KEMPPI K5 WELDING EQUIPMENT KempArc Pulse TCS 22.03.2018 PRODUCTIVE WELDING TO THE POWER OF TWO KempArc Pulse TCS DUAL-WIRE TANDEM WELDING SYSTEM FOR MECHANIZED MIG/MAG WELDING Replacing single-wire welding with dual-wire tandem welding is an efficient way to increase welding speed and productivity, and also reduce costs. Suiting a wide range of welding applications from heavy duty welding to thin sheet fabrication, KempArc Pulse TCS (Tandem Control System) is able to increase productivity between 40 and 80% over single-wire process in a reliable way. The intelligent TCS software solutions provide easy system setup and automatic arc regulation, achieving significant welding speed increase and consistent welding quality. As the arcs are actively monitored and controlled separately by the TCS software, it is possible to precisely adjust them independently from each other. The trail arc continuously monitors the lead arc and adjusts itself accordingly, resulting in several performance benefits. KempArc Pulse TCS can be delivered with a welding torch option of your choice, either normal or push-pull model specially designed for tandem MIG/MAG welding. For monitoring welding parameters from a distance and freedom to position the power sources in a space-efficient way, you can either use the KF 62 remote control pendant, or KempArc Browser, an optional software application that offers a web interface to KempArc equipment. KEY APPLICATIONS THIN SHEET FABRICATION 2 KempArc Pulse TCS YELLOW GOODS SHIPBUILDING 22032018 KEY BENEFITS INCREASE IN PRODUCTIVITY 450 A POWER SOURCES At best compared to single-wire process Allow different welding processes in each wire BENEFITS • • • • • • • • • • • Increases productivity between 40-80% over single wire process Easy process setting and parameter control Fast and flexible parameter adjustment Optimized, independent and real time arc length adjustment No system arc interference Four process options available (variations of Pulse/Spray arc combinations) Optional ON/OFF switching of either electrode during the weld cycle Suitable for steel and aluminum applications Reduced heat input on thin sheet materials Can be used for single-wire welding with either the first or second wire Reliable 4-roll DuraTorque wire feeding mechanism and full metal feed rolls with excellent wear resistance in both wire feeders • Connects to all common robot brands 22032018 KempArc Pulse TCS 3 BENEFITS EASY SETUP SAVES TIME AND MONEY One of the great benefits of the TCS technology is that it makes the KempArc Pulse TCS more tolerant of welding parameter variations compared to traditional tandem welding processes. This adds up to significantly shorter setup times of the equipment, both in the initial setup phase and when the welding application changes. With KempArc Pulse TCS, the change from one mechanization application to another is fast and flexible. WISE APPLICATION SOFTWARE COMPATIBILITY Wise software products are available to further enhance KempArc Pulse TCS performance. They increase welding productivity and quality by automating welding power and arc length control. Further Wise products are available for root pass welding and thin sheet applications. ACCESS YOUR KEMPARC SYSTEM THROUGH THE WEB KempArc Browser is an optional software application that offers a web interface for selected robot brands or computer use. It is an easy way to make changes to the welding parameter values from a distance, without moving between the welding power source and the mechanization application. When used with a computer, KempArc Browser allows you to establish a connection through to the mechanization application located elsewhere - whether it be in the same building or other side of the globe. 4 KempArc Pulse TCS 22032018 WHAT'S IN THE SYSTEM - EQUIPMENT KempArc Pulse 450 TCS Digital DT400 Wire feeder DT400L Wire feeder 450 A power source for dual-wire tandem welding mechanization. The two units included in KempArc Pulse TCS mechanized welding system can be controlled independently from each other. Right-hand side wire feeder for automated welding with a reliable 4-roll wire feeding mechanism and full metal feed rolls. DT400 can be mounted on the back of the robot arm or integrated with any mechanized welding system. Euro connection. Left-hand side wire feeder for automated welding with a reliable 4-roll wire feeding mechanism and full metal feed rolls. DT400L can be mounted on the back of the robot arm or integrated with any mechanized welding system. Euro connection. DeviceNet Tandem control cable Fieldbus card Cable for connecting KempArc Pulse TCS power sources. Interconnection cable ROBOT 95-25-WH TANDEM KempCool 40 Binzel Tandem W 800 CAT torch Cooling unit suitable for use with KempArc Pulse TCS. KempCool 40 performs 4 kW of cooling power with an eight liter tank that can be filled with 20%-40% ethanol/water mixture, or any other suitable antifreeze agent. 22032018 Includes WH Tandem W 800 liquid-cooled welding gun, gun holder, robot mount CAT2, adapter flange according to robot model and cable bundle. KempArc Pulse TCS 5 WHAT'S IN THE SYSTEM - SOFTWARE 6 WiseFusion-A WisePenetration-A Kemppi Wise welding function for automated welding. Kemppi Wise welding function for automated welding. WiseRoot-A WiseThin-A Kemppi Wise welding process for automated welding. Kemppi Wise welding process for automated welding. KempArc Pulse TCS 22032018 ALTERNATIVE - EQUIPMENT AND SOFTWARE KempArc Pulse TCS package Can Open KempArc Pulse TCS package Ethernet KempArc Pulse TCS package Profibus Dual-wire tandem welding system package (product code P162) for mechanized MIG/ MAG welding with two digital 450 A power sources, KempCool 40 cooling unit, two DT400 wire feeders, cables and Can Open robot interface. Dual-wire tandem welding system package (product code P163)for mechanized MIG/ MAG welding with two digital 450 A power sources, KempCool 40 cooling unit, two DT400 wire feeders, cables and Ethernet robot interface. Dual-wire tandem welding system package (product code P164) for mechanized MIG/ MAG welding with two digital 450 A power sources, KempCool 40 cooling unit, two DT400 wire feeders, cables and Profibus robot interface. KempArc Pulse TCS package Profinet Interconnection cable ROBOT 95-10-WH Ethernet Fieldbus card Profibus Profinet Can Open Fieldbus card Fieldbus card Fieldbus card Dual-wire tandem welding system package (product code P165) for mechanized MIG/ MAG welding with two digital 450 A power sources, KempCool 40 cooling unit, two DT400 wire feeders, cables and Profinet robot interface. 22032018 KempArc Pulse TCS 7 TECHNICAL SPECIFICATIONS KempArc Pulse TCS Product code KempArc Pulse TCS package DeviceNet - P161 Connection voltage 3~ 50/60 Hz 400 V -15...+20% Fuse (delayed) 35 A Minimum generator power 35 kVA Welding range 10 ... 50 V Open circuit voltage 50 V Rated power 60% ED 221,1 kVA Rated power 100% ED 17,8 kVA Idle power (no load power) 100 W Efficiency 88 % Power factor 0,90 Voltage supply for auxiliary devices 50 V / 100 W Auxiliary device supply fuse (X14, X15) 6, 3 A delayed Voltage supply for the cooling device 24 VDC / 50 W Max. output current 450 A (60 %) Operating temperature range -20 ... +40 °C External dimensions LxWxH 590 × 230 × 430 mm Weight (no accessories) 36 kg Degree of protection IP23S EMC class A Storage temperature range -40 ... +60 °C DT400 Wire feeder 8 Product code 6203400 Filler wire sizes (Fe solid) 0.6…1.6 mm EMC class A KempArc Pulse TCS 22032018 KempCool 40 Product code 6208400 Connection voltage 1~ 50/60 Hz 230 V ±10 % Rated power 300 W (10 %) Rated power 100% ED 300 W Cooling liquid 20 - 40% Monopropylenglycol - water Max. pressure at output 0,35 MPa Operating temperature range -20 ... +40 °C External dimensions LxWxH 700 × 600 × 600 mm Weight (no accessories) 40 kg Degree of protection IP23S EMC class A Cooler tank volume 8l Cooling power 4 kW Storage temperature range -40 ... +60 °C 22032018 KempArc Pulse TCS 9 WWW.KEMPPI.COM Kemppi is the pioneering company within the welding industry. It is our role to develop solutions that make you win business. Headquartered in Lahti, Finland, Kemppi employs over 600 welding experts in 13 countries and has a revenue of more than 110 MEUR. Our offering includes welding solutions - intelligent equipment, welding management software and expert services - for both demanding industrial applications and ready-to-weld needs. Local expertise is available via our global partner network covering over 60 countries.