Kemppi KEMPARC COOL 10 User manual

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Operating manual • English
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Manuel d’utilisation • Français
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KEMPARC™
COOL 10

EN
OPERATING MANUAL
English
KempArc™ COOL 10 / © Kemppi Oy / 0725

EN
CONTENTS
1. PREFACE ...................................................... 3
1.1 General..........................................................................................................................3
1.2 Safety Instructions..................................................................................................3
2. INSTALLATION ............................................ 7
2.1 Removal from packaging ...................................................................................7
2.2 Locating the machine...........................................................................................7
2.3 Serial number............................................................................................................7
2.4. Installation and main parts................................................................................7
2.4.1 Assembling the equipment .......................................................................7
2.4.2 Main parts of cooling unit ..........................................................................8
2.5 Preparing for operation.......................................................................................8
2.6 Cooler operation .....................................................................................................9
2.7 Overheat signal lamp............................................................................................9
2.8 Storage..........................................................................................................................9
3. MAINTENANCE ........................................... 9
3.1 Daily maintenance...............................................................................................10
3.2 Regular maintenance.........................................................................................10
3.2.1 Every sixth months.....................................................................................10
3.2.2 Maintenance by agreement....................................................................10
3.3 Disposal of the machine...................................................................................10
4. TROUBLE SHOOTING ...............................11
5. TECHNICAL DATA .....................................11
6. WARRANTY POLICY.................................. 12
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1. PREFACE
1.1 GENERAL
Congratulations on your choice of the Kemparc™ Cool 10 cooling unit.
Reliable and durable, Kemppi products are aordable 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 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 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.
1.2 SAFETY INSTRUCTIONS
Kemppi welding devices conform to international safety standards. Safety
is an important issue in equipment design and manufacturing. Therefore,
Kemppi welding solutions are unparalleled in safety. There are, however,
always certain hazards involved in using welding equipment. Therefore, to
ensure your personal safety and the safety of your working environment,
carefully read the safety instructions below and respect them.
Use of personal protective equipment
• The arc and its reecting radiation damage unprotected eyes. Shield
your eyes and face appropriately before you start welding or observe
welding. Also note the dierent requirements for the darkness of the
screen in the mask as the welding current changes.
• The arc radiation and spatters burn unprotected skin. Always wear
protective gloves, clothing and footwear when welding.
• Always wear hearing protection if the ambient noise level exceeds the
allowable limit (e.g., 85 dB).
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General operating safety
• Exercise caution when handling parts heated in welding. For example,
the tip of the welding torch, the end of the welding rod and the work
piece will heat during gouging to a burning temperature.
• Never wear the device on the shoulder during welding and never
suspend it by the carrying strap during welding.
• Do not expose the machine to high temperatures, as this may cause
damage to the machine.
• Keep the torch cable and earthing cable as close to each other as
possible throughout their length. Straighten any loops in the cables. This
minimises your exposure to harmful magnetic elds, which may interfere
with a pacemaker, for example.
• Do not wrap the cables around the body.
• In environments classied as dangerous, only use S-marked welding
devices with a safe idle voltage level. These work environments include,
for example, humid, hot or small spaces where the user may be directly
exposed to the surrounding conductive pieces.
Spatter and re safety
• Welding is always classied as hot work, so pay attention to re safety
regulations during welding and after it.
• Remember that re can break out from sparks even several hours after
the welding work is completed.
• Protect the environment from welding spatter. Remove ammable
materials, such as ammable uids, from the welding vicinity and supply
the welding site with adequate re ghting equipment.
• In special welding jobs, be prepared for hazards such as re or explosion
when welding container-type work pieces.
• Never direct the spark spray or cutting spray of a grinder toward the
welding machine or ammable materials.
• Beware of hot objects or spatter falling on the machine when working
above the machine.
• Welding in ammable or explosive sites is absolutely forbidden.
General electric safety
• Only connect the welding machine to an earthed electric network.
• Note the recommended mains fuse size.
• Do not take the welding machine inside a container, vehicle or similar
work piece.
• Do not place the welding machine on a wet surface and do not work on
a wet surface.
• Do not allow the mains cable to be directly exposed to water.
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• Ensure cables or welding torches are not squashed by heavy objects and
that they are not exposed to sharp edges or a hot work piece.
• Make sure that faulty and damaged welding torches are changed
immediately as they can be lethal and may cause electrocution or re.
• Remember that the cable, plugs and other electric devices may be
installed or replaced only by an electrical contractor or engineer
authorised to perform such operations.
• Turn o the welding machine when it is not in use.
Welding power circuit
• Insulate yourself from the welding circuit by using dry and undamaged
protective clothing.
• Never touch the work piece and welding rod, welding wire, welding
electrode or contact tip at the same time.
• Do not put the welding torch or ground cable on the welding machine
or other electric equipment.
Welding fumes
• Ensure proper ventilation and avoid inhaling the fumes.
• Ensure sucient supply of fresh air, particularly in closed spaces. You can
also ensure the supply of clean and sucient breathing air by using a
fresh-air mask.
• Take extra precautions when working on metals or surface-treated
materials containing lead, cadmium, zinc, mercury or beryllium.
Transportation, lifting and suspension
• Never pull or lift the machine by the welding torch or other cables.
Always use the lift points or handles designed for that purpose.
• Only use a transport unit designed for the equipment.
• Try to transport the machine in an upright position, if possible.
• Never lift a gas cylinder and the welding machine at the same time.
There are separate provisions for gas cylinder transportation.
• Never use a welding machine when suspended unless the suspension
device has been designed and approved for that particular purpose.
• Do not exceed the maximum allowed load of suspension beams or the
transportation trolley of welding equipment.
• It is recommended that the wire coil be removed during lifting or
transportation.
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Environment
• Protect welding machines from heavy rain and direct sunshine even if it
were suitable for outdoor use.
• Always store the machine in a dry and clean space.
• Protect the machine from sand and dust during use and in storage.
• The recommended operating temperature range is -20 to +40 °C. The
machine’s operation eciency decreases and it becomes more prone to
damage if used in temperatures in excess of 40 °C.
• Place the machine so that it is not exposed to hot surfaces, sparks or
spatter.
• Make sure the airow to and from the machine is unrestricted.
• This electromagnetic compatibility (EMC) of professional equipment
is usually designed for industrial use. Such class-A equipment is not
intended for use in residential locations where the electrical power is
provided by the public low-voltage supply system. The machine may
interfere with sensitive home electronic devices.
Gas bottles and pneumatic devices
• Adhere to the instructions for handling pneumatic devices and gas
bottles.
• Make sure that gas bottles are used and stored in properly ventilated
spaces. A leaking gas bottle may replace the oxygen in the inhaled air,
causing suocation.
• Before use, make sure that the gas bottle contains gas suitable for the
intended purpose.
• Always x the gas cylinder securely in an upright position, against a
cylinder wall rack or purpose-made cylinder cart.
• Never move a protective gas bottle when the ow adjuster is in place.
Put the valve cover in place during transportation.
• Close the cylinder valve after use.
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2. INSTALLATION
2.1 REMOVAL FROM PACKAGING
The equipment is packed in durable packages specially designed for them.
Check the equipment before taking it into use, to make sure that the
equipment or a part of it have not got damaged during the transportation.
Also check that the delivery corresponds your order and that you have
received all the necessary instructions for installing and operating the
equipment. The packaging material can be recycled.
2.2 LOCATING THE MACHINE
Place the machine on a horizontal, stable and clean ground. Protect the
machine from heavy rain and burning sunshine. Check that there is enough
space for cooling air circulation in front of and behind the machine.
2.3 SERIAL NUMBER
The serial number of the machine is marked on the machine CE-marking.
Identicating the serial number is the only proper means of maintaining
and identifying parts for a specic product. It is important to make correct
reference to the serial number of the product when making repairs or
ordering spare parts.
2.4. INSTALLATION AND MAIN PARTS
2.4.1 Assembling the equipment
The equipment is assembled in the following order:
1. Transport unit PM500 6185291
2. Cooling unit KempArc Cool 10 620810001
Assembly the transport unit according to the instructions in the package.
Fasten the cooling unit to the transport unit by using the screws and bolts
delivered with the equipment.
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2.4.2 Main parts of cooling unit
E
F
G
H
A
B
C
D
TEST
Front machine
A Housing
B Test switch
C Overheat control lamp
D Filling hole
Back side
E Mains voltage connection cable
F Control cable
G Cooling water output hose
H Cooling water input hose
2.5 PREPARING FOR OPERATION
NOTE! Cooling liquid is injurious! Avoid also contact with skin or eyes. In case of
injury, seek for medical advice.
See also 2.4.2. Main parts of cooling unit.
1. Connect the mains voltage and control connectors of the cooler unit
to the corresponding connectors on the base of the power supply.
The connection can be established through the base of the power
supply when the devices are separated or through the right side of the
KempArc™ Cool 10 cooler by removing the right side plate.
2. Attach the power supply on the KempArc™ Cool 10 cooler.
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3. Connect the cooling water hoses with the wire feed unit, follow colour
markings.
4. Fill the reservoir with a 40 - 20 % mixture of etanol and water, or with any
other suitable antifreeze agent. The capacity of the reservoir is 3 litres.
5. Switch on the power supply.
6. Press and hold down the test switch until the torch hoses are lled with
liquid.
7. Device is ready to weld.
2.6 COOLER OPERATION
See also 2.4.2. Main parts of cooling unit
KempArc™ Cool 10 operation is controlled by the microprocessor of the
power supply. The cooler pump starts to operate when the welding begins.
After the welding has stopped, the pump will operate 1 to 5 minutes longer
depending on the welding time. During this time the liquid will cool down
to the surrounding temperature. If the pump is stopped, the need for
maintenance of the cooler will be reduced.
Check the tank liquid level regularly and ll in liquid, if necessary.
If the liquid ow is blocked, a hose is blocked or folded, or the container has
ran out of liquid the welding is stopped and error code, Err 5, appears on the
KempArc panel.
2.7 OVERHEAT SIGNAL LAMP
The overheat signal lamp is lighting when temperature control of the
machine has detected cooling water overheat. The ventilator cools down the
machine and when the lamp goes out welding can be started again.
2.8 STORAGE
The machine must be stored in a clean and dry room. Protect the machine
from rain and keep it away from direct sunshine in places where temperature
exceeds +25 °C. Check that there is free space in front of and behind the
machine for air circulation.
3. MAINTENANCE
NOTE! Watch out for mains voltage when handling electric cables!
In planning product maintenance machine utilization degree and
circumstances should be considered. Careful use and preventive
maintenance help to avoid unnecessary production disturbances and breaks.
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3.1 DAILY MAINTENANCE
The following maintenance opeations should be carried out daily:
• Check water level and input ow, add liquid if needed.
• Check cables and connections. Tighten, if necessary and replace defect
parts
3.2 REGULAR MAINTENANCE
Make sure that the machine receives regular and appropriate maintenance.
Authorised Kemppi service agents perform regular maintenance by
agreement. For more information on regular maintenance, contact a Kemppi
representative.
3.2.1 Every sixth months
The following maintenance opeations should be carried out at least every
sixth months:
• Clean o dust and dirt. Change the cooling liquid and wash up the pipes
and water reservoir with pure water.
• Check seals, cables and connections. Tighten, if necessary and replace
defect parts.
3.2.2 Maintenance by agreement
Authorised Kemppi service agents perform regular maintenance by
agreement. During the maintenance the machine is cleaned and checked
for faults. The functionality of all parts is tested and the possible faults are
repaired.
3.3 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 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.
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4. TROUBLE SHOOTING
See also 2.7. Overheat signal lamp.
Overheat signal lamp is lit.
The unit is overheated.
• Check water circulation.
• Check that there is enough free space behind the machine for cooling air
circulation.
Error code Err 5 on the KempArc panel
• Check the liquid hoses for damages.
• Remove any hose blockages.
• Check water circulation, add liquid if needed.
For further information and assistance, contact your nearest Kemppi service
workshop.
5. TECHNICAL DATA
Cooling unit KempArc™ Cool 10
Connection voltage 24 V DC
Connection capacity 100 % ED 50 W
Cooling power 1 kW
Start pressure, max. 450 kPa
Cooling liquid 20 % - 40 % etanol/water
Reservoir volume ca. 3 l
Overall dimension: length 570 mm
width 230 mm
height 280 mm
Weight 11 kg
Operating temperature range -20 … +40 °C
Storage temperature range -40 … +60 °C
Degree of protection IP 23 S
The products meet the conformity requirements of CE-marking.
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6. WARRANTY POLICY
Kemppi Oy provides a warranty for products manufactured and sold by the
company if defects in materials or workmanship occur. Warranty repairs
are to be carried out only by an authorised Kemppi Service Agent. Packing,
shipping, and insurance are at the orderer’s expense.
The warranty starts on the date of purchase. Spoken promises not included in
the terms of warranty are not binding on the warrantor.
Limitations of the warranty
The following conditions are not covered under the terms of warranty:
defects arising from normal wear and tear, non-compliance with operation
and maintenance instructions, overloading, negligence, connection
to incorrect or faulty supply voltage (including voltage surges outside
equipment specications), incorrect gas pressure, anomalies or failures in
the electric network, transport or storage damage, and re or damage due to
forces of nature. This warranty does not cover direct or indirect travel costs,
daily allowances, or accommodation related to warranty service.
The warranty does not cover welding torches and their consumables, feeder
drive rolls, and feeder guide tubes. Direct or indirect damage caused by a
defective product is not covered under the warranty.
The warranty becomes void if modications are made to the machine that
are not approved by the manufacturer or if non-original spare parts are used
in repairs. The warranty is also voided if repairs are carried out by a repair
agent not authorised by Kemppi.
Undertaking warranty repairs
Warranty defects must be reported to Kemppi or an authorised Kemppi
Service Agent without delay.
Before a warranty repair is undertaken, the customer must present proof
of warranty or otherwise prove the validity of the warranty in writing. The
proof must indicate the date of purchase and the manufacturing number of
the unit to be repaired. The parts replaced under the terms of this warranty
remain the property of Kemppi and must be returned to Kemppi if requested.
After a warranty repair, the warranty of the machine or equipment, repaired
or replaced, shall be continued to the end of the original warranty period.
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