Kemppi M 420 User manual

FastMig
M 320, 420, 520
Operating manual
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OPERATING MANUAL
English

EN
CONTENTS
1. Preface........................................................................................................... 3
1.1 General ....................................................................................................................................... 3
1.2 Product introduction ............................................................................................................ 4
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.................................................................................................... 6
2.1 Positioning of the machine ................................................................................................ 6
2.2 Distribution network............................................................................................................. 6
2.3 Connection to the mains supply ...................................................................................... 7
2.4 Welding and earth return cables...................................................................................... 8
3. Operation controls ..................................................................................... 8
3.1 Main switch I/O ....................................................................................................................... 8
3.2 Pilot lamps................................................................................................................................. 8
3.3 Operation of cooling fan ..................................................................................................... 8
4. Manual metal arc welding........................................................................ 9
5. Maintenance................................................................................................ 9
5.1 Daily maintenance................................................................................................................. 9
5.2 Periodic maintenance........................................................................................................... 9
5.3 Service Workshop maintenance.....................................................................................10
6. Operation disturbances.......................................................................... 10
7. Disposal of the machine ......................................................................... 11
8. Ordering numbers.................................................................................... 11
9. Technical data............................................................................................ 12
FastMig M 320, 420, 520
2

EN
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.
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1.2 Product introduction
FastMig M 320, 420 and 520 are multi-purpose power sources designed for demanding
professional use. They are suitable for MMA and MIG welding in DC.
1.2.1 Operation control and connectors
H12
H11
S11
X11
X12
X14
6,3A
X13 X15
01
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.
1. Control of MMA welding current, reference scale
1 – 5.
R20
2.
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 M 320, 420, 520
4

EN
1.3.2 Cables
NOTE ! Always check before use that the mains cable, earth return cable and its clamp,
interconnection cable and shielding gas hose are in a serviceable condition. Ensure that connectors
are correctly fastened. Loose connectors can impair welding performance and damage connectors.
Liquid cooled system: FastMig power source + MXF + FastCool 10
1.
4.
8.
2.
3.
9.
5.
6.
7.
1. MXF wire feed unit
2. FastMig power source
3. FastCool water cooler and power connection
4. Gas supply
5. MMA electrode holder
6. Remote control device
7. Liquid cooled welding Gun
8. Power cable
9. Earth return cable and clamp
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Air cooled system: FastMig power source + MXF
1.
4.
5.
6.
8.
2.
3.
7.
1. MXF wire feed unit
2. FastMig power source
3. Gas supply
4. MMA electrode holder
5. Remote control device
6. Air cooled welding Gun
7. Power cable
8. Earth return cable and clamp
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 M 520:
This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc
is greater than or equal to 5.8 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
FastMig M 320, 420, 520
6

EN
equipment is connected only to a supply with a short-circuit power Ssc greater than or equal
to 5.8 MVA.
FastMig M 420:
This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc
is greater than or equal to 5.6 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 5.6 MVA.
FastMig M 320:
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 as standard with 5 meters of mains power cable. No
mains plug is tted at the Kemppi factory.
NOTE! If local country-based regulations state an alternative power cable is required, the mains
cable must be replaced in conformity with the regulations. Connection and installation of the
mains cable and plug should only be carried out by a suitably qualied person.
Remove the machine cover plate to enable mounting of a mains cable. FastMig M 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 the
marked connector.
NOTE! If you are using 5-lead cable, do not connect neutral conductor.
05
*)
L3
L2
L1
*) In cables of S type there is a protective grounding conductor coloured green-yellow.
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2.4 Welding and earth return cables
Recommended copper cables with cross-sectional area are as follows:
FastMig M 320 50 – 70 mm²
FastMig M 420 70 – 90 mm²
FastMig M 520 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.
NOTE ! Always check the serviceability of the earth return cable and clamp. Ensure the metal
surface to which the cable is connected is clean from metal oxide or paint. Check the connector to
the power source is fastened correctly.
3. OPERATION CONTROLS
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.
FastMig M 320, 420, 520
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EN
4. MANUAL METAL ARC WELDING
The FastMig power source can be used in electrode welding by connecting a FastMig
MXF 63, MXF 65 or MXF 67 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.
5. MAINTENANCE
When considering and planning routine maintenance, please consider the frequency of
machine use and the working environment.
Correct operation of the machine and regular maintenance will help you avoid unnecessary
downtime and equipment failure.
NOTE! Disconnect the machine from the mains before handling the electrical cables.
5.1 Daily maintenance
• Check the overall condition of the welding gun. Remove welding spatter from the
contact tip and clean the gas nozzle. Replace worn or damaged parts. Only use original
Kemppi spare parts.
• Check the condition and connection of the welding circuit components: welding gun,
earth return cable and clamp, sockets and connectors.
• Check the condition of the feed rolls, needle bearings and shafts. Clean and lubricate
bearings and shafts with a small quantity of light machine oil if necessary. Assemble,
adjust and test function.
• Check that the feed rolls are suitable for the ller wire you are using, and that their
pressure adjustment is correct.
5.2 Periodic maintenance
NOTE! Periodic maintenance should only be carried out by a suitably qualied person. Disconnect
the plug of the machine from the mains socket and wait about 2 minutes (capacitor charge) before
removing the cover plate.
Check at least every half year:
• Electric connectors of the machine – clean any oxidized parts and tighten loose
connections.
NOTE! You must know the correct tension torques values before starting the reparation of the loose
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 grill.
Do not use compressed air, there is a risk that the dirt will compact even more tightly into
gaps of cooling proles.
Do not use pressure washing devices.
Only an authorized trained electrician should carry out repairs to Kemppi machines.
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5.3 Service Workshop maintenance
Kemppi Service Workshops complete maintenance according to their Kemppi service
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 condition are replaced by new ones
• Maintenance testing.
• Operation and performance values of the machine are checked, and when necessary
adjusted by means of software and test equipment.
Software loading
• Kemppi Service Workshops can also test and load rmware and welding software.
6. OPERATION DISTURBANCES
Should you experience a malfunction from your machine, please consult the basic
troubleshooting text above rst, and complete some basic checks.
If the machine malfunction cannot be corrected with these measures, contact your Kemppi
maintenance service workshop.
Operation of the overload protection
Yellow thermal protection lamp is lit when the thermostat is operating due to loading beyond
the stated duty cycle.
The thermostat will operate, if machine is continuously loaded over rated values or cooling air
circulation is blocked.
Internal fans will cool the machine, and when the pilot lamp is not lit the machine is
automatically ready for welding.
Control fuses
Fuse, 6.3 A delayed, on the rear wall of machine provides protection for auxiliary devices.
Use the same type and rating of fuse as marked beside the fuse adapter. Damage caused by
incorrect fuse selection is not covered by the guarantee.
Under and over voltages in the mains supply
Primary circuits of the machine are protected against sudden, transient overvoltages. The
machine is designed to withstand 3 x 440 V voltage continuously. Ensure that voltage is kept
within this permissible limit, especially when the mains supply is provided by a combustion
engine generator. If the mains has under voltage (under approx. 300 V) or overvoltage (over
approx. 480 V) machine control stops operation automatically.
Loss of a phase in the mains supply
Loss of a mains power phase causes noticeably poor welding properties. In some cases the
machine won't start at all. Loss of a phase can be due to following:
• Blowing of mains supply fuse
• Defective mains cable
• Bad connection of mains power cable on machine terminal block or plug of machine.
FastMig M 320, 420, 520
10

EN
7. 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.
8. ORDERING NUMBERS
FastMig M 320 6132320
FastMig M 420 6132420
FastMig M 520 6132520
Wire feeders
MXF 65 EL To be used with MS panels 6152100EL
MXF 67 EL To be used with MS panels 6152200EL
MXF 63 EL To be used with MS panels 6152300EL
MXF 65 To be used with MR panels 6152100
MXF 67 To be used with MR panels 6152200
MXF 63 To be used with MR panels 6152300
Panels for wire feeders
FastMig MR 200 6136100
FastMig MR 300 6136200
FastMig MS 200 6136300
FastMig MS 300 6136400
Accessories
Earth return cable 5 m, 50 mm² 6184511
Earth return cable 5 m, 70 mm² 6184711
Cable for MMA welding 5 m, 50 mm² 6184501
Cable for MMA welding 5 m, 70 mm² 6184701
R10 6185409
AS KIT 6264263
Remote controlled interconnecting cable 10 m 6185481
Cooling unit FastCool 10 6068100
Transport unit PM 500 6185291
Gun holder GH 30 6256030
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9. TECHNICAL DATA
FastMig M 320 FastMig M 420 FastMig M 520
Connection voltage
3~, 50/60 Hz 400V -15 %...+20 % 400V -15 %...+20 % 400V -15 %...+20 %
Rated power
60 % ED - 20 kVA 27 kVA
100 % ED 15 kVA 18 kVA 20 kVA
Connection cable H07RN-F 4G6 (5 m) H07RN-F 4G6 (5 m) H07RN-F 4G6 (5 m)
Fuse (delayed) 25 A 35 A 35 A
Output 40 °C
60 % ED - 420 A 520 A
100 % ED 320 A 380 A 430 A
Welding current and voltage range
MMA 15 A/20V – 320 A/45V 15 A/20V – 420 A/44V 15 A/20V – 520 A/43V
MIG 20 A/12V – 320 A/45V 20 A/12V – 420 A/44V 20 A/12V – 520 A/43V
Max. welding voltage 45V 45V 45V
Open circuit voltage MMA U0= 48 – 53V
Uav = 50V
U0= 48 – 53V
Uav = 50V
U0= 48 – 53V
Uav = 50V
Open circuit voltage MIG/MAG U0= 50 – 58V U0= 50 – 58V U0= 50 – 58 V
Idle power 25W 25W 25W
Efficiency at max. current 88 % 89 % 89 %
Power factor at max. current 0.80 0.87 0.90
Operating temperature range -20 ... +40 °C -20 ... +40 °C -20 ... +40 °C
Storage temperature range -40 ... +60 °C -40 ... +60 °C -40 ... +60 °C
Degree of protection IP23S IP23S IP23S
EMC class A A A
Minimun short circuit power Ssc
of supply network*
- 5.6 MVA 5.8 MVA
External dimensions
length 590 mm 590 mm 590 mm
width 230 mm 230 mm 230 mm
height 430 mm 430 mm 430 mm
weight 34 kg 35 kg 36 kg
Voltage supply for auxiliary
devices
50V DC 50V DC 50V DC
X14, X15 fuse 6.3 A delayed fuse 6.3 A delayed fuse 6.3 A delayed
Operating voltage
(for cooling unit)
400V -15 %...+20 % 400V -15 %...+20 % 400V -15 %...+20 %
*) See paragraph 2.2.
FastMig M 320, 420, 520
12

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1903470
1515
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