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  5. Operation Instructions Manual

Kemppi WELDFORCE KWF 200S Operation Instructions Manual

Summary of WELDFORCE KWF 200S

  • Page 1

    Operation instructions • english gebrauchsanweisung • deutsch gebruiksaanwijzing • nederlands manuel d’utilisation • français 1931550us 0541 weldforce kwf 200s.

  • Page 2

    2 – weldforce kwf 200s / 0541 © kemppi oy contents 1. Preface ...................................................................................................................... 3 1.1. Introduction ......................................................................................................

  • Page 3: 1. Preface

    Weldforce kwf 200s / 0541 – 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...

  • Page 4

    4 – weldforce kwf 200s / 0541 © kemppi oy 1.2.1. Operation control and connectors kwf200s functions of kwf200s function panel operation panel connection of remote control unit connection of welding gun euro shield gas flow control lead-in and clamping of cooling liquid hoses connection for control ca...

  • Page 5

    Weldforce kwf 200s / 0541 – 5 © kemppi oy 1.2.2. Connection of system.

  • Page 6

    6 – weldforce kwf 200s / 0541 © kemppi oy 1.2.3. Parts of wire feed mechanism weldforce kwf200s ...

  • Page 7

    Weldforce kwf 200s / 0541 – 7 © kemppi oy 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. Use a proper face shield fitted with a correct filter and...

  • Page 8

    8 – weldforce kwf 200s / 0541 © kemppi oy welding fumes take care that there is sufficient ventilation during welding. Keep your head out of the fumes. Do not breath the fumes. Breathing welding fumes can be hazardous to your health. Take special safety precautions when welding metal, which contain l...

  • Page 9: 2. Installation

    Weldforce kwf 200s / 0541 – 9 © kemppi oy 21 23 24 21 22 25 22 20 25 2. Installation 2.1. Assembly of mig system assemble the units in order mentioned below and follow mounting and operation instructions which are delivered in packages. 1. Installation of power source read paragraph: ”installation” ...

  • Page 10

    10 – weldforce kwf 200s / 0541 © kemppi oy 5. Mounting of weldforce wire feed units to boom wire feed unit must be mounted to boom in such a way that its chassis is galvanic separated both from swing arm and boom. Kwf 200 needs hanging frame (accessorie) for mounting to boom. Do not hang it from han...

  • Page 11

    Weldforce kwf 200s / 0541 – 11 © kemppi oy 28 28 a b kwf 200s check that in filler wire reel there are no parts sticking out, which could e.G. Chafe against chassis or door of wire feed unit. Dragging parts might expose chassis of wire feed unit under voltage. 2.5. Automatic wire feed to gun automati...

  • Page 12

    12 – weldforce kwf 200s / 0541 © kemppi oy a b kwf 200s 2.6. Adjustment of pressure adjust the pressure of feed rolls with the control screw (20) so that the wire is fed into the wire guide tube evenly and allows a little braking when coming out from the contact tip without slipping at the feed roll...

  • Page 13

    Weldforce kwf 200s / 0541 – 13 © kemppi oy e b d c f g a 2.10. Shield gas handle gas bottle with care. There is a risk for injury if gas bottle or bottle valve is damaged! For welding stainless steels, mixed gases are normally used. Check that the gas bottle valve is suitable for the gas. The flow ra...

  • Page 14

    14 – weldforce kwf 200s / 0541 © kemppi oy 14 1 4 2 6 7 11 12 8 13 9 10 5 3 2.11. Main switch i/o when you turn the main switch of the kemppi weldforce power source into i-position, the pilot lamp closest to this switch will light up, indicating the power source is ready for welding. The equipment i...

  • Page 15

    Weldforce kwf 200s / 0541 – 15 © kemppi oy selection of mig operating procedure (6) mig 2t: mig welding with two-sequence procedure of welding gun start switch 1. Switch pressed: welding starts 2. Switch released: welding stops mig 4t: mig welding with four-sequence procedure of welding gun start sw...

  • Page 16

    16 – weldforce kwf 200s / 0541 © kemppi oy setup functions (6) the unit is equipped with a number of additional functions, the selection and parameter value settings for which are performed via the setup function. The setup function is activated by pressing the setup button (6) for >1 second. The ad...

  • Page 17: Kwf Wire Feed Unit

    Weldforce kwf 200s / 0541 – 17 © kemppi oy r61 r63 r20 r61 r10, rmt10 r63 r61 mig setting for wire feed: i 1...18 m/min (39.3...709 ipm) ii 1...25m/min (39.3....984 ipm) setting for voltage: 10 v...Max. Voltage of power source (35...46 v) memory channel selection: 1...5 corresponding to settings 1, ...

  • Page 18: 5. Weldforce Error Codes

    18 – weldforce kwf 200s / 0541 © kemppi oy 5. Weldforce error codes the existence of possible faults in the equipment is investigated in connection with each wire feed unit start-up. If a fault is detected, the fault in question will be indicated as an ‘err’ message on the (ls) panel display (see en...

  • Page 19: 7. Disposal Of The Machine

    Weldforce kwf 200s / 0541 – 19 © kemppi oy 6. Service, operation disturbances the amount of use and the working environment should be taken into consideration when planning the frequency of maintenance of kwf. Careful use and preventive maintenance will help to ensure trouble-free operation. The fol...

  • Page 20: 8. Ordering Numbers

    20 – weldforce kwf 200s / 0541 © kemppi oy 8. Ordering numbers kwf 200s 6232200us kps 3500 3 ph 480v 6131351 transport unit t 400 6185267 transport unit p40 6185264 kwf300/300sp500 6185265 kv 400 6185247 accessories kwf 200 hanging frame (incl. Kps mounting set) 6185285 kwf 200 protection slides (in...

  • Page 21

    Weldforce kwf 200s / 0541 – 21 © kemppi oy mmt 42w 3 m (9.8 ft) 6254203mmt mmt 42w 4.5 m (14.8 ft) 6254204mmt mmt 52w 3 m (9.8 ft) 6255203mmt mmt 52w 4.5 m (14.8 ft) 6255204mmt interconnecting cables kwf 70-1,8-gh 6260401 kwf 70-1,8-wh 6260403 kwf 70-5-gh 6260405 kwf 70-5-wh 6260407 promig 2/3 70-10...

  • Page 22: 9. Technical Data

    22 – weldforce kwf 200s / 0541 © kemppi oy kwf 200s working voltage (safety voltage) 50 vdc rated power 100 w max. Load (nominal values) 60 % ed 520 a 100 % ed 440 a operation principle 4 roll feed diameter of feed roll 32 mm (1.26”) wire feed speed i 0...18 m/min (0...709 ipm) wire feed speed ii ¹)...