Kemppi HiArc M 400R User manual

Operating manual
Manual de instrucciones
Manuel d’utilisation
Manual de utilização
Инструкции по эксплуатации
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HiArc
M 400R, M 500R

OPERATING MANUAL
English

EN
CONTENTS
1. Introduction ......................................................................................................................... 3
1.1 General ....................................................................................................................................... 3
1.2 About HiArc M product series ........................................................................................... 3
2. Installation............................................................................................................................. 4
2.1 Before use.................................................................................................................................. 4
2.2 Machine introduction........................................................................................................... 4
2.3 Positioning of the machine ................................................................................................ 5
2.4 Distribution network............................................................................................................. 5
2.5 Connecting cables ................................................................................................................. 5
2.5.1 Mains connection ............................................................................................................ 6
2.5.2 Wire feeder connection................................................................................................... 7
2.5.3 Earth return cable connection........................................................................................ 8
2.5.4 Gas heater ........................................................................................................................ 8
2.6 Optional accessories ............................................................................................................. 8
3. Using the machine........................................................................................................... 9
3.1 Control panel functions ....................................................................................................... 9
3.2 Starting the machine ..........................................................................................................10
3.3 LCD display .............................................................................................................................10
3.4 LED indicators........................................................................................................................10
3.5 Selecting shielding gas ......................................................................................................11
3.6 Gas test.....................................................................................................................................11
3.7 Trigger logic and Crater Fill function ............................................................................11
3.8 Calibrating wire feed speed..............................................................................................13
4. Troubleshooting..............................................................................................................15
5. Maintenance......................................................................................................................16
5.1 Regular maintenance..........................................................................................................16
5.2 Disposal of the machine ....................................................................................................16
6. Technical data...................................................................................................................16
7. Ordering codes.................................................................................................................17
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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 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.
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.
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 About HiArc M product series
Kemppi’s HiArc M products are inverter MIG/MAG welding power sources to be used in
a 3-phase mains power supply. HiArc welding machines are designed for industrial and
professional use.
These MIG/MAG power sources can be used with various wire feeders. However, it is
recommended to use the Kemppi wire feeder unit, which has been designed especially for use
with your HiArc power source.
The HiArc power sources are equipped with gas type selection buttons. HiArc automatically
presets the welding dynamic characteristic according to your gas selection choice.
Enjoy welding with your Kemppi product!
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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, 2 A
10. Connector for shielding gas heater
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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.
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.
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2.5.1 Mains connection
HiArc must be connected to an earthed 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 data’.
NOTE! The mains cable or wall plug may be installed or replaced only by an electrical contractor or
installer authorised to perform such operations.
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2.5.2 Wire feeder connection
The HiArc power source is designed to be used with the HiArc F wire feed unit.
To connect the HiArc F wire feeder unit to the power source, complete the following steps:
1.
2.
3.
1. Attach the HiArc F 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 HiArc F 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 HiArc F 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.
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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.
2.5.4 Gas heater
When using CO₂ shielding gas, a 110 V gas heater can be connected to the power supply
located at the back of the HiArc power source.
2.6 Optional accessories
Castor wheel kit replaces the static front support leg of the machine and allows the machine
to be free wheeled.
Fastening plate can be used to fasten the wire feeder on the top of the power source.
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3. USING THE MACHINE
3.1 Control panel functions
ON/OFF switch
This switch turns the machine on and o.
Gas test button
Press to test the shielding gas ow.
Gas selection button
Press to select either CO₂ or mixed shielding gas (MAG).
Press to select between 2T and 4T gun trigger modes.
Crater Fill selection button
Press to select the Crater Fill mode ON or OFF.
Wire feed speed adjustment knob
Turn to set the wire feed speed value for the Crater Fill mode.
Voltage adjustment knob
Turn to set the welding voltage value for the Crater Fill mode.
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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 LCD display
The HiArc power source is equipped with an LCD display. Welding parameter settings are
made through the HiArc F wire feeder control panel for wire feed speed (A) and voltage (V).
During welding the display always shows the welding current (A) used.
The average welding values remain on display for 10 seconds after you stop welding.
The lower part of LCD shows the Crater Fill values. The upper part of the LCD display shows
wire feed speed, the selected welding voltage and gas type selection.
3.4 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.
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3.5 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 has a factory set pre-gas time of 0.2 s and a Post-gas time of between 2 – 4 s,
depending on the welding power settings.
3.6 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.
3.7 Trigger logic and Crater Fill function
The HiArc M 400R 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
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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
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3.8 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
5. When wire feed stops, cut the wire at the contact tip and measure the length of the fed
wire in mm.
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6. At the power source control panel, enter the length of the wire using the buttons below.
To toggle between ones, tens
and hundreds
To add the number by one
To subtract the number by one
NOTE! If you enter a value that does not t in, the machine forces the value within the acceptable
limits. This is to prevent you from entering false values.
7. Press Wire Inch button again.
• Wire feed starts and continues for 2 seconds.
8. When wire feed stops, cut the wire and measure its length.
9. At the power source control panel, enter the length of the wire in the same manner as in
step 6
10. Press Wire Inch button.
To skip the calibration
• If you want to skip the calibration, press Crater Fill button for 3 seconds. The machine
exits the calibration mode.
• If the device is left idle for 5 minutes, it automatically exits the calibration mode.
• If the device is turned o before the step 10, it automatically exits the calibration mode,
and the old calibration values remain.
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4. TROUBLESHOOTING
Problem Cause
The machine stops working.
Overheating indicator is lit, and
Err 4 is displayed.
The machine has overheated.
• Ensure that cooling air has unrestricted ow.
• The machine’s duty cycle has been exceeded.
If no other damage is caused, the fan starts working and the machine recovers within a
couple of minutes.
If the problem persists, please contact Kemppi service representative.
Machine stops working.
Err 2 or Err 3 is displayed.
The mains voltage is either too low (Err 2) or too high (Err 3). *
The machine recovers automatically, when the mains voltage is in the recommended
range (342 – 484V).
Machine stops working.
Err 43 is displayed.
The wire feeder motor is overloaded.
Check that you are using the right wire type and that the wire feed route is unobstructed.
Poor welding result Several factors aect the welding quality.
• Check wire feed calibration.
• Check that the earth return clamp is properly attached, the point of contact is clean and
that the cable and its connectors are intact.
• Check the voltage and wire speed settings on the control panel are correct for the given
wire size and type.
• Check that the shielding gas ow rate at the gun nozzle is correct.
• Check that the shielding gas is suitable for the ller wire used.
• Check that the wire feed is constant, and adjust if necessary.
• Check that the mains voltage is not too irregular.
Main switch indicator does not
switch on
The machine has no mains voltage
• Check the mains fuses
• Check the mains cable and the wall plug
* Contact Kemppi service in case of Err 2 and Err 3 without mains voltage cause.
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5. MAINTENANCE
5.1 Regular maintenance
Check regularly the electrical connections of the machine. Clean any oxidised connections,
and tighten the loosened cable connections.
Let authorised Kemppi service workshop make periodic service to your machine. Appropriate
use and regular service guarantee trouble-free use of the machine. This allows you to avoid
interruptions and increase the productivity of the machine.
NOTE! Remember that the machine may be repaired only by an electrical contractor or installer
authorised to perform such operations.
5.2 Disposal of the machine
Do not dispose of electrical equipment with normal waste!
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 you will improve the environment and human health.
6. TECHNICAL DATA
HiArc M 400R M 500R
Connection voltage 3~, 50/60 Hz 380 – 440V (-10 %…+10 %) 380 – 440V (–10 %…+10 %)
Rated power at max. current 60 % ED 17.6 kVA 24.5 kVA
100 % ED 12.5 kVA 17 kVA
Supply current I1max 27 A 37 A
I1e 19 A 29 A
Output at 40 °C 60 % ED 400 A / 34V 500 A / 39.0V
100 % ED 310 A / 29V 390 A / 33.5V
Fuse (delayed) 25 A 35 A
Open circuit voltage 60 – 70V 60 – 70V
Power factor at 60 % 0.90 0.92
Efficiency at 100 % 87 % 87 %
Welding range 13 – 39V 13 – 50V
External dimensions L xW x H 647 x 385 x 485 mm 716 x 385 x 485 mm
Weight 36 kg 41 kg
EMC class A A
Degree of protection IP23S IP23S
Gas heater connection 110V/150 W 110 V/150 W
Standards
IEC 60974-1
IEC 60974-10
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7. ORDERING CODES
HiArc M 400R power source 63104002
HiArc M 500R power source 63105002
HiArc F 10 wire feeder 6310010
HiArc F 30 wire feeder 6310030
Welding guns
FE 42 3.5 m 6604203
FE 42 5.0 m 6604204
Interconnection cables
HiArc F30 50-5-GH 50 mm², 5 m 6260500
HiArc F30 70-5-GH 70 mm², 5 m 6260501
HiArc F30 50-10-GH 50 mm², 10 m 6260513
HiArc F30 70-10-GH 70 mm², 10 m 6260514
HiArc F30 50-15-GH 50 mm², 15 m 6260515
HiArc F30 70-15-GH 70 mm², 15 m 6260516
HiArc F30 70-20-GH 70 mm², 20 m 6260523
HiArc F30 70-30-GH 70 mm², 30 m 6260633
Optional extensions
HiArc 10-70-G 70 mm², 10 m 6310710
HiArc 15-70-G 70 mm², 15 m 6310715
HiArc 10-50-G 50 mm², 10 m 6310510
HiArc 15-50-G 50 mm², 15 m 6310515
Earth return cables
Earth return cable, HiArc 50 mm², 5 m 6184511H
Earth return cable, HiArc 70 mm², 5 m 6184711H
Accessories
Castor wheel kit W005977
Fastening plate HiArc M 400R W007362
HiArc M 500R W007378
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KEMPPI OY
Kempinkatu 1
PL 13
FI-15801 LAHTI
FINLAND
Tel [phone]
Telefax [phone]
[email protected]
www.kemppi.com
Kotimaan myynti:
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Telefax [phone]
myynti.@kemppi.com
KEMPPI SVERIGE AB
Box 717
S-194 27 UPPLANDS VÄSBY
SVERIGE
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Telefax [phone]
[e-mail]
KEMPPI NORGE A/S
Postboks 2151, Postterminalen
N-3103TØNSBERG
NORGE
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[e-mail]
KEMPPI DANMARK A/S
Literbuen 11
DK-2740 SKOVLUNDE
DANMARK
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[e-mail]
KEMPPI BENELUX B.V.
Postbus 5603
NL-4801 EA BREDA
NEDERLAND
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[e-mail]
KEMPPI (UK) Ltd
Martti Kemppi Building
Fraser Road
Priory Business Park
BEDFORD, MK44 3WH
UNITED KINGDOM
Tel [phone]
Telefax [phone]
[e-mail]
KEMPPI FRANCE S.A.S.
65 Avenue de la Couronne des Prés
78681 EPONE CEDEX
FRANCE
Tel [phone]
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[e-mail]
KEMPPI GmbH
Perchstetten 10
D-35428 LANGGÖNS
DEUTSCHLAND
Tel [phone]
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[e-mail]
KEMPPI SPÓŁKA Z O.O.
Ul. Borzymowska 32
03-565WARSZAWA
POLAND
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info[email protected]
KEMPPI AUSTRALIA PTY LTD.
13 Cullen Place
P.O. Box 5256, Greystanes NSW 2145
SMITHFIELD NSW 2164
AUSTRALIA
Tel. [phone]
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info[email protected]
OOO KEMPPI
Polkovaya str. 1, Building 6
127018 MOSCOW
RUSSIA
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info[email protected]
ООО КЕМППИ
ул. Полковая 1, строение 6
127018 Москва
Tel [phone]
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info[email protected]
KEMPPI, TRADING (BEIJING) COMPANY,
LIMITED
Room 420, 3 Zone, Building B,
No.12 Hongda North Street,
Beijing Economic Development Zone,
100176 Beijing
CHINA
Tel [phone]
[phone]
Telefax [phone]
[e-mail]
肯倍贸易（北京）有限公司
中国北京经济技术开发区宏达
北路12号
创新大厦B座三区420室 (100176)
电话：[phone]
[phone]
传真：[phone]
[e-mail]
KEMPPI INDIA PVT LTD
LAKSHMITOWERS
New No. 2/770,
First Main Road,
Kazura Garden,
Neelankarai,
CHENNAI - 600 041
TAMIL NADU
Tel [phone]
Telefax [phone]
[e-mail]
www.kemppi.com
1921710
1308