KEMPPI 6152100EL 520 A Automated Welding Equipment Instructions

: June 6, 2024
: KEMPPI

Table of Contents

Safety Instructions
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Safety Instructions

These instructions contain important information which either supplements or supersedes other instructions relating to this product. Read these instructions carefully before
commencing operation.
Furthermore, the installation and use of the device must follow the instructions given in the international standard: IEC 60974-9 Arc welding equipment
– Part 9: Installation and use.

Use of personal protective equipment

The arc and its reflecting radiation damage unprotected eyes. Shield your eyes and face appropriately before you start welding or observe welding. Also, note the different requirements for the darkness of the screen in the mask as the welding current changes.
Ensure the supply of clean and sufficient breathing air by using a fresh-air mask or otherwise providing adequate ventilation.
The arc radiation and spatters burn unprotected skin. Always wear protective gloves, clothing, and footwear when welding.
Always wear hearing protection if the ambient noise level exceeds the allowable limit (e.g., 85 dB).

General operating safety

Exercise caution when handling parts heated in welding. For example, the tip of the welding torch, the end of the welding rod, and the workpiece will heat to a burning temperature.
Never carry the device or suspend it by the carrying strap during welding.
Do not expose the machine to high temperatures, as this may cause damage to the machine.
Keep the torch cable and earthing cable as close to each other as possible throughout their length. Straighten any loops in the cables. This minimizes your exposure to harmful magnetic fields, which may interfere with a pacemaker, for example.
Do not wrap the cables around the body.
In environments classified as dangerous, only use S-marked welding devices with a safe idle voltage level. These work environments include, for example, humid, hot, or small spaces where the user may be directly exposed to the surrounding conductive materials.
Do not use arc welding equipment for pipe thawing.

Spatter and fire safety

Welding is always classified as hot work, so pay attention to fire safety regulations during welding and after it.
Remember that fire can break out from sparks even several hours after the welding work is completed.
Protect the environment from welding spatter. Remove flammable materials, such as flammable fluids, from the welding vicinity and supply the welding site with adequate fire fighting equipment.
In special welding jobs, be prepared for hazards such as fire or explosion when welding container-type workpieces.
Never direct the spark spray or cutting spray of a grinder toward the welding machine or flammable materials.
Beware of hot objects or spatter falling on the machine when working above the machine.
Welding inflammable or explosive sites is absolutely forbidden.

General electric safety

Only connect the welding machine to an earthed electric network.
Note the recommended main fuse size.
Do not take the welding machine inside a container, vehicle, or similar workpiece.
Do not place the welding machine on a wet surface and do not work on a wet surface.
Do not allow the main cable to be directly exposed to water.
Ensure cables or welding torches are not squashed by heavy objects and that they are not exposed to sharp edges or a hot workpiece.
Make sure that faulty and damaged welding torches are changed immediately as they can be lethal and may cause electrocution or fire.
Remember that the cable, plugs, and other electric devices may be installed or replaced only by an electrical contractor or engineer authorized to perform such operations.
Turn off the welding machine when it is not in use.
In the case of abnormal behavior of the equipment, such as smoke coming from the machine during normal use, take the machine to a Kemppi service representative for
inspection.

Welding power circuit

Insulate yourself from the welding circuit by using dry and undamaged protective clothing.
Never touch the workpiece and welding rod, welding wire, welding electrode, or contact tip at the same time.
Do not put the welding torch or ground cable on the welding machine or other electric equipment.
Turn off the machine from the main switch always before you need to touch any components of the electric circuit, for example when replacing the electrode or contact
tip or moving the earth return clamp.

Welding fumes

Ensure proper ventilation and avoid inhaling the fumes.
Ensure a sufficient supply of fresh air, particularly in closed spaces. You can also ensure the supply of clean and sufficient breathing air by using a fresh-air mask.
Take extra precautions when working on metals or surface-treated materials containing lead, cadmium, zinc, mercury or beryllium.

Transportation, lifting, and suspension

Pay attention to correct working position when lifting a heavy device – the risk of injury to the back.
Never pull or lift the machine by the welding torch or other cables. Always use the lift points or handles designed for that purpose.
Only use a transport unit designed for the equipment.
Try to transport the machine in an upright position, if possible.
Never lift a gas cylinder and the welding machine at the same time. There are separate provisions later for gas cylinder transportation.
Never use a welding machine when suspended unless the suspension device has been designed and approved for that particular purpose.
Do not exceed the maximum allowed load of suspension beams or the transportation trolley of welding equipment.
It is recommended that the wire coil be removed during lifting or transportation.

Environment

The welding power source is not suitable for use in rain or snow, although it can be used and stored outdoors. Protect the equipment against rain and strong sunlight.
Always store the machine in a dry and clean space.
Protect the machine from sand and dust during use and in storage.
The recommended operating temperature range is -20 to +40 °C. The machine’s operation efficiency decreases and it becomes more prone to damage if used in temperatures in excess of 40 °C.
Place the machine so that it is not exposed to hot surfaces, sparks, or spatter.
Make sure the airflow to and from the machine is unrestricted.
Always use the machine in an upright position only.
EMC classification of this product is class A in accordance with electromagnetic compatibility standards CISPR 11 and IEC 60974-10, and therefore the product is designed to be used in an industrial environment only.
WARNING: This class A equipment is not intended for use in residential locations where the electrical power is provided by a public low-voltage supply system. In those locations, it may be difficult to ensure electromagnetic compatibility due to conducted and radiated disturbances.
Arc welding equipment always causes an electromagnetic disturbance. To minimize the harmful effects of this, use the equipment strictly according to the operating manual and other recommendations.

Gas cylinders and regulators

Adhere to the instructions for handling gas cylinders and regulators.
Make sure that gas cylinders are used and stored in properly ventilated spaces. A leaking gas cylinder may replace the oxygen in the inhaled air, causing suffocation. Before use, make sure that the gas cylinder contains gas suitable for the intended purpose.
Always fix the gas cylinder securely in an upright position, against a cylinder wall rack or purpose-made cylinder cart.
Never move a gas cylinder when the flow adjuster is in place. Put the valve cover in place during transportation.
Close the cylinder valve after use.

Circuit diagram and spare part lists
If the circuit diagram and the spare parts list are not included in your delivery package, please request them from your local Kemppi service representative. For more information, please visit www.kemppi.com.

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.