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
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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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© Kemppi Oy / 1515

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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
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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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© Kemppi Oy / 1515

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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
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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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© Kemppi Oy / 1515

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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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