The Kemppi WeldForce KWF series comprises professional-grade wire feeders designed for demanding welding applications. This manual covers the KWF 200, KWF 300, KWF 200S, and KWF 300S models, with the 'S' versions offering a less extensive range of functions compared to their parent units. All operations and adjustments are microprocessor-controlled, ensuring precision and reliability.
Function Description:
The WeldForce KWF units are primarily MIG/MAG wire feeders. They are designed to be integrated into a complete MIG system, including a power source and, optionally, a cooling unit. The units facilitate the feeding of various filler wires (Fe, Ss, Cored wire, Al) with different diameters, supporting a wide range of welding applications.
The control panels, while varying slightly between the 'S' and non-'S' models, offer comprehensive control over welding parameters. The KWF 200S and KWF 300S feature a main switch, displays for wire feed speed/welding current and welding voltage, potentiometers for adjusting these parameters, and buttons for selecting MIG process (2T/4T), MIG dynamics, MMA welding, gas/water-cooled MIG gun selection, gas test, wire inch, and accessing SETUP parameters. The KWF 200 and KWF 300 models offer additional functionalities, including activation of welding dynamics adjustment, selection of additional MIG functions, 1-MIG selection check/welding arc selection, manual/remote control unit selection, memory channels for storing MIG parameters, and a dedicated 1-MIG program selection button.
Important Technical Specifications:
The KWF 200/200S and KWF 300/300S models share several core specifications, with differences primarily in wire reel capacity and physical dimensions.
- Working Voltage (safety voltage): 50 VDC for all models.
- Rated Power: 100 W for all models.
- Max. Load (nominal values):
- 60% ED: 520 A for all models.
- 100% ED: 440 A for all models.
- Operation Principle: 4-roll feed for all models.
- Diameter of Feed Roll: 32 mm for all models.
- Wire Feed Speed I: 0...18 m/min for all models.
- Wire Feed Speed II (optional): 0...25 m/min for all models (requires changing gear wheel).
- Filler Wires:
- Ø Fe, Ss: 0.6...1.6 mm (KWF 200/200S), 0.6...2.4 mm (KWF 300/300S).
- Ø Cored wire: 0.8...1.6 mm (KWF 200/200S), 0.8...2.4 mm (KWF 300/300S).
- Ø Al: 1.0...1.6 mm (KWF 200/200S), 1.0...2.4 mm (KWF 300/300S).
- Wire Reel:
- Max. weight: 5 kg (KWF 200/200S), 20 kg (KWF 300/300S).
- Max. size: Ø 200 mm (KWF 200/200S), Ø 300 mm (KWF 300/300S).
- Gun Connector: Euro for all models.
- Operation Temperature Range: -20...+40 °C for all models.
- Storage Temperature Range: -40...+60 °C for all models.
- Degree of Protection: IP 23 C for all models.
- Dimensions:
- Length: 510 mm (KWF 200/200S), 590 mm (KWF 300/300S).
- Width: 200 mm (KWF 200/200S), 240 mm (KWF 300/300S).
- Height: 310 mm (KWF 200/200S), 445 mm (KWF 300/300S).
- Weight: 9.4 kg (KWF 200/200S), 13.6 kg (KWF 300/300S).
Usage Features:
- Easy Installation: The units are designed for straightforward assembly with Kemppi WeldForce power sources and transport wagons.
- Wire Feed Mechanism: Features a 4-roll wire feed mechanism with pressure adjustment. Various wire guide tubes and feed rolls (plain, knurled, U groove, trapezoid slotted) are available, color-coded for easy identification and selection based on wire diameter and type.
- Automatic Wire Feed to Gun: This feature simplifies wire reel changes by automatically feeding the filler wire to the correct line without needing to release feed roll pressure.
- Adjustable Reel Brake: Allows adjustment of brake force to prevent wire spillage when the reel stops, with increased force needed for higher wire feed speeds.
- Burn Back Time Control: Electronic control automatically stops welding to prevent the wire end from melting and fastening to the contact tip or workpiece.
- MIG Operating Procedures: Supports both 2T (two-sequence) and 4T (four-sequence) welding gun start switch procedures.
- MIG Dynamics/Arc Force Adjustment: Allows fine-tuning of welding stability and spatter amount, with settings for softer or harder arcs depending on the material and shielding gas.
- Gas Test Function: Opens the gas valve without activating wire feed or power source, with adjustable flow time.
- Wire Feed Test Function: Starts the wire feed motor without gas or power, with adjustable default speed.
- Liquid-/Gas-Cooled MIG Gun Selection: Users can select between gas-cooled or liquid-cooled MIG guns, with the unit automatically starting the cooling unit if liquid cooling is chosen.
- Weld Data Recall: Displays the last used welding current and voltage values.
- MMA Welding: The KWF 200/300 models support MMA welding, with current adjustment via potentiometer.
- SETUP Functions: Provides access to advanced settings such as Creep Start (slowed/accelerated start), Post Current, Wire Feeder Address, Maximum Wire Feed Speed, Disable PMT MIG guns, and Restore Factory Settings.
- Memory Functions: Allows storage of up to ten different welding parameter sets (including 2T/4T, Creep Start, Crater Level) for quick recall.
- Synergic 1-MIG Welding: For KWF 200/300 models, this feature provides optimal welding parameters for specific wires and gases, controlled by adjusting welding power and arc length. Pre-programmed welding arcs/programs are selected via a dedicated button.
- Additional MIG Functions (KWF 200/300): Includes Creep Start, Hot Start (for highly heat-conductive materials), and Crater Levelling (to reduce end cratering defects).
- Remote Control Unit Compatibility: Supports R10, R20, and RMT10 remote control units for adjusting wire feed speed, voltage, and arc length, and selecting memory channels.
Maintenance Features:
- Regular Checks: The manual recommends checking the wear of feed roll grooves and wire guide tubes at least every six months. Worn components should be replaced.
- Wire Guide Tube Positioning: Ensure the gun's wire guide tube is positioned correctly, close to but not touching the feed rolls, allowing a straight wire path.
- Reel Brake Adjustment: Periodically adjust the reel brake to maintain proper tension.
- Electrical Connections: Clean oxidized couplings and tighten loose connections to prevent overheating and ensure optimal performance.
- Cleaning: Regularly clean dust and dirt from the equipment. When using compressed air for cleaning, appropriate eye protection is mandatory.
- Error Codes: The unit displays error codes (Err 2-4, Err 5-14) to indicate faults such as disrupted data transfer, cooling unit failure, gun overheating, or wire feed motor overloading. These codes help in diagnosing and resolving operational disturbances.
- Service and Support: In case of problems, users are advised to contact their Kemppi dealer.
- Disposal: The machine is designed for environmentally compatible recycling, adhering to European Directive 2002/96/EC on Waste Electrical and Electronic Equipment.
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