Kemppi WELDFORCE KWU10 Technical manual

WeldForce
KWU10
1931450E
0613

2 – KWU10 / 0613 © Kemppi oy
Contents
1. PREFACE....................................................................................................................... 3
1.1. introduCtion ......................................................................................................... 3
1.2. ProduCt introduCtion ...................................................................................... 3
1.3. oPeration safety................................................................................................. 3
2. INSTALLATION.............................................................................................................. 4
2.1. removal from PaCkaging.................................................................................. 4
2.2. loCating the maChine......................................................................................... 4
2.3. serial number ....................................................................................................... 4
2.4. installation and main Parts ............................................................................ 4
2.4.1. assembling the equiPment.................................................................. 4
2.4.2. main Parts of Cooling unit................................................................. 4
2.5. PreParing for oPeration ................................................................................. 5
3. OPERATION .................................................................................................................. 5
3.1. Cooler oPeration ............................................................................................... 5
3.2. overheat signal lamP ........................................................................................ 5
3.3. storage ................................................................................................................... 5
4. MAINTENANCE............................................................................................................. 5
4.1. daily maintenanCe ............................................................................................... 5
4.2. every siXth months ............................................................................................ 6
4.3. trouble shooting ............................................................................................... 6
5. dISPOSAL OF ThE MAChINE ..................................................................................... 6
6. TEChNICAL dATA ....................................................................................................... 7
7. TERMS OF GUARANTEE ............................................................................................. 7

KWU10 / 0613 – 3© Kemppi oy
1. PREFACE
1.1. INTROdUCTION
Congratulations on having purchased this product. Properly installed Kemppi products should
prove to be productive machines requiring maintenance at only regular intervals. This manual is
arranged to give you a good understanding of the equipment and its safe operation. It also contains
maintenance information and technical specications. Read this manual from front to back before
installing, operating or maintaining the equipment for the rst time. For further information on
Kemppi products please contact us or your nearest Kemppi distributor.
The specications and designs presented in this manual are subject to change without prior
notice.
In this document, for danger to life or injury the following symbol is used:
Read the warning texts carefully and follow the instructions. Please also study the Operation safety
instructions and respect them when installing, operating and servicing the machine.
1.2. PROdUCT INTROdUCTION
KWU10 is a cooling unit designed to be connected to the Kemppi WeldForce welding machine
and used for cooling the welding gun. The operation of KWU10 is controlled by a microprocessor.
KWU10 is delivered equipped with a plastic funnel for relling the water.
1.3. OPERATION SAFETy
Please study these Operation safety instructions and respect them when installing, operating and
servicing the machine.
Welding arc and spatters
Welding arc hurts unprotected eyes. Be careful also with reecting arc ash. Welding arc and
spatter burn unprotected skin. Use safety gloves and protective clothing.
Danger for re or explosion
Pay attention to re safety regulations. Remove ammable or explosive materials from welding
place. Always reserve sufcient re-ghting equipment on welding place. Be prepared for hazards
in special welding jobs, eg. for the danger of re or explosion when welding container type work
pieces. Note! Fire can break out from sparks even several hours after the welding work has been
nished!
Mains voltage
Never take welding machine inside a work piece (eg. container or truck). Do not place welding
machine on a wet surface. Always check cables before operating the machine. Change defect cables
without delay. Defect cables may cause an injury or set out a re. Connection cable must not be
compressed, it must not touch sharp edges or hot work pieces.
Welding power circuit
Isolate yourself by using proper protective clothing, do not wear wet clothing. Never work on a
wet surface or use defect cables. Do not put MIG-gun or welding cables on welding machine or
on other electric equipment. Do not press MIG-gun switch, if the gun is not directed towards a
work piece.
Welding fumes
Take care that there is sufcient ventilation during welding. Take special safety precautions when
welding metals which contain lead, cadmium, zinc, mercury or beryllium.

4 – KWU10 / 0613 © Kemppi oy
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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 has not been 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cation of 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 T400 6185267
Transport unit P40/P40L 6185264/6185264L
2. KWU10 cooling unit 6262110
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.
2.4.2. Main parts of cooling unit
This equipment’s electromagnetic compatibility (EMC) is designed for use in an
industrial environment. ClassA equipment is not intended for use in residential location
where the electrical power is provided by the public low-voltage supply system.
Front machine
A Housing
C Test switch
D Overheat control lamp
F Filling hole
Back side
G Mains voltage connection cable
H Control cable
I Cooling water output hose
J Cooling water input hose

KWU10 / 0613 – 5© Kemppi oy
2.5. PREPARING FOR OPERATION
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. Install the cooling unit control cable into the wire feed unit.
2. Connect the cooling water hoses with the wire feed unit, follow colour markings.
3. Fill the reservoir with a 40 - 20 % mixture of glycol and water, or with any other suitable
antifreeze agent. The capacity of the reservoir is 3 litres.
4. 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
KWU10 cooler by removing the right side plate.
5. Attach the power supply on the KWU10 cooler.
6. Switch on the power supply.
7. Press and hold down the test switch until the torch hoses are lled with liquid. The text
ERROR will remain on the KWF wire feeder panel as long as the gun hoses contain air.
8. Device is ready to weld.
3. OPERATION
3.1. COOLER OPERATION
See also 2.4.2. Main parts of cooling unit
KWU10 cooler 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.
When the system loses pressure, e.g., the reservoir is empty or one of the hoses leaks, the display
will show ’Error’ and welding will be interrupted.
3.2. 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.
3.3. 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.
4. MAINTENANCE
Watch out for mains voltage when handling electric cables!
In planning product maintenance machine utilisation degree and circumstances should be considered.
Careful use and preventive maintenance help to avoid unnecessary production disturbances and
breaks.
4.1. dAILy MAINTENANCE
The following maintenance operations 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

6 – KWU10 / 0613 © Kemppi oy
4.2. EvERy SIXTh MONThS
The following maintenance operations should be carried out at least every sixth months:
• Clean off 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.
4.3. TROUbLE ShOOTING
See also 3.2. 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.
Text ERROR 5 on the KWF wire feeder panel
• Check the liquid hoses for damages.
• Remove any hose blockages.
• Check water circulation, clean the ventilation grilles and add liquid if needed.
For further information and assistance, contact your nearest Kemppi service workshop.
5. dISPOSAL OF ThE MAChINE
Do not dispose of electrical equipment together 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 returned to an
environmentally compatible recycling facility. As the owner of the equipment, you should
get information on approved collection systems from our local representative.
By applying this European Directive you will improve the environment and human
health!

KWU10 / 0613 – 7© Kemppi oy
6. TEChNICAL dATA
Cooling unit kWU10
Connection voltage 1 ~, 50/60 Hz 400 V
Connection capacity 100 % ED 120 W
Power factor 0,42
Control voltage 24 V DC
Cooling power 1,25 kW
Start pressure, max. 400 kPa
Cooling liquid 20 % - 40 % glycol/water
Reservoir volume ca. 3 l
Overall dimension: length 550 mm
width 230 mm
height 290 mm
Weight 12,5 kg
Operating temperature range -20 … +40 °C
Storage temperature range -40 … +60 °C
Degree of protection IP 23 C
The products meet the conformity requirements of CE-marking.
7. TERMS OF GUARANTEE
Kemppi Oy provides a guarantee for products manufactured and sold by them if defects in
manufacture and materials occur. Guarantee repairs must be carried out only by an Authorised
Kemppi Service Agent. Packing, freight and insurance costs to be paid by orderer. The guarantee is
effected on the date of purchase. Verbal promises which do not comply with the terms of guarantee
are not binding on guarantor.
Limitations on guarantee
The following conditions are not covered under the terms of guarantee: defects due to natural wear
and tear, non-compliance with operating and maintenance instructions, connection to incorrect or
faulty supply voltage (including voltage surges outside equipment spec.), incorrect gas pressure,
overloading, transport or storage damage, re of damage due to natural causes i.e. lightning or
ooding.
This guarantee does not cover direct or indirect travelling costs, daily allowances or accommodation.
Note: Under the terms of guarantee, welding torches and their consumables, feeder drive rolls and
feeder guide tubes are not covered. Direct or indirect damage due to a defective product is not
covered under the guarantee. The guarantee is void if changes are made to the product without
approval of the manufacturer, or if repairs are carried out using non-approved spare parts.
The guarantee is also void if repairs are carried out by non-authorised agents.
Undertaking guarantee repairs
Guarantee defects must be informed to Kemppi or authorised Kemppi Service Agents within the
guarantee period. Before any guarantee work is undertaken, the customer must provide proof of
guarantee or proof of purchase, and serial number of the equipment in order to validate the guarantee.
The parts replaced under the terns of guarantee remain the property of Kemppi.
Following the guarantee repair, the guarantee of the machine or equipment, repaired or replaced,
will be continued to the end of the original guarantee period.

KEMPPI OY
PL 13
FIN – 15801 LAHTI
FINLAND
Tel [phone]
Telefax [phone]
www.kemppi.com
KEMPPIKONEET OY
PL 13
FIN – 15801 LAHTI
FINLAND
Tel [phone]
Telefax [phone]
e-mail: myynti.fi@kemppi.com
KEMPPI SVERIGE AB
Box 717
S – 194 27 UPPLANDS VÄSBY
SVERIGE
Tel [phone]
Telefax [phone] 94
e-mail: [e-mail]
KEMPPI NORGE A/S
Postboks 2151, Postterminalen
N – 3103 TØNSBERG
NORGE
Tel [phone]
Telefax 33 34 60 10
e-mail: [e-mail]
KEMPPI DANMARK A/S
Literbuen 11
DK – 2740 SKOVLUNDE
DANMARK
Tel [phone]
Telefax 44 941 536
e-mail:[e-mail]
KEMPPI BENELUX B.V.
Postbus 5603
NL – 4801 EA BREDA
NEDERLAND
Tel [phone]
Telefax [phone]
e-mail: [e-mail]
KEMPPI (UK) Ltd
Martti Kemppi Building
Fraser Road
Priory Business Park
BEDFORD, MK443WH
ENGLAND
Tel [phone]
Fax [phone]
e-mail: [e-mail]
KEMPPI FRANCE S.A.
65 Avenue de la Couronne des Prés
78681 EPONE CEDEX
FRANCE
Tel [phone]
Telefax (01) 30 90 04 45
e-mail: [e-mail]
KEMPPI GmbH
Otto – Hahn – Straße 14
D – 35510 BUTZBACH
DEUTSCHLAND
Tel [phone]
Telefax (06033) 72 528
e-mail:[e-mail]
KEMPPI SP. z o.o.
Ul. Piłsudskiego 2
05-091 ZA¸BKI
Poland
Tel [phone]
Telefax [phone]
e-mail: info[email protected]
KEMPPI WELDING
MACHINES AUSTRALIA PTY LTD
P.O. Box 404 (2/58 Lancaster Street)
Ingleburn NSW 2565, Australia
Tel. [phone]
Telefax [phone]
e-mail: info[email protected]
www.kemppi.com
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