiArc power
source. Hand tighten the connector with a clockwise push and twist action to lock.
2. Attach the HF10 wire feed unit control cable plug to the control socket of the power
source.
3. Connect the shielding gas hose to the gas bottle or to the shielding gas distribution
system.
NOTE! Please read carefully the wire feeder installation and operation instructions in the Kemppi
HF10 operating manual.
NOTE! Normally the wire feeder should be connected to the plus pole. However, with some ller
wires and shielding gases, you should connect the feeder to the minus pole, and the earth return
cable to the plus pole.
HiArc M 350A, M 500A
8

EN
2.5.3 Earth return cable connection
Attach the earth return cable to the minus (–) connector. Hand tighten the connector with a
clockwise push and twist action to lock.
Attach the other end of the earth return cable to the workpiece before welding.
NOTE! When attaching the earth return clamp to the work piece, remember to clean the work piece
surface so as to achieve safe and undisturbed operation.
2.6 Optional accessories
There are two optional kits available to be used with the power source.
• When using CO₂ shielding gas, a 36 V gas heater can be connected to the power supply
located at the back of the HiArc power source. Please see the plug-in delivery package
for usage and tting instructions.
• Castor wheel kit replaces the static front support leg of the machine and allows the
machine to be free wheeled.
9
© Kemppi Oy / 1445

EN
3. USING THE MACHINE
3.1 Control panel
2.
4.
5.
1.
3.
9.
12. 13.
8. 10.
7. 11.
6.
Control panel oer the following control functions
1. Indicator light for ON/OFF
2. Overheating indicator
3. Selection for MANUAL or AUTOMATIC mode
4. Selection for ller wire material type (automatic mode)
5. Selection for ller wire diameter (automatic mode)
6. Selection for shielding gas (automatic mode)
7. Selection of crater ll function
8. Gas test
9. Display
10. Selection for display of amperes/wire feed speed (automatic mode)
11. Selection of 2T/4T gun operating mode
12. Control knob for wire feed speed or power (Crater ll only)
13. Control knob for voltage or arc length (Crater ll only)
HiArc M 350A, M 500A
10

EN
3.2 Starting the machine
To start the machine, turn the main switch to position 'I'. Initially, the rmware version number
is displayed in the LCD display. After that, the rmware number is replaced with the parameter
display, and the machine is ready for setup.
3.3 LED indicators
There are two LED indicator lights on the top of the control panel.
ON
GAS TEST
(MAG)
Ar + CO
2
CO
2
2T
CRATER
FILL
1
2
3
4
56
7
8
9
10
V
4T
1
2
3
4
56
7
8
9
10
W005163
1. 2.
1. The ON light indicates that the power source is turned on.
2. The second light indicates that the machine is over heated.
NOTE! The machine stops automatically when it reaches its maximum operating temperature.
If the heat indicator led is on, the machine has exceeded its normal maximum operating
temperature. Stop welding and wait until the led turns o. The machine is then ready for welding to
continue.
3.4 Manual and Automatic operating modes
The HiArc power source has two operating modes: Automatic mode and Manual mode. To
change between operating modes, press control panel button 3.
• In Manual mode you set the welding current and wire feed parameters manually using
the control knobs on the wire feeder panel.
• In Automatic mode you can use the ready-made HiArc welding programs (synergic
curves) to easily select the optimal welding parameters. Just set the welding wire and
shielding gas type you are using, and let the HiArc calculate the optimal settings for the
welding parameters. You can then adjust the welding power and ne tune the welding
voltage at the wire feeder panel. In Automatic mode you can use the pre-set Automatic
values also when making the Tail Arc settings.
NOTE! There are welding programs available only for Fe wires.
11
© Kemppi Oy / 1445

EN
3.4.1 Using Manual operating mode
1
2
3
47
8
9
1
2
3
47
65
8
9
10
WIRE INCH
Press Automatic/Manual button to select the Manual mode. In Manual mode, the display
shows no Automatic mode information, such as welding wire thickness.
In Manual operating mode, you use control knobs of the wire feeder to set the welding
voltage and wire feed speed.
Set these values according to the base material, the type and size of the welding wire, and
according to your own welding style.
3.4.2 Using Automatic operating mode
1
2
3
47
8
9
1
2
3
47
65
8
9
10
WIRE INCH
The Automatic mode is in use by default, when you start the machine. Press the Automatic/
Manual button to change between Automatic and manual operating modes.
When you set the welding power with the wire feeder's control knob (A), the HiArc calculates
the optimal welding parameters. With the wire feeder's arc length control knob (V) you
can make ne-adjustments to the arc lenght. The optimal Automatic values are calculated
automatically also when you select the Tail Arc settings with the power source controls.
HiArc M 350A, M 500A
12

EN
3.4.3 Selection for ller wire, diameter and gas
Solid/Flux button (Automatic mode)
With this button you can select the welding wire type that you are using. You can select either
solid wire or ux-cored wire. The Automatic option can be used for Fe wires.
Filler wire diameter (Automatic mode)
With this button you can select the thickness of the welding wire you are using. By pressing
the button repeatedly you can browse thicknesses in the range 0.8–1.6 mm (0.8–1.4 mm with
M 350A)
Selecting shielding gas
Press the shielding gas selection button to set the shielding gas type to either CO₂ or mixed
gas according to the gas you are using.
Select CO₂ if you are using carbon dioxide. Select Ar + CO₂ (MAG) if you are using mixed gas.
NOTE! HiArc M 350A and M 500A have a factory set pre-gas time of 0.2 sec and a Post-gas time of
between 2 and 4 sec, depending on the welding power settings.
13
© Kemppi Oy / 1445

EN
3.4.4 Gas test
To test the shielding gas ow, press the gas test button once. The shielding gas starts to ow
and stops automatically after 20 seconds.
To interrupt the gas test, press the button again.
3.4.5 Selection for display of amperes/wire feed speed (automatic mode)
A long press (5 secs) of button 11 also switches the display from m/min to amperes.
3.4.6 LCD display
1.
2.
3.
1. Automatic settings
2. Welding parameters
3. Crater ll parameters
HiArc M 350A, M 500A
14

EN
3.4.7 Material thickness and weld shape display
When operating in AUTOMATIC mode the material thickness is displayed, based on your input
selections for plate thickness in mm. As you adjust the power control (2), you will see the
graphic indicating plate thickness become thicker or thinner. Select the desired settings and
you are ready to weld.
3.5 Crater ll
Crater ll function is OFF by default, when you start the machine. Press Crater ll button to
select Crater ll function ON.
3.5.1 Crater ll (wire feed speed or power)
This control knob increases and reduces the speed of ller wire delivery or power to the
welding arc at crater ll phase. The scale is regulated in meters per minute or amperes.
3.5.2 Crater ll (voltage or arc length)
This control knob increases and reduces the available output voltage of the machine to the
welding arc. The scale is regulated in volts.
In automatic mode this control knob oers minor arc voltage adjustment for ne tuning the
welding arc at crater ll phase.
15
© Kemppi Oy / 1445

EN
3.6 Trigger logic function
The HiArc power source is equipped with a crater ll function, which makes your welding
more ecient and helps you avoid welding defects at the end of the weld sequence.
With this function you can use an additional crater ll current level, which can be lower or
higher than your normal welding current level.
2T mode
MIG welding with 2T mode of the gun trigger.
• Push the trigger – welding starts after preset pre-gas time.
• Release the trigger – welding ends. Post-gas ows for preset time.
1. 2.
1. Pre-gas time
2. Post-gas time
2T mode and crater ll function
• Push the trigger – welding starts after preset pre-gas time.
• Release the trigger – values drop to preset crater ll level and welding ends after preset
time. Post-gas ows for preset time.
1. 2. 3.
1. Pre-gas time
2. Crater ll time
3. Post-gas time
HiArc M 350A, M 500A
16

EN
4T mode
MIG welding with 4T mode of the gun trigger.
• Trigger pushed down – ow of shielding gas starts.
• Trigger released – welding starts.
• Trigger pushed down – welding ends and shielding gas ow continues.
• Trigger released – ow of shielding gas ends.
Notice: PostGas Time at least preset minimum.
1. 2.
1. Pre-gas time
2. Post-gas time
4T mode and crater ll function
• Trigger pushed down – ow of shielding gas starts.
• Trigger released – welding starts.
• Trigger pushed down – welding values change to crater ll level.
• Trigger released – welding ends. Post-gas time ows for preset time.
1. 2. 3.
1. Pre-gas time
2. Crater ll time
3. Post-gas time
CV mode
In CV mode the welding machine maintains a relatively stable, consistent voltage regardless
of the amperage. You can use the CV mode for carbon arc gouging.
17
© Kemppi Oy / 1445

EN
Using the CV mode
• Turn the CV mode on by pressing Crater ll and 2T/4T buttons simultaneously.
• When the CV mode is on, the voltage is shown on the display with one of the digits
blinking (the active digit).
• You can change the voltage value by pressing Gas select (decrease the active digit) or
2T/4T (increase the active digit) buttons. You can change the active digit by pressing
Crater ll button.
• The machine is now ready for carbon arc gouging.
• Exit CV mode by pressing the welding gun trigger or pressing Crater ll and 2T/4T
buttons simultaneously.
NOTE! For your safety, the CV mode turns o automatically if you use the Wire Inch button or
press the welding gun trigger.
3.7 Calibrating wire feed speed
To ensure that the pre-sets and meter displays work as planned, you must calibrate the wire
feed speed of your Hiarc power source and F 10 wire feeder welding equipment.
Calibration
1. Start the calibration by pressing Crater Fill button for 3 seconds.
2. Press Gas Test button to select either HiArc F 10 or HiArc F 30 wire feeder.
3. Cut the ller wire at the contact tip.
4. Press Wire Inch button at the wire feeder.
• Wire feed starts and continues for 12 seconds
Wire Inch button
1
2
3
47
8
9
1
2
3
47
65
8
9
10
WIRE INCH
HiArc M 350A, M 500A
18