Kemppi WeldForce KPS 3500 MVU Bedienungsanleitung

1931350E

0617

WeldForce

kps 3500

kps 4500

kps 5500

kps 3500 MVU

kps 4500 MVU

kps 5500 MVU

2 – Kemppi WeldForce KpS3500, KpS4500, KpS5500, KpS3500mVU, KpS4500mVU, KpS5500mVU / 0606 © Kemppi oy

CONTENTS

1. PREFACE....................................................................................................................... 3

1.1. INTRODUCTION......................................................................................................... 3

1.2. PRODUCT INTRODUCTION ...................................................................................... 3

1.2.1. OPERATION CONTROL AND CONNECTORS............................................. 3

1.3. ACCESSORIES........................................................................................................... 4

1.3.1. REMOTE CONTROL DEVICES..................................................................... 4

1.3.2. CABLES ......................................................................................................... 4

1.4. OPERATION SAFETY................................................................................................. 5

2. INSTALLATION.............................................................................................................. 6

2.1. SITING THE MACHINE............................................................................................... 6

2.2. CONNECTION TO THE MAINS SUPPLY ................................................................... 6

2.3. WELDING AND EARTH CABLES ............................................................................... 7

3. OPERATION CONTROL SWITCHES AND POTENTIOMETERS AND THEIR USE.... 7

3.1. MAIN SWITCH I/O....................................................................................................... 7

3.2. PILOT LAMPS ............................................................................................................. 7

3.3. OPERATION OF COOLING FAN ................................................................................ 8

4. MANUAL METAL ARC WELDING ................................................................................ 8

5. MAINTENANCE............................................................................................................. 8

5.1. CABLES ...................................................................................................................... 8

5.2. POWER SOURCE....................................................................................................... 8

5.3. REGULAR MAINTENANCE........................................................................................ 8

6. OPERATION DISTURBANCES..................................................................................... 9

6.1. OPERATION OF THE OVERLOAD PROTECTION.................................................... 9

6.2. CONTROL FUSES ...................................................................................................... 9

6.3. UNDER- AND OVERVOLTAGES IN THE MAINS SUPPLY ........................................ 9

6.4. LOSS OF A PHASE IN THE MAINS SUPPLY............................................................. 9

7. DISPOSAL OF THE MACHINE ................................................................................... 10

8. ORDERING NUMBERS............................................................................................... 10

9. TECHNICAL DATA .......................................................................................................11

10. TERMS OF GUARANTEE ......................................................................................... 12

Kemppi WeldForce KpS3500, KpS4500, KpS5500, KpS3500mVU, KpS4500mVU, 5500KpSmVU / 0606 – 3

H12

H11

S11

KPS KPS MVU

H12

H11

S11 X12X11

F11

X13

X14

X15

X12

X11

F11

X13

X14

X15

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

Kemppi WeldForce KPS3500, 4500 ja 5500 are multi-operator power sources designed for

demanding professional use. They are suitable for MMA/MIG and pulsed MIG as well as for TIG

welding in DC.

1.2.1. Operation control and connectors

F11 Fuse for connection for control table 6,3 A delayed

H11 Signal lamp I/O

H12 Warning lamp for thermal protection

S11 Main switch I/O

X11, Welding connection parallel

X12

X13 Earth connection

X14, Connection for control cable parallel

X15

01 Inlet of mains cable

4 – Kemppi WeldForce KpS3500, KpS4500, KpS5500, KpS3500mVU, KpS4500mVU, KpS5500mVU / 0606 © Kemppi oy

1.3. ACCESSORIES

1.3.1. Remote control devices

R10

R20

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.

1.3.2. Cables

WeldForce KPS3500, WeldForce KPS4500, WeldForce KPS5500

WeldForce KPS3500 MVU, WeldForce KPS4500 MVU, WeldForce KPS5500 MVU

16d Extension cable for remote control

20 Earth cable

21 MMA welding cable

R10, Remote control devices

R20

Wire feed adjustment,

electrode current adjustment

Control of MMA/TIG welding

current, reference scale 1 … 5.

Voltage adjustment

Kemppi WeldForce KpS3500, KpS4500, KpS5500, KpS3500mVU, KpS4500mVU, 5500KpSmVU / 0606 – 5

1.4. 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 ensure that you have sufcient re ghting equipment available where you are

welding. 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 damaged

cables without delay. Damaged cables may cause an injury or set out a re. Connection cable must

not be crushed, 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 the MIG-gun or welding cables on welding machine

or on other electric equipment. Do not press the 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 metal, which contain lead, cadmium, zinc, mercury or beryllium.

This equipment’s electromagnetic compatibility (EMC) is designed for use in an

industrial environment. Class A equipment is not intended for use in residential location

where the electrical power is provided by the public low-voltage supply system.

6 – Kemppi WeldForce KpS3500, KpS4500, KpS5500, KpS3500mVU, KpS4500mVU, KpS5500mVU / 0606 © Kemppi oy

60º

max. 15º

2. INSTALLATION

2.1. SITING THE MACHINE

Site the machine on a stationary, horizontal, dry base in a position that does NOT allow

dust, dirt or metal particles to enter the machines cooling air ow.

2.2. CONNECTION TO THE MAINS SUPPLY

Kemppi WeldForce power sources are delivered equipped with 5 m mains cable without plug.

If local electricity regulations of operating country are stating otherwise, the mains cable should

be replaced in conformity with the local regulations.

Connection of the mains cable, mounting and change of the plug should only be carried out by a

competent electrician.

Remove the machine’s right side plate to enable the mounting of a mains cable.

KPS power sources can be connected to the mains supply of 400 V 3~ . KPS MVU power

sources can be connected to 230 V 3~ or 400 V 3~ . Power source automatic recognize the mains

voltage.

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 connector.

If you are using 5-lead cable, you must connect neutral conductor with terminal N.

rain water

– Preferably site the machine somewhat higher above

the oor level.

– Ensure that the front as well as the rear of the

machine there is at least 20 cm free distance to

allow good circulation of the cooling air through

the machine.

– Protect the machine against heavy rain and in hot

circumstances against direct sunshine. Ensure the

free circulation of the cooling air.

Degree of protection of machine IP23 allows at

its maximum the water spray coming in 60º angle

to hit machine’s outer covering.

See to that the machine is positioned away from the line

of particle spray, created by grinding tools etc.

Kemppi WeldForce KpS3500, KpS4500, KpS5500, KpS3500mVU, KpS4500mVU, 5500KpSmVU / 0606 – 7

Sizes of the mains cables and fuse ratings for the machine at 100 % duty cycle are specied in

the table below:

*) In cables of S type there is a protective grounding conductor coloured green-yellow.

2.3. WELDING AND EARTH CABLES

Recommended copper cables with cross-sectional area are as follows:

Kemppi WeldForce KPS3500 50 ... 70 mm²

Kemppi WeldForce KPS4500 70 ... 90 mm²

Kemppi WeldForce KPS5500 70 ... 90 mm²

In enclosed table are shown typical load capacities of rubber insulated copper cables, when ambient

temperature is 25 ºC and lead temperature is 85 ºC.

Do not overload welding cables due to voltage losses and heating.

Fasten the earth clamp of the return current cable carefully, preferably direct onto the piece to be

welded. The contact surface of the earth clamp should always be as large as possible.

Clean the fastening surface from paint and rust.

3. OPERATION CONTROL SWITCHES AND

POTENTIOMETERS AND THEIR USE

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.

Always turn the machine on and off 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

off the machine is ready to weld.

Rated voltage Mains voltage range Fuses,

slow-blow

Connection

cable *) mm²

KPS3500 400 V 3~ 360 V… 440 V 25 A 4 x 6.0 S

KPS4500 400 V 3~ 360 V… 440 V 35 A 4 x 6.0 S

KPS5500 400 V 3~ 360 V… 440 V 35 A 4 x 6.0 S

KPS3500MVU 400 V 3~ 230 V 3~ 360 V… 440 V 200 V… 260 V 35 A 4 x 6.0 S

KPS4500MVU 400 V 3~ 230 V 3~ 360 V… 440 V 200 V… 260 V 50 A 4 x10 S

KPS5500MVU 400 V 3~ 230 V 3~ 360 V… 440 V 200 V… 260 V 60 A 4 x 16 S

Cable Duty cycle ED Voltage loss / 10 m

100 % 60 % 30 %

50 mm² 285 A 370 A 520 A 0,35 V / 100 A

70 mm² 355 A 460 A 650 A 0,25 V / 100 A

95 mm² 430 A 560 A 790 A 0,18 V / 100 A

8 – Kemppi WeldForce KpS3500, KpS4500, KpS5500, KpS3500mVU, KpS4500mVU, KpS5500mVU / 0606 © Kemppi oy

3.3. OPERATION OF COOLING FAN

In Kemppi WeldForce KPS3500 there is one and in Kemppi WeldForce KPS4500 and Kemppi

WeldForce KPS5500 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.

– On no-load fan is started in intervals of approx. half an hour for minute’s time.

4. MANUAL METAL ARC WELDING

The Kemppi WeldForce power source can be used in electrode welding by connecting a Kemppi

WeldForce KWF200, KWF300 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

The amount of use and the working environment should be taken into consideration when planning

the frequency of maintenance of the machine. Careful use and preventive maintenance will help

to ensure trouble-free operation.

5.1. CABLES

Check the condition of welding and connection cables daily. Do not use damaged cables.

Make sure that the mains cables in use are safe and according to laid down regulations.

The repair and mounting of a mains connection cable should be carried out only by an authorised

electrician.

5.2. POWER SOURCE

Note! Disconnect the plug of the machine from the mains socket and wait approx.

2 minutes (capacitor charge) before removing the cover plate.

Check at least every half year:

– Electric connectors of the machine - clean the oxidised parts and tighten the loosened

ones.

– Note! You must know correction tension torques before starting the reparation of the

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 grate.

– Do not use compressed air, there is a risk that dirt is packed even more tightly into gaps of

cooling proles.

– Do not use pressure washing device.

– Only authorised electrician shall carry out repairs to the machines.

5.3. REGULAR MAINTENANCE

Kemppi Service Workshops make regular maintenance according to 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

Kemppi WeldForce KpS3500, KpS4500, KpS5500, KpS3500mVU, KpS4500mVU, 5500KpSmVU / 0606 – 9

– Damaged parts or parts in bad connection are replaced by new ones

– Maintenance testing. Operation and performance values of the machine are checked, and

adjusted when necessary by means of test equipment.

6. OPERATION DISTURBANCES

In case of problems contact the Kemppi works in Lahti, Finland, or your local Kemppi dealer.

Check the maintenance objects before the machine is sent to the Service Workshop.

6.1. OPERATION OF THE OVERLOAD PROTECTION

Yellow pilot lamp H12 of thermal protection is lit when thermostat has operated due to overheating

of machine.

The thermostat of machine will operate, if machine is continuously loaded over rated values or

cooing air circulation is blocked.

Cooling fan cools down the machine and when the pilot lamp is not lit the machine is automatically

ready for welding.

6.2. CONTROL FUSES

Fuse F11, 6,3 A delayed, on the rear wall of machine is as protection for connection of auxiliary

devices X14-15.

Use same type and rating of fuse which is marked beside the fuse adapter. Damage

caused by a wrong type fuse is not covered by the guarantee.

6.3. UNDER- AND OVERVOLTAGES IN THE MAINS SUPPLY

Primary circuits of machine are protected against sudden, transient overvoltages.

Machine is designed to withstand 3 x 440 V voltage continuously (see technical data). See to

it that voltage is kept within admissible limits especially when mains supply is taken e.g. from

combustion engine generator.

If the mains has undervoltage (under approx. 300 V), machine control stops to operate

automatically.

6.4. LOSS OF A PHASE IN THE MAINS SUPPLY

Loss of a phase causes noticeable poorer welding properties than normally or the machine doesn’t

get started at all. Loss of a phase can be due to following:

– blowing of mains supply fuse

– defective mains cable

– bad connection of mains connection cable on terminal block or plug of machine

10 – Kemppi WeldForce KpS3500, KpS4500, KpS5500, KpS3500mVU, KpS4500mVU, KpS5500mVU / 0606 © Kemppi oy

7. 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!

8. ORDERING NUMBERS

Kemppi WeldForce KPS 3500 6131350

Kemppi WeldForce KPS 4500 6131450

Kemppi WeldForce KPS 5500 6131550

Kemppi WeldForce KPS 3500MVU 613135003

Kemppi WeldForce KPS 4500MVU 613145003

Kemppi WeldForce KPS 5500MVU 613155003

Return current cable 5 m - 50 mm² 6184511

Return current 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

Remote controlled interconnecting cable 10 m 6185481

T400 6185267

P40 6185264

P40L 6185264L

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