The Kemppi KempArc SYN 400 is a digital MIG/MAG power source prepared for robot stations and welding automats. The current reaches 400 A, the duty cycle is 400 A at 80%, and the supply is 3x400 V. The set includes a new DT400 wire feeder.
What this machine is for
You build this power source into a robot cell or a longitudinal seam automat, and you do not set it up at a manual station. The robot controller drives it through an analogue or digital interface, with a Fieldbus option. The manufacturer lists work with ABB, Fanuc, Kuka and Yaskawa manipulators, and you match the protocol to your controller, for example Profibus, Profinet, DeviceNet or EtherCAT. The power source and the controller exchange data over a digital bus, so a change of parameters takes microseconds.
Typical uses are gantries and automats welding beams, sections and structural parts along the seam in continuous mode, and large batch production in the car and machine industries, where 100% repeatability of the parameters is required and the weld has to be clean, with no spatter. A duty cycle of 400 A at 80% at an ambient temperature of 40 degrees Celsius covers shift work with no breaks for cooling.
You run wire in diameters from 0.8 to 1.6 mm, so one cell covers thin sheet and heavier structural joints. Synergic programs based on the Kemppi Wise curves shorten the choice of parameters when you change the material or the wire diameter.
Features and equipment
- WiseFusion, that is adaptive arc control. It holds a short arc in the short circuit and spray ranges and narrows it, so the energy density rises. The robot welds faster with no undercut and no arc wander, and the heat affected zone and the distortion of the part are smaller.
- WisePenetration, that is holding constant fusion. When the free wire length, known as stick-out, changes, the system holds the set current, so the depth of fusion does not drop with deviations of the part and no lack of fusion appears.
- A new DT400 wire feeder with the DuraTorque mechanism and four driven rollers, intended for mounting on the third axis of the robot. The motor tachometer works in a feedback loop and corrects the feed speed hundreds of times a second, also during sharp movements of the arm and bends in the liner. In robot work the feeder is the most heavily loaded part, and play in the drive shifts the tool centre point, that is the TCP, which is why this module was replaced with a new one.
- A robot interface with support for the Teach Pendant, that is control of the process from the robot panel.
- Job Recall, that is calling up saved memory channels during work, for example when you change from the root run to the cap or when the welding position changes.
- Arc On and Gas On signals and fault statuses sent as they happen, so the controller reacts to a loss of the arc or to the wire sticking.
- Synergic programs on the Kemppi Wise curves.
- A digital bus between the power source and the robot controller.
- A modular build with support for Fieldbus interfaces, so you plug the power source into the existing control network of the cell.
Technical data
| Brand | Kemppi |
|---|---|
| Process | MIG/MAG |
| Supply voltage | 3x400 V, tolerance from minus 15% to plus 20% |
| Welding current | up to 400 A |
| Duty cycle at 40 degrees Celsius | 400 A at 80% |
| Wire feeder | new DT400 DuraTorque module |
| Communication with the robot | analogue or digital interface, Fieldbus option |
| Synergic programs | Kemppi Wise curves |
| Wire diameter range | 0.8 to 1.6 mm |
| Cooling | air |
What you get
- used Kemppi KempArc SYN 400 power source
- new DT400 wire feeder with the DuraTorque mechanism and four driven rollers
What to watch out for
The supply is 3x400 V with a tolerance from minus 15% to plus 20%, so the connection has to be an industrial one. The product record gives gas cooling, while the manufacturer description lists the Kemppi CoolArc liquid module, so confirm the configuration before you buy, because the choice of torch depends on it. To start the cell you add a communication card for your controller, a robot torch and cables, and the record does not list them. It gives no weight and no dimensions, so arrange transport before collection.
This is kit for an integrator, not for hand work: without a robot or an automat and without an interface you will not start the process. The feeder is new, while the power source itself is used, so we run the measurements and the load test on the power source. The Wise algorithms help with fast movements of the arm and with a changing wire stickout, but they will not replace a well set fixture or a properly prepared part.
How we sell used machines
This unit was checked in our service workshop in Krotoszyn with measurements to PN-EN 60974-4 and a load test. The price includes the first year of the basic service package: an inspection with cleaning of the machine and a validation measurement. Further years can be added. We ship across the European Union, collection in person by appointment.
