Kemppi WELDFORCE KWU10 Technisches Handbuch

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

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 (03) 899 11

Telefax (03) 899 428

www.kemppi.com

KEMPPIKONEET OY

PL 13

FIN – 15801 LAHTI

FINLAND

Tel (03) 899 11

Telefax (03) 7348 398

e-mail: myynti.ﬁ@kemppi.com

KEMPPI SVERIGE AB

Box 717

S – 194 27 UPPLANDS VÄSBY

SVERIGE

Tel (08) 590 783 00

Telefax (08) 590 823 94

e-mail: sales.se@kemppi.com

KEMPPI NORGE A/S

Postboks 2151, Postterminalen

N – 3103 TØNSBERG

NORGE

Tel 33 34 60 00

Telefax 33 34 60 10

e-mail: sales.no@kemppi.com

KEMPPI DANMARK A/S

Literbuen 11

DK – 2740 SKOVLUNDE

DANMARK

Tel 44 941 677

Telefax 44 941 536

e-mail:sales.dk@kemppi.com

KEMPPI BENELUX B.V.

Postbus 5603

NL – 4801 EA BREDA

NEDERLAND

Tel +31 (0)76-5717750

Telefax +31 (0)76-5716345

e-mail: sales.nl@kemppi.com

KEMPPI (UK) Ltd

Martti Kemppi Building

Fraser Road

Priory Business Park

BEDFORD, MK443WH

ENGLAND

Tel 0845 6444201

Fax 0845 6444202

e-mail: sales.uk@kemppi.com

KEMPPI FRANCE S.A.

65 Avenue de la Couronne des Prés

78681 EPONE CEDEX

FRANCE

Tel (01) 30 90 04 40

Telefax (01) 30 90 04 45

e-mail: sales.fr@kemppi.com

KEMPPI GmbH

Otto – Hahn – Straße 14

D – 35510 BUTZBACH

DEUTSCHLAND

Tel (06033) 88 020

Telefax (06033) 72 528

e-mail:sales.de@kemppi.com

KEMPPI SP. z o.o.

Ul. Piłsudskiego 2

05-091 ZA¸BKI

Poland

Tel +48 22 781 6162

Telefax +48 22 781 6505

e-mail: info[email protected]

KEMPPI WELDING

MACHINES AUSTRALIA PTY LTD

P.O. Box 404 (2/58 Lancaster Street)

Ingleburn NSW 2565, Australia

Tel. +61-2-9605 9500

Telefax +61-2-9605 5999

e-mail: info[email protected]

www.kemppi.com

Ver. 9

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