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Operating manual • English
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Gebrauchsanweisung • Deutsch
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Manuel d’utilisation • Français
Manual de instrucciones • Español
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Инструкции по эксплуатации • По-русски
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KempArc
SYN 300, 400, 500
DT 400
1

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  • Page 1

    KempArc

    SYN 300, 400, 500
    DT 400

    Operating manual • English
    Käyttöohje • Suomi

    EN
    FI

    Bruksanvisning • Svenska

    SV

    Bruksanvisning • Norsk

    NO

    Brugsanvisning • Dansk

    DA

    Gebrauchsanweisung • Deutsch

    DE

    Gebruiksaanwijzing • Nederlands

    NL

    Manuel d’utilisation • Français

    FR

    Manual de instrucciones • Español

    ES

    Instrukcja obsługi • Polski

    PL

    Инструкции по эксплуатации • По-русски

    RU

    Manual de utilização • Português

    PT



  • Page 2



  • Page 3

    OPERATING MANUAL

    English

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117



  • Page 4

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117

    CONTENTS
    1. PREFACE. ........................................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
    1.1 General. ............................................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
    1.2 Introduction. ..................................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

    2. USE. . .................................................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

    2.1 Power source..................................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
    2.1.1 Power source components. ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
    2.1.2 Positioning of the machine. ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
    2.1.3 Distribution network. ............... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
    2.1.4 Connecting the power source to the electric network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
    2.1.5 Connecting the cables. ............ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
    2.1.6 Installing the field bus card...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
    2.1.7 Starting the power source. ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
    2.1.8 Power source indicators. .......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
    2.2 Control panel. ................................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
    2.2.1 Control panel parts................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
    2.2.2 Adjusting MIG dynamics (Arc Force). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
    2.2.3 Gas test. ..................................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
    2.2.4 Wire feed test. ........................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
    2.2.5 Selection of liquid- or gas-cooled MIG gun.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
    2.2.6 Retrieving weld data. ............... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
    2.2.7 Selecting the welding process.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
    2.2.8 Additional MIG features included in the standard delivery.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
    2.2.9 Optional additional MIG features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
    2.2.10 Memory features (MEMORY button). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
    2.2.11 Synergetic 1-MIG welding and WiseThin welding.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
    2.2.12 SETUP features of the control panel.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
    2.3 Wire feeder......................................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

    EN

    3. MAINTENANCE......................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
    3.1 Cables................................................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
    3.2 Power source..................................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
    3.2.1 DuraTorque™ 400, 4-wheel wire feeder mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
    3.3 Regular maintenance..................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
    3.4 Disposal of the machine............... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

    4. TROUBLESHOOTING. .......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

    2

    4.1
    4.2
    4.3
    4.4
    4.5

    Overload (yellow indicator lit). ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
    Control cable connector fuse...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
    Electric network overvoltage or undervoltage.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
    Missing phase in the electric network.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
    Error codes. ........................................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

    5.
    6.

    ORDERING NUMBERS. ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
    TECHNICAL DATA................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22



  • Page 5

    PREFACE

    1.1

    GENERAL
    Congratulations on your choice of the Kemparc SYN-series welding system. Reliable
    and durable, Kemppi products are affordable to maintain, and they increase your work
    productivity.
    This user manual contains important information on the use, maintenance and safety of
    your Kemppi product. The technical specifications of the device can be found at the end of
    the manual. Please read the manual carefully before using the equipment for the first time.
    For your 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 specifications presented in this manual are subject to change without prior notice.
    NOTE! Items in the manual that require particular attention in order to minimise damage and
    personal harm are indicated with this symbol. Read these sections carefully and follow their
    instructions.

    Disclaimer
    While every effort 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 specification 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.

    1.2

    INTRODUCTION
    KempArc SYN is a product family for welding automation that includes all welding devices
    needed in robot welding. The KempArc SYN welding system includes the following devices:
    • KempArc SYN 300, SYN 400 and SYN 500 are synergetic welding power sources
    designed particularly for welding automation that are suitable for MIG welding with
    direct current. There are three power types of power sources: the 300, 400 and 500
    ampere models. For more information on using power sources and their functions, see
    "Power source".
    • RF 59 is a control panel that contains the programs and welding parameters needed
    in controlling the welding hardware. The panel functions allow the user to control the
    operation of the welding hardware and adjust its welding settings. The control panel is
    located in the front panel of the welding power source. For more information on using
    the control panel and its functions, see "Control panel".
    • KempArc DT 400 is a wire feeding device that feeds welding wire to the welding robot
    at the speed it requires at any time. For more information on using the wire feeder and
    its functions, see "Wire feeder".
    This guide presents the functions, operation and technical properties of the above devices.
    The devices also include the KempCool 10 cooler, but its functions and features are presented
    in a separate guide.
    The KempArc Synergic hardware is connected to the welding robot control system with the
    control unit on top of the power source.

    3

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117

    1.

    EN



  • Page 6

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117

    2.

    USE

    2.1

    POWER SOURCE

    2.1.1 Power source components
    1

    2

    3

    4

    A12
    A1

    A9

    A3
    A2

    A11

    A10

    A5

    A8

    A4
    A7
    A6

    EN

    1 Robot Control
    2 Wire Feeder
    A1
    A2
    A3
    A4
    A5
    A6
    A7
    A8
    A9
    A10
    A11
    A12

    3 Throughput
    4 Analog

    Control panel
    Main switch
    Signal light (I/O)
    Thermal warning light
    Welding cable connection (parallel)
    Earthing cable connection
    Control cable connection (parallel)
    Cooling unit
    Mains cable
    Fuse for control cable connection (6.3 A slow)
    Fan grill
    Transportation handles

    2.1.2 Positioning of the machine
    Place the machine on a firm, dry and level surface. Where possible, do not allow dust or other
    impurities to enter the machines cooling air flow. Preferably site the machine above floor 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.

    4



  • Page 7

    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.

    KempArc 500
    This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc
    is greater than or equal to 4.6 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 4.6 MVA.

    KempArc 400
    This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc
    is greater than or equal to 4.7 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 4.7 MVA.

    KempArc 300:
    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.

    2.1.4 Connecting the power source to the electric network

    EN

    The KempArc SYN power source is connected to a 400-V three-phase network. The machine
    is equipped with a five-metre mains cable that does not have a plug. Before use, check the
    mains cable and install a mains plug. If the cable does not comply with the local electrical
    regulations, replace it with a compliant cable.
    NOTE! The mains cable or plug may be installed or replaced by only an electrical contractor or
    installer authorised to perform such operations.

    Replacement of the mains cable
    1.
    2.
    3.
    4.
    5.

    Unscrew the mounting screws on the top and sides of the machine, and remove the case
    by lifting it.
    Disconnect the phase leads from connectors L1, L2, and L3, and disconnect the
    protective earth lead.
    Pass the cable to the machine through the inlet ring at the rear of the machine, and
    secure the cable with a cable clamp.
    Connect the cable’s phase leads to connectors L1, L2, and L3.
    Connect the yellow-green protective earth lead to its connector .

    NOTE! Do not connect the zero lead if you are using a five-lead cable.

    The table below lists the fuse sizes for 100% load in a 400-V three-phase network with
    4 x 6-mm² cable for different power source models.

    Model

    Fuse

    SYN 300

    20 A delayed

    SYN 400

    25 A delayed

    SYN 500

    35 A delayed

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117

    2.1.3 Distribution network

    5



  • Page 8

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117

    2.1.5 Connecting the cables

    A
    D

    C

    DT 400
    B

    B
    control

    Wire feeder

    +

    SYN 300/400/500
    Analog
    +
    Robot
    H
    KempArc

    F

    KempCool 10
    G
    E

    A.
    B.
    C.
    D.
    E.
    F.
    G.
    H.

    EN

    air hose
    shield gas hose
    air blow
    intermediate cable
    earthing cable
    cooling liquid hoses
    robot controller
    cooling unit control cable

    Welding and earthing cables
    The welding and earthing cables are rubber-insulated copper cables. The recommended
    cross-sections of the cables for different power source models are as follows:

    Model

    Welding cable

    SYN 300

    50 ... 70 mm²

    SYN 400

    70 ... 90 mm²

    SYN 500

    70 ... 90 mm²

    The table below shows the typical load capacities of the cables when the ambient
    temperature is 25 °C and the lead temperature is 85 °C.

    Welding 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

    NOTE! Do not overload the welding cables, as an overload may cause voltage loss and
    overheating.

    6



  • Page 9

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117

    Connecting welding and earthing cables
    The power source has two welding cable and control cable connectors. With them, the
    welding robot's welding torch and, if necessary, a manual welding torch for tack welding can
    be connected to the power source.
    Connect the welding and earthing cables as follows.
    1. Connect the power source to the electric network according to the instructions above.
    2. Connect the earthing cable to the earthing connector A6.
    3. Connect the welding cable to the welding current connector A5.
    NOTE! Do not overload the welding cables, as an overload may cause voltage loss and
    overheating.

    You can conect the control cables of manual welding wire feeders or the control cable of a
    remote controller to the control cable connectors.
    Before starting the welding, connect the earth clamp directly to the work piece in such a way
    as to maximise the contact surface of the clamp. The point of connection must be unpainted
    and free of corrosion.

    2.1.6 Installing the field bus card
    1.
    2.
    3.
    4.

    Remove the cover of the control unit on top of the power source by unscrewing the
    cover screws.
    Put the field bus card on top of the interface card and attach with two M3 nuts (see
    image).
    Put the control unit cover back in place.
    Connect the welding robot's field bus cable to the control unit connector.

    EN

    M3 nuts
    Field bus card

    Interface card

    NOTE! Separate the field bus cable for the welding robot from the mains cables, as they may
    interfere with the control logic operation.

    7



  • Page 10

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117

    2.1.7 Starting the power source
    Start the power source by turning the main switch A2 on the front panel to the I position. The
    standby indicator A3 turns on.
    NOTE! Always turn the device on and off using the main switch, not via the mains socket.

    The cooling fan is started for a moment when the main switch is turned to the ‘I’ position. The
    fan turns off after a while and then restarts during welding when the machine has warmed up
    sufficiently. The fan continues running even after up to 10 minutes of welding, depending on
    the temperature of the machine.

    2.1.8 Power source indicators
    The following indicators can be found on the front panel of the power source:
    • When the green mains indicator A3 is on, the power source is in standby mode. This
    indicator is on when the machine is connected to the mains supply with the main switch
    in the ‘I’ position.
    • When the yellow overheating indicator A4 is on, the machine has overheated. When the
    indicator turns off, the machine can be used again.
    • When indicator A4 blinks, the machine has encountered a failure. Attempt to remedy the
    problem according to the instructions in Section 4, ‘Troubleshooting’. If the failure cannot
    be eliminated, turn off the machine, and turn it on again. If the failure persists, write
    down any fault code that may be shown on the display and contact authorised Kemppi
    service agent.

    2.2

    CONTROL PANEL

    2.2.1 Control panel parts
    P11

    P2

    EN

    P3

    P4

    P5

    P6

    P13

    P8

    P7

    P9

    P10

    The control panel is used for controlling and monitoring the operation of the power source
    and the wire feeder. The buttons are used for adjusting functions. The displays and indicators
    reflect the operating modes of the machine.

    8



  • Page 11

    Use the Esc button to move to the previous menu level.

    Displays

    • The control panel displays show adjustable operation parameters, their values, and the
    units of measure.
    • During welding, display P2 shows the welding current value that is currently in use, while
    display P6 shows the welding voltage.

    Control knobs

    • The left-hand control knob P11 allows the adjustment of the speed of wire feeding. The
    selected speed is shown on the display on the left-hand side.
    • The right-hand side control knob P13 allows for controlling the welding voltage in MIG
    and 1-MIG processes, in which case the selected voltage is shown on the right-hand side
    display, and the base current in WiseThin processes, in which case the adjustment range
    is +/- 50.
    These control knobs are also used for specifying the operating parameters. A parameter for
    adjustment is selected with the left-hand knob, while the value of the parameter is selected
    with the right-hand knob.

    2.2.2 Adjusting MIG dynamics (Arc Force)
    When you press button P3, you can adjust the MIG welding dynamics of the machine by
    means of the right-hand knob.
    When using the MIG or 1-MIG welding process, the welding dynamics setting affects the
    features of the welding arc and the amount of welding spatter as shown below:
    • The value 0 is the recommended basic setting.
    • Use values -1...-9 if you want a softer arc and less spatter.
    • Use values 1...9 if you want a rougher and more stable arc. This setting is useful when you
    are using 100% CO₂ shielding gas when welding steel.
    When using a WiseThin process, the welding dynamics setting affects the forming pulse as
    shown below:
    • Use values -1...-30 if you want a softer arc and smaller penetration.
    • Use values 1...30 if you want a rougher and greater penetration.

    2.2.3 Gas test
    The gas test button P4 opens the gas valve without activating the wire feed or power source.
    By default, gas flows for 20 seconds. The gas flow time remaining is shown on the display.
    The right-hand knob allows you to set the default gas flow time, between 10 and 60 seconds,
    and store the new default value in the machine’s memory. To stop the gas test, press the ESC
    button.

    2.2.4 Wire feed test
    When you press the Wire inch button, P6, the wire feeder engine starts but the gas valve does
    not open and the power source is not activated.
    The wire feed pace is 2 m/min for the first two seconds, and then 10 m/min.
    When the button is released, the wire feeding stops. The machine automatically goes back
    to the normal state after approximately 3 seconds from release of the button or immediately
    when you press the ESC button.

    2.2.5 Selection of liquid- or gas-cooled MIG gun
    You can select a MIG gun cooled with liquid or gas by pressing buttons P3 and P4
    simultaneously and holding them down for at least one second.
    • When the display reads GAS, you can use a gas-cooled MIG gun with the equipment.
    • When the display reads COOLEr, you can use a liquid-cooled MIG gun with the
    equipment.

    9

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117

    Esc button

    EN



  • Page 12

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117

    You can change the gun selection by pressing buttons P3 and P4 again, as above. With a
    liquid-cooled gun selected, the liquid cooling function is started when the power source is
    started the next time.

    2.2.6 Retrieving weld data
    The weld data function allows you to return to the welding current and voltage used during
    the previous session, with the weld data feature. To use the feature, press buttons P4 and P5
    simultaneously.

    2.2.7 Selecting the welding process
    The welding process selector button P9 allows you to select the welding process you want to
    use. You can select one of the following processes:
    • normal MIG welding
    • 1-MIG welding
    • WiseThin (optional)
    In normal MIG welding, the wire feed speed and welding voltage are adjusted separately.
    Unlike the above, the 1-MIG and WiseThin processes are synergetic welding processes where
    the welding voltage and other welding parameters are interconnected so that the welding
    power and arc length are adjusted to attain optimal welding values.
    The WiseThin process is an optional feature intended for welding automation. It must be
    acquired separately and is therefore not available in all configurations.

    2.2.8 Additional MIG features included in the standard delivery
    The standard welding machine delivery includes three additional MIG features that facilitate
    welding and improve weld quality. These additional features are creep start, hot start and
    crater fill.
    To use an additional MIG feature, press the feature selector button P10. Press the selector
    button repeatedly to use one or several features. Only the additional features allowed for the
    welding method you have chosen will be available.

    EN

    Creep start
    The purpose of the creep start feature is to make controlled weld start easier and smoothen
    the initial stage of welding, for example when welding with high wire feed speeds. At the
    beginning, the machine will use a slow wire feed speed until the wire touches the work piece
    and the current starts flowing.
    Creep start is available for normal MIG welding and the synergetic 1-MIG welding.

    Hot start
    The purpose of hot start is to reduce start faults, for example when welding aluminium or
    other materials with particularly good thermal conductivity. In this scenario, there is a fixed
    pre-gas time at the beginning of the welding, after which the welding power briefly rises
    above the specified power level. The power and time parameters for hot start can be specified
    in the SETUP settings.
    Hot start is available for synergetic 1-MIG welding.

    Crater fill
    The purpose of crater fill is to facilitate controlled finishing of welding and to reduce the
    welding faults caused by the final crater. When you press the welding gun trigger completely
    down at the end of welding, the welding power is reduced to a preset crater fill level. To end
    the crater fill stage, release the gun trigger. The crater fill parameters can be specified in the
    SETUP settings.
    Crater fill is available for synergetic 1-MIG welding.

    10



  • Page 13

    To set the values of the functional parameters for additional MIG features, use either the
    SETUP feature in the control panel (see 2.2.12 "SETUP functions in the control panel") or the
    QUICK SETUP feature, which you can activate by pressing the QUICK SETUP button, P8.
    Select the parameter to adjust using the left-hand side control knob P11 or the button P10
    and then set the parameter value with the right-hand side control know P13. The value
    you specified is instantly stored in the control panel memory. The following table lists the
    parameter values that can be specified for additional MIG features.

    Name of
    parameter
    Creep Start Level

    Name
    Parameter values
    displayed

    Factory setting

    Description

    Cre

    10 ... 170 %

    50 %

    Percent of wire feed
    speed default
    10% refers to slow start,
    170% refers to fast start

    Hot Start Level

    Hot

    -50 ... 75 %

    30 %

    Percent of welding power:
    -50% refers to cold start
    +75% refers to hot start

    Hot Start Time

    H2t

    0 ... 9.9 s

    1.2 s

    The duration of the hot start in
    seconds.

    Crater Fill Start
    Level

    CrS

    10 ... 90 %

    90 %

    The welding power at the
    beginning of the crater fill stage as
    a percentage of the welding power
    preset value.

    Crater Fill End
    Level

    CrL

    10 ... 90 %

    30 %

    The welding power at the end of
    the crater fill stage as a percentage
    of the welding power preset value.

    Crater Fill Time

    Crt

    0 ... 9.9 s

    2s

    The duration of the crater fill stage
    in seconds.

    NOTE! In crater fill, the initial value of the welding power must be greater than the final value,
    and therefore the adjustment ranges for the initial and final values are restricted automatically, if
    necessary.

    Welding Level

    Crater Fill Start Level

    Crater Fill End Level

    Crater Fill Time

    11

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117

    Specifying the SETUP settings for additional features

    EN



  • Page 14

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117

    EN

    2.2.9 Optional additional MIG features
    In addition to the additional MIG features included in the standard delivery, it is also possible
    to acquire optional features that further expand the operating features of the machine.
    To use the optional features, enter a machine-specific activation code in the machine's control
    panel as shown below. To purchase an activation code, contact a Kemppi representative.

    Activating optional additional features
    1.

    Press and hold down the SETUP button P8 for at least 5 seconds. The SETUP settings
    menu appears on the display.
    2. Select the Cod alternative with the left-hand side control knob in the control panel and
    then select the value Ent using the right-hand side control knob.
    3. Briefly press the SAVE button.
    4. When the display on the left-hand side reads 1, enter the first value of the activation
    code using the right-hand side control knob. The value you have entered is shown in the
    right-hand side display.
    5. Select the entry of the next value using the left-hand side control knob.
    6. Enter the value corresponding to the value shown in the left-hand side display using the
    right-hand side control knob.
    7. Repeat steps 5 and 6 until you have entered all values of the activation code.
    8. Finally, press the SAVE button briefly.
    The control panel will read Suc cEs to indicate that the activation code has been entered
    correctly and the additional feature is available. You can exit the code entry mode at any time
    by briefly pressing ESC.
    If the code entry failed, the control panel display will show an error code. For more
    information on error codes, see "Troubleshooting".
    The operating instructions for optional additional features can be found in the documentation
    supplied with the additional feature.

    2.2.10 Memory features (MEMORY button)
    Use the control panel memory features to store welding parameters you use into the
    machine's memory for easy use later without the need to readjust all parameters. The control
    panel has 90 memory positions, numbered 0...89.
    You can store the welding parameters you use, i.e., the wire feed speed and the welding
    voltage. You can also store additional feature settings, such as creep start or crater fill settings.

    Storing welding parameters in memory
    1.

    Press the MEMORY button twice. If a memory channel is free, the SET indicator starts
    flashing. In other cases the indicator will be turned on constantly.
    (If the memory is empty, one push of the button is enough.)
    2. Select the memory channel you want using the CH button.
    3. Specify the welding settings you want and store the selections by pressing SAVE.
    4. Press the MEMORY button twice. The ON indicator light will turn on and the welding
    parameters you selected are activated.
    5. Start welding.
    If you want to change the welding parameters stored in a welding channel, go to the SET
    mode by pressing the MEMORY button. Now select the parameters you want and store them
    by pressing SAVE.
    You can also store the welding parameters with the SET button when the memory feature is in
    the OFF state, i.e., when the MEMORY indicators are not on.
    To clear the data in a memory channel, press the MEMORY and CH buttons simultaneously
    when the control panel is in the SET mode (the SET indicator is on).

    Using stored welding parameters
    6.
    7.
    8.

    12

    Press the MEMORY button to turn on the ON indicator.
    Select the memory channel you want from the robot.
    Start welding.



  • Page 15

    In synergetic 1-MIG welding, the machine selects the optimal welding parameters suitable to
    the filler wire and shield gas using the programs, or synergetic curves, stored in the control
    panel. The welder controls the welding by adjusting the welding power and arc length.
    The synergetic WiseThin process (advanced auto arc) is a synergetic welding process
    developed for the special needs of robotic welding with weldig characteristics optimised
    particularly for welding automation.

    Selecting a welding program
    1.
    2.
    3.
    4.

    Before you start welding, find the welding program suitable to your filler wire and shield
    gas in the tables below and then activate the program as follows:
    Press the SYNERGIC PROGRAM button P7 for more than 1 second. This will activate
    program selection and the control panel displays start flashing.
    Select the material group with the left-hand side control knob and the welding program
    for the material group with the right-hand side control knob according to the tables
    below. The program you selected is immediately recorded in the memory.
    Press ESC button or the SYNERGIC PROGRAM button P7 to exit the menu.

    MIG programs in the KempArc SYN machine
    1-MIG, Fe group
    Program number

    Wire, mm

    Material

    Shield gas

    101

    0,8

    Fe

    102

    0,9

    Fe

    Ar+18%-25%CO2
    Ar+18%-25%CO2

    103

    1,0

    Fe

    104

    1,2

    Fe

    106

    1,6

    Fe

    111

    0,8

    Fe

    112

    0,9

    Fe

    113

    1,0

    Fe

    114

    1,2

    Fe

    116

    1,6

    Fe

    121

    0,8

    Fe

    122

    0,9

    Fe

    123

    1,0

    Fe

    124

    1,2

    Fe

    126

    1,6

    Fe

    152

    0,9

    FEMC

    154

    1,2

    FEMC

    164

    1,2

    FEMC

    174

    1,2

    FEFC rutile

    184

    1,2

    FEFC rutile

    Ar+18%-25%CO2
    CO2

    194

    1,2

    FEFC basic

    Ar+18%-25%CO2

    Ar+18%-25%CO2
    Ar+18%-25%CO2

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117

    2.2.11 Synergetic 1-MIG welding and WiseThin welding

    EN

    Ar+18%-25%CO2
    CO2
    CO2
    CO2
    CO2
    CO2
    Ar+8%CO2
    Ar+8%CO2
    Ar+8%CO2
    Ar+8%CO2
    Ar+8%CO2
    Ar+18%-25%CO2
    Ar+18%-25%CO2
    CO2

    13



  • Page 16

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117

    1-MIG, SS group

    EN

    Program number

    Wire, mm

    Material

    Shield gas

    201

    0,8

    SS-316

    202

    0,9

    SS-316

    Ar+2%CO2
    Ar+2%CO2

    203

    1,0

    SS-316

    204

    1,2

    SS-316

    206

    1,6

    SS-316

    211

    0,8

    SS-316

    212

    0,9

    SS-316

    213

    1,0

    SS-316

    214

    1,2

    SS-316

    216

    1,6

    SS-316

    221

    0,8

    SS-309

    222

    0,9

    SS-309

    223

    1,0

    SS-309

    224

    1,2

    SS-309

    231

    0,8

    SS-309

    232

    0,9

    SS-309

    233

    1,0

    SS-309

    234

    1,2

    SS-309

    242

    0,9

    FC-316

    244

    1,2

    FC-316

    252

    0,9

    FC-316

    254

    1,2

    FC-309L

    CO2
    Ar+18%-25%CO2

    Program number

    Wire, mm

    Material

    Shield gas

    303

    1,0

    Al-5356

    Ar

    304

    1,2

    Al-5356

    Ar

    306

    1,6

    Al-5356

    Ar

    313

    1,0

    AL-4043

    Ar

    314

    1,2

    Al-4043

    Ar

    316

    1,6

    Al-4043

    Ar

    401

    0,8

    CuSi 3

    Ar

    402

    0,9

    CuSi 3

    Ar

    403

    1,0

    CuSi 3

    Ar

    404

    1,2

    CuSi 3

    Ar

    411

    0,8

    CuSi 3

    Ar+2% CO2

    412

    0,9

    CuSi 3

    Ar+2% CO2

    413

    1,0

    CuSi 3

    Ar+2% CO2

    421

    0,8

    CuAl 8

    Ar

    423

    1,0

    CuAl 8

    Ar

    424

    1,2

    CuAl 8

    Ar

    Ar+2%CO2
    Ar+2%CO2
    Ar+2%CO2
    Ar+30%He+1%O2
    Ar+30%He+1%O2
    Ar+30%He+1%O2
    Ar+30%He+1%O2
    Ar+30%He+1%O2
    Ar+2%CO2
    Ar+2%CO2
    Ar+2%CO2
    Ar+2%CO2
    Ar+30%He+1%O2
    Ar+30%He+1%O2
    Ar+30%He+1%O2
    Ar+30%He+1%O2
    Ar+18%-25%CO2
    Ar+18%-25%CO2

    1-MIG, AI group

    1-MIG, SPE group

    14



  • Page 17

    903
    904
    913
    914

    1,0
    1,2
    1,0
    1,2

    Fe
    Fe
    Fe
    Fe

    Ar+18%-25%CO2
    Ar+18%-25%CO2
    CO²
    CO²

    1,0
    1,2
    1,0
    1,2

    SS-316
    SS-316
    SS-316
    SS-316

    Ar+2%CO2
    Ar+2%CO2
    Ar+30%He+1%O2
    Ar+30%He+1%O2

    WiseThin, SS group
    923
    924
    933
    934

    Using the welding program
    5.
    6.
    7.
    8.

    Select the welding process 1-MIG with the P9 button.
    Press the SYNERGIC PROGRAM button to display the material group and the welding
    program number. Make sure that the welding program corresponds to the filler wire and
    shield gas you use.
    Check the wire type and shield gas for the welding program in the table below.
    Adjust the welding power with the left-hand side knob and the arc length with the righthand side knob.

    2.2.12 SETUP features of the control panel
    The machine has a number of additional features, or parameters, whose settings can be
    specified with the control panel's SETUP function as follows:
    1. Press and hold down the SETUP button P10 for at least 5 seconds.
    2. Select the parameter to adjust using the left-hand side control knob. The parameter
    name is shown in display 2.
    3. Specify the parameter value with the right-hand side control knob. The selected value is
    shown in the display P6. The parameter’s value is immediately stored in the memory.
    4. You can exit the SETUP mode by pressing and holding down the SETUP button again for
    at least 5 seconds or by briefly pressing the ESC button.
    All welding processes have their own SETUP parameters. For example, adjusting the postcurrent for synergetic MIG welding does not affect the post-current of normal MIG welding.
    The tables below show the additional features available in this welding machine and their
    possible values.

    Normal MIG welding parameters and their values
    Name of
    Name
    Parameter
    Factory setting
    parameter
    displayed values

    Description

    Pre Gas Time

    PrG

    0.0 ... 9.9 s

    0.0 s

    Pre-gas time 0 ... 9.9 s.

    Post Gas Time

    PoG

    Aut, 0.1 ... 32.0 s

    1,0

    Post gas time,
    Aut = Automatic, depending on welding
    current 0.1 ... 32 s

    Creep Start Level

    Cre

    10 ... 170%

    50 %

    Percentage of wire feed speed, 10% refers
    to slow start, 170% to accelerated start

    Post Current Time

    PoC

    -9 ... +9

    0

    Post-welding current time

    15

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117

    WiseThin, Fe group

    EN



  • Page 18

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117

    Synergetic MIG welding parameters and their values
    Name of
    parameter

    Name
    Parameter values Factory setting
    displayed

    Description

    Creep Start Level

    Cre

    10 ... 170 %

    50 %

    Hot Start Level

    Hot

    -50 ... 75 %

    30 %

    Crater Fill Level

    CrL

    10 ... 90 %

    30 %

    -9 ... +9
    m/min, mm, A

    0
    m/min

    Percentage of wire feed speed, 10% refers
    to slow start, 170% to accelerated start
    Percent of welding power: -50% refers to
    cold start and +75% to hot start
    The crater fill level, 10% is the lowest
    power and 90% the greatest one, relative to
    welding power (preset value).
    Post-welding current time
    In synergic welding, the parameter shown
    in the left-hand side display (wire feed
    speed/plate thickness/average current).

    Post Current Time PoC
    Synergic MIG Unit Unl

    Parameters common to all MIG processes and their values
    Name of
    parameter

    Name
    Parameter values Factory setting
    displayed

    Description

    Cable
    Compensation
    Code Entry
    Restore Factory
    Settings
    Scaling

    CAL

    -5.0 ... 9.0 V/100 A

    1.0 V/100 A

    Cod
    FAC

    ---, Ent
    OFF, PAn, All

    --OFF

    SCA

    0 ... 5000

    0

    Cable compensation (MIG) for voltage
    losses.
    Entry of additional features, see page 14.
    Restores factory settings if you select ON
    and exit the menu.
    A coefficient with which the values in the
    welding machine are scaled to the scale
    used by the robot.

    EN
    Checking the parameters in the MEMORY ON state

    You can check parameter values in the MEMORY ON state by pressing the button of the
    parameter you want. The parameter value will be shown in the display. You cannot modify
    parameter values in the MEMORY ON state.

    2.3

    WIRE FEEDER
    Wire guide adapter
    The welding wire is taken to the wire feeder through a metallic wire guide adapter. Push the
    wire guide to the end of the adapter and screw in with the top fixing locks. Attach a spring at
    the end of the adapter to serve as the bend support for the wire guide and to prevent the wire
    from bending too heavily. Fix the support spring with the bottom fixing locks.

    16



  • Page 19

    1.

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117

    Threading the wire and adjusting tightness

    2.

    EN

    2.

    1.

    1.

    2.

    17



  • Page 20

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117

    3.

    MAINTENANCE
    The utilisation level of the power source and its working environment should be taken into
    consideration in planning the frequency of maintenance of the machine. Proper use of the
    machine and regular maintenance help you avoid unnecessary downtime and failures.

    3.1

    CABLES
    • Check the condition of welding and mains cables daily.
    • Make sure to replace damaged cables immediately. Only use original Kemppi spare
    parts.
    • Make sure that all extension cables used in the mains connection are in proper condition
    and compliant with regulations.
    NOTE! The mains cables may be repaired and installed only by electrical contractors and installers
    authorised to perform such operations.

    3.2

    POWER SOURCE
    Before cleaning the interior of the machine, you need to remove the case by unscrewing the
    mounting screws of the machine.
    NOTE! To prevent damage, wait approximately two minutes after disconnecting the mains cable
    before removing the machine’s case.

    Perform the following cleaning and maintenance at least every six months:
    1. Clean the interior of the machine and the fan grill’s net of any dust and stains – for
    example, with a soft brush and vacuum cleaner.
    • Do not use pressurised air. The stain may become compressed into the grooves of the
    coolers.
    • Do not use a pressure-washing device.
    2. Check the electrical connections of the machine. Clean any oxidised connections, and
    tighten the loosened ones.
    • Check for the right tension before tightening the connections.

    EN

    NOTE! Remember that the machine may be repaired only by an electrical contractor or installer
    authorised to perform such operations.

    18



  • Page 21

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117

    3.2.1 DuraTorque™ 400, 4-wheel wire feeder mechanism
    Wire guide tubes
    Ss, Al, Fe, ø 0.6...1.6 mm
    Mc, Fc

    ø 2.5/64 mm,
    W000762,
    silver, plastic

    ø 2.5/33 mm,
    W000956,
    silver, plastic

    ø 2.0 mm,
    W000624,
    plastic

    ø 1.6..0.20.4
    mm

    ø 3.5/64 mm,
    W001430,
    silver, plastic

    ø 3.5/33 mm,
    W001431,
    silver, plastic

    ø 3.5 mm,
    W001389,
    plastic

    Fe, Mc, Fc ø 0.6..0.00.8
    mm

    ø 1.0/67 mm,
    W001432,
    white, steel

    ø 2.0/33 mm,
    W001435,
    orange, steel

    ø 2.0 mm,
    W000624,
    plastic

    ø 0.9...1.6 mm

    ø 2.0/64 mm,
    W001433,
    orange, steel

    ø 1.6..0.20.4
    mm

    ø 4.0/63 mm,
    W001434,
    blue, steel

    ø 3.5 mm,
    W001389,
    plastic
    ø 4.0/33 mm,
    W001436,
    blue, steel

    ø 3.5 mm,
    W001391,
    brass

    2.

    EN
    1.

    Parts of the DT400 metal feed rolls

    3.3

    W000731

    gear ring 1

    driving

    2 pcs per unit

    W000732

    gear ring 2

    pressing

    2 pcs per unit

    W000711

    drive ring

    V groove

    1,2/1,2

    optional

    4 pcs per unit

    W000718

    drive ring

    V groove

    1,0/1,0

    optional

    4 pcs per unit

    W000891

    drive ring

    V groove

    1,0/1,2

    optional

    4 pcs per unit

    9420507

    washer

    10.5x30x2.5

    2 pcs per unit

    REGULAR MAINTENANCE
    Make sure that the machine receives regular and appropriate maintenance. Authorised
    Kemppi service agents perform regular maintenance by agreement. For more information on
    regular maintenance, contact a Kemppi representative.

    19



  • Page 22

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117

    3.4

    DISPOSAL OF THE MACHINE
    Do not dispose of electrical equipment 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 taken to an appropriate
    environmentally responsible recycling facility.
    The owner of the equipment is obliged to deliver a decommissioned unit to a regional
    collection centre, per the instructions of local authorities or a Kemppi representative. By
    applying this European Directive you will improve the environment and human health.

    4.

    TROUBLESHOOTING
    In the event of a failure of the machine, contact an authorised Kemppi service agent. Before
    taking your unit for servicing, check the list below.

    4.1

    OVERLOAD (YELLOW INDICATOR LIT)
    Two simultaneously operating fans cool the power source. The machine may, however,
    overheat if continuously loaded above the rated values or if the circulation of cooling air is
    prevented.
    Overheating is indicated by a yellow indicator light in the front panel of the power source. You
    then need to stop welding and let the machine cool down. The indicator light turns off when
    welding can be resumed.

    4.2

    CONTROL CABLE CONNECTOR FUSE
    The back panel of the power source has a fuse that protects the control cable connector. Using
    an incorrect type of fuse will damage the power source. Therefore, it is important that you
    always use the correct fuse type. The type and size of the fuse are indicated next to the fuse
    socket.

    EN
    4.3

    ELECTRIC NETWORK OVERVOLTAGE OR UNDERVOLTAGE
    If the power source is used in an electric network with insufficient voltage (less than 300 V),
    the control features of the device are automatically disabled.
    The primary circuits of the power source are protected against power spikes. The product’s
    mains voltage range is broad enough to prevent over-voltage problems at up to 440 V. Make
    sure that the voltage remains within the allowed range, especially if the operating power is
    supplied by a generator set. For information on the allowable voltage range, see "Technical
    specifications" in this guide.

    4.4

    MISSING PHASE IN THE ELECTRIC NETWORK
    If a phase is missing from the mains current, the welding features will be adversely affected or
    the machine may have problems starting. Loss of a phase can be caused by a:
    • Blown mains fuse
    • Damaged mains cable
    • Poor mains cable connection in the machine’s terminal block or mains socket

    4.5

    ERROR CODES
    The machine always checks its operation automatically during start-up and reports any
    failures detected. If failures are detected during start-up, they are shown as error codes on the
    control panel display.

    Err3: Power source overvoltage
    The machine has stopped the welding because it has detected momentary voltage spikes or
    continuous overvoltage dangerous to the machine in the electric network. Check the quality
    of the supply network.

    20



  • Page 23

    The power source has overheated. The cause may be one of the following:
    • The power source has been used for a long time at maximum power.
    • The circulation of cooling air to the power source is blocked.
    • The cooling system has experienced a failure.
    Remove any obstacle to air circulation, and wait until the power source fan has cooled down
    the machine.

    Err5 Water unit alarm
    The water circulation is blocked. The cause may be one of the following:
    • Congestion or disconnection in the cooling pipeline
    • Insufficient cooling liquid
    • Excessive cooling liquid temperature
    Check the circulation of the cooling liquid and the air circulation of the water unit.

    Err23: Power source overvoltage warning
    The power source has detected voltage spikes in the electric network. Short power spikes
    can be managed. They do not lead to interruptions in welding but may decrease the welding
    quality. Check the quality of the supply network.

    Err61: The water unit is not found
    The water unit is not connected to the equipment, or the connection has failed. Connector the
    water unit.

    Other error codes:

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117

    Err4: Power source overheating

    If an error code not listed above is shown, contact Kemppi service and tell them the error
    code.

    EN

    21



  • Page 24

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117

    EN

    5.

    ORDERING NUMBERS
    Power source/Interface
    KempArc

    KempArc

    Wire feeder
    Interbus S
    Interbus S
    Profibus
    Devicenet
    Cooling unit KempCool 10
    Cables
    Intermediate cable
    Intermediate cable
    Earthing cable
    Earthing cable

    6.

    6201300

    SYN 400 (digital)

    6201400

    SYN 500 (digital)

    6201500

    SYN 300 (analogue)

    6201300AN

    SYN 400 (analogue)

    6201400AN

    SYN 500 (analogue)

    6201500AN

    DT 400

    6203400
    9774120IBC

    optical

    9774120IBO
    9774120PRF
    9774120DEV
    6208100

    5 m (power source - wire feeder)

    6260421

    10 m (power source - wire feeder)

    6260425

    70 mm², 5 m

    6184711

    70 mm², 10 m

    6184712

    TECHNICAL DATA
    KempArc
    Connection voltage
    Rated power

    Primary current
    Connection cable
    Fuse, delayed
    Load capacity 40 °C

    SYN 300

    SYN 400

    SYN 500

    400 V -15 % ... +20 % 400 V -15 % ... +20 % 400 V -15 % ... +20 %
    60% ED

    -

    -

    26.1 kVA

    80% ED

    -

    19.5 kVA

    -

    100% ED

    13.9 kVA

    18.5 kVA

    20.3 kVA

    50% ED I1max 19.8

    28

    40

    100% ED I1

    19.8

    25.5

    31

    HO7RN-F

    4G6 (6 mm²), 5 m

    4G6 (6 mm²), 5 m

    4G6 (6 mm²), 5 m

    25 A

    35 A

    35 A

    60% ED

    -

    80% ED

    -

    400 A

    -

    100% ED

    300 A

    380 A

    430 A

    10 V ... 39 V

    10 V ... 42 V

    Idle power
    Efficiency
    Power factor
    Voltage supply for auxiliary devices
    Fuse (X14, X15)
    Voltage supply for the cooling device
    MIG
    Welding voltage range
    Max. welding voltage
    Open circuit voltage

    22

    SYN 300 (digital)

    500 A

    25 W
    87%
    0.9
    50 V DC
    6.3 A delayed
    50 VDC
    10 V ... 37 V
    46 V
    50 V



  • Page 25

    SYN 300

    SYN 400

    SYN 500

    -20 ... +40 °C

    -20 ... +40 °C

    -20 ... +40 °C

    -40 ... +60 °C

    -40 ... +60 °C

    -40 ... +60 °C

    IP23S

    IP23S

    IP23S

    A

    A

    A

    -

    4.7

    4.6

    590x230x500 mm

    590x230x500 mm

    590x230x500 mm

    35 kg

    36 kg

    37 kg

    KempArc SYN 300, 400, 500, DT 400 / © Kemppi Oy / 1117

    KempArc
    Operating temperature
    range
    Storage temperature range
    Degree of protection
    EMC class
    Minimun short circuit power
    Ssc of supply network *
    External dimensions LxWxH
    Weight
    * See paragraph 2.1.3.

    DT 400
    Operating voltage

    50 V DC

    Rated power

    100 W

    Load capacity

    80% ED

    600 A

    100% ED

    500 A

    Operating principle

    4-wheel feed

    Wire feed speed

    0 ... 25 m/min

    Filler wires

    ø Fe, Ss

    0.6 – 1.6 mm

    ø Flux-cored wire

    0.8 – 1.6 mm

    ø Al

    1.0 – 1.6 mm

    Welding gun connector

    Euro

    Operating temperature range

    -20 ... +40 °C

    Storage temperature range

    -40 ... +60 °C

    Degree of protection

    IP23S

    External dimensions LxWxH

    269x175x169 mm

    Weight

    4.5 kg

    EN

    23



  • Page 26

    KEMPPI OY
    Hennalankatu 39
    PL 13
    FIN-15801 LAHTI
    FINLAND
    Tel +358 3 899 11
    Telefax +358 3 899 428
    export@kemppi.com
    www.kemppi.com

    KEMPPI (UK) Ltd
    Martti Kemppi Building
    Fraser Road
    Priory Business Park
    BEDFORD, MK44 3WH
    UNITED KINGDOM
    Tel +44 (0)845 6444201
    Telefax +44 (0)845 6444202
    sales.uk@kemppi.com

    Kotimaan myynti:
    Tel +358 3 899 11
    Telefax +358 3 734 8398
    myynti.fi@kemppi.com

    KEMPPI FRANCE S.A.S.
    65 Avenue de la Couronne des Prés
    78681 EPONE CEDEX
    FRANCE
    Tel +33 1 30 90 04 40
    Telefax +33 1 30 90 04 45
    sales.fr@kemppi.com

    KEMPPI SVERIGE AB
    Box 717
    S-194 27 UPPLANDS VÄSBY
    SVERIGE
    Tel +46 8 590 783 00
    Telefax +46 8 590 823 94
    sales.se@kemppi.com
    KEMPPI NORGE A/S
    Postboks 2151, Postterminalen
    N-3103 TØNSBERG
    NORGE
    Tel +47 33 346000
    Telefax +47 33 346010
    sales.no@kemppi.com
    KEMPPI DANMARK A/S
    Literbuen 11
    DK-2740 SKOVLUNDE
    DANMARK
    Tel +45 4494 1677
    Telefax +45 4494 1536
    sales.dk@kemppi.com
    KEMPPI BENELUX B.V.
    Postbus 5603
    NL-4801 EA BREDA
    NEDERLAND
    Tel +31 765717750
    Telefax +31 765716345
    sales.nl@kemppi.com

    ООО КЕМППИ
    ул. Полковая 1, строение 6
    127018 Москва
    Tel +7 495 739 4304
    Telefax +7 495 739 4305
    info.ru@kemppi.com
    KEMPPI, TRADING (BEIJING) COMPANY,
    LIMITED
    Room 420, 3 Zone, Building B,
    No.12 Hongda North Street,
    Beijing Economic Development Zone,
    100176 Beijing
    CHINA
    Tel +86-10-6787 6064
    +86-10-6787 1282
    Telefax +86-10-6787 5259
    sales.cn@kemppi.com

    KEMPPI SPÓŁKA Z O.O.
    Ul. Borzymowska 32
    03-565 WARSZAWA
    POLAND
    Tel +48 22 7816162
    Telefax +48 22 7816505
    info.pl@kemppi.com

    肯倍贸易(北京)有限公司
    中国北京经济技术开发区宏达北路12号
    创新大厦B座三区420室 (100176)

    KEMPPI AUSTRALIA PTY LTD.
    13 Cullen Place
    P.O. Box 5256, Greystanes NSW 2145
    SMITHFIELD NSW 2164
    AUSTRALIA
    Tel. +61 2 9605 9500
    Telefax +61 2 9605 5999
    info.au@kemppi.com

    KEMPPI INDIA PVT LTD
    LAKSHMI TOWERS
    New No. 2/770,
    First Main Road,
    KAZURA Gardens,
    Neelangarai,
    CHENNAI - 600 041
    TAMIL NADU
    Tel +91-44-4567 1200
    Telefax +91-44-4567 1234
    sales.india@kemppi.com

    电话: +86-10-6787 6064
    +86-10-6787 1282
    传真: +86-10-6787 5259
    sales.cn@kemppi.com

    1920130
    1117

    www.kemppi.c om

    KEMPPI GmbH
    Otto-Hahn-Straße 14
    D-35510 BUTZBACH
    DEUTSCHLAND
    Tel +49 6033 88 020
    Telefax +49 6033 72 528
    sales.de@kemppi.com

    OOO KEMPPI
    Polkovaya str. 1, Building 6
    127018 MOSCOW
    RUSSIA
    Tel +7 495 739 4304
    Telefax +7 495 739 4305
    info.ru@kemppi.com






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