KempArc Pulse TCS

Productive welding to the power of two

Dual-wire tandem welding system for mechanized MIG/MAG welding

Kemppi K5 Welding equipment Read more


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 benefits

Increase in productivity

Increase in productivity

At best compared to single-wire process

450 A power sources

450 A power sources

Allow different welding processes in each wire

Key applications

Thin sheet fabrication

Thin sheet fabrication

Yellow goods

Yellow goods

Shipbuilding

Shipbuilding

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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

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.

What's in the system

Equipment

Kemppi KempArc Pulse 450 TCS Digital product image

KempArc Pulse 450 TCS Digital

450 A power source for dual-wire tandem welding mechanization. The two units included...

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.

Kemppi DT400 Wire feeder product image

DT400 Wire feeder

Right-hand side wire feeder for automated welding with a reliable 4-roll wire feeding...

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.

Kemppi DT400L Wire feeder product image

DT400L Wire feeder

Left-hand side wire feeder for automated welding with a reliable 4-roll wire feeding ...

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.

Kemppi DeviceNet product image

DeviceNet

Fieldbus card

Fieldbus card

Kemppi Tandem control cable product image

Tandem control cable

Cable for connecting KempArc Pulse TCS power sources.

Cable for connecting KempArc Pulse TCS power sources.

Kemppi Interconnection cable ROBOT 95-25-WH TANDEM product image

Interconnection cable ROBOT 95-25-WH TANDEM

Kemppi KempCool 40 product image

KempCool 40

Cooling unit suitable for use with KempArc Pulse TCS. KempCool 40 performs 4 kW of co...

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.

Kemppi Binzel Tandem W 800 CAT torch product image

Binzel Tandem W 800 CAT torch

Includes WH Tandem W 800 liquid-cooled welding gun, gun holder, robot mount CAT2, ada...

Includes WH Tandem W 800 liquid-cooled welding gun, gun holder, robot mount CAT2, adapter flange according to robot model and cable bundle.

Application software and welding programs

Kemppi WiseFusion-A product image

WiseFusion-A

Kemppi Wise welding function for automated welding.

Kemppi Wise welding function for automated welding.

Kemppi WisePenetration-A product image

WisePenetration-A

Kemppi Wise welding function for automated welding.

Kemppi Wise welding function for automated welding.

Kemppi WiseRoot-A product image

WiseRoot-A

Kemppi Wise welding process for automated welding.

Kemppi Wise welding process for automated welding.

Kemppi WiseThin-A product image

WiseThin-A

Kemppi Wise welding process for automated welding.

Kemppi Wise welding process for automated welding.

Alternative

Equipment and software

Kemppi KempArc Pulse TCS package Can Open product image

KempArc Pulse TCS package Can Open

Dual-wire tandem welding system package (product code P162) for mechanized MIG/MAG we...

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.

Kemppi KempArc Pulse TCS package Ethernet product image

KempArc Pulse TCS package Ethernet

Dual-wire tandem welding system package (product code P163)for mechanized MIG/MAG wel...

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.

Kemppi KempArc Pulse TCS package Profibus product image

KempArc Pulse TCS package Profibus

Dual-wire tandem welding system package (product code P164) for mechanized MIG/MAG we...

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.

Kemppi KempArc Pulse TCS package Profinet product image

KempArc Pulse TCS package Profinet

Dual-wire tandem welding system package (product code P165) for mechanized MIG/MAG we...

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.

Kemppi Interconnection cable ROBOT 95-10-WH product image

Interconnection cable ROBOT 95-10-WH

Kemppi Ethernet product image

Ethernet

Fieldbus card

Fieldbus card

Kemppi Profibus product image

Profibus

Fieldbus card

Fieldbus card

Kemppi Profinet product image

Profinet

Fieldbus card

Fieldbus card

Kemppi Can Open product image

Can Open

Fieldbus card

Fieldbus card

Extras and accessories

Accessories

Technical specifications

Kemppi KempArc Browser Pulse product image

KempArc Browser Pulse

Additional module incorporated in robot interface that enables parameter setup and co...

Additional module incorporated in robot interface that enables parameter setup and control through a web user interface. Suitable for use with KempArc Pulse automated welding equipment.

Technical specifications

KempArc Pulse TCS
Product codeKempArc Pulse TCS package DeviceNet - P161
Connection voltage 3~ 50/60 Hz400 V -15...+20%
Fuse (delayed)35 A
Minimum generator power35 kVA
Welding range10 ... 50 V
Open circuit voltage50 V
Rated power 60% ED221,1 kVA
Rated power 100% ED17,8 kVA
Idle power (no load power)100 W
Efficiency88 %
Power factor0,90
Voltage supply for auxiliary devices50 V / 100 W
Auxiliary device supply fuse (X14, X15)6, 3 A delayed
Voltage supply for the cooling device24 VDC / 50 W
Max. output current450 A (60 %)
Operating temperature range-20 ... +40 °C
External dimensions LxWxH590 × 230 × 430 mm
Weight (no accessories)36 kg
Degree of protectionIP23S
EMC classA
Storage temperature range-40 ... +60 °C
DT400 Wire feeder
Product code6203400
Filler wire sizes (Fe solid)0.6…1.6 mm
EMC classA
KempCool 40
Product code6208400
Connection voltage 1~ 50/60 Hz230 V ±10 %
Rated power300 W (10 %)
Rated power 100% ED300 W
Cooling liquid20 - 40% Monopropylenglycol - water
Max. pressure at output0,35 MPa
Operating temperature range-20 ... +40 °C
External dimensions LxWxH700 × 600 × 600 mm
Weight (no accessories)40 kg
Degree of protectionIP23S
EMC classA
Cooler tank volume8 l
Cooling power4 kW
Storage temperature range-40 ... +60 °C

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Technical specifications