Kempomat 1701,2100 User Manual - Rapid Welding and Industrial
Contents
1. 10 A delayed 220 V 10 240 V 6 380 V 10 415 V 6 7 5 KVA 4 0 KVA 2 8 kVA 200A 23V 130A 20 5 V 100A 19V 30A 14 V 200A 24 V 10 steps 40 V 85 200A 24 V 0 90 200A 24 V 0 18 m min stepless 0 6 1 0 mm 0 9 1 2 mm 1 0 mm 20 kg 300 mm Euro H 180 C 20 40 C 40 60 C IP 23 C 910 mm 410 mm 820 mm 54 kg KEMPPI OY beem 8 TERMS OF GUARANTEE Kemppi Oy provides a guarantee for products manufactured and sold by them if defects in manufacture and materials occur Guarantee repairs must be carried out only by an Authorised Kemppi Service Agent Packing freight and insurance costs to be paid by orderer The guarantee 1s effected on the date of purchase Verbal promises which do not comply with the terms of guarantee are not binding on guarantor Limitations on guarantee The following conditions are not covered under the terms of guarantee defects due to natural wear and tear non compliance with operating and maintenance instructions connection to incorrect or faulty supply voltage including voltage surges outside equipment spec incorrect gas pressure overloading transport or storage damage fire of damage due to natural causes 1 e lightning or flooding This guarantee does not cover direct or indirect travelling costs daily allowances or accommodation Note Under the terms of guarantee welding torches and their consumables feeder drive rolls and2. feeder guide tubes are not covered Direct or indirect damage due to a defective product is not covered under the guarantee The guarantee is void if changes are made to the product without approval of the manufacturer or if repairs are carried out using non approved spare parts The guarantee 1s also void if repairs are carried out by non authorised agents Undertaking guarantee repairs Guarantee defects must be informed to Kemppi or authorised Kemppi Service Agents within the guarantee period Before any guarantee work is undertaken the customer must provide proof of guarantee or proof of purchase and serial number of the equipment in order to validate the guarantee The parts replaced under the terns of guarantee remain the property of Kemppi Following the guarantee repair the guarantee of the machine or equipment repaired or replaced will be continued to the end of the original guarantee period KEMPPI OY KEMPOMAT 1701 KEMPOMAT 2100 0531 13 KEMPPI OY PL 13 FIN 15801 LAHTI FINLAND Tel 03 899 11 Telefax 03 899 428 www kemppi com KEMPPIKONEET OY PL 13 FIN 15801 LAHTI FINLAND Tel 03 899 11 Telefax 03 7348 398 e mail myynti fi kemppi com KEMPPI SVERIGE AB Box 717 S 194 27 UPPLANDS VASBY SVERIGE Tel 08 59 078 300 Telefax 08 59 082 394 e mail sales se 9 kemppi com KEMPPI NORGE A S Postboks 2151 Postterminalen N 3103 TONSBERG NORGE Tel 33 34 60 00 Telefax
3. move the machine Use ropes for lifting Do not use a hook or a chain Place the machine on a horizontal stable and clean base Protect from hard rain and intensive sun shine Ensure unhindered circulation of cooling air 1 7 Operation safety Please study these Operation safety instructions and respect them when installing operating and servicing the machine Welding arc and spatters Welding arc hurts unprotected eyes Be careful also with reflecting arc flash Welding arc and spatter burn unprotected skin Use safety gloves and protective clothing Danger for fire or explosion Pay attention to fire safety regulations Remove flammable or explosive materials from welding place Always reserve sufficient fire fighting equipment on welding place Be prepared for hazards in special welding jobs eg for the danger of fire or explosion when welding container type work pieces Note Fire can break out from sparks even several hours after the welding work has been finished Mains voltage Never take welding machine inside a work piece eg container or truck Do not place welding machine on a wet surface Always check cables before operating the machine Change defect cables without delay Defect cables may cause an injury or set out a fire Connection cable must not be compressed it must not touch sharp edges or hot work pieces Welding power circuit Isolate yourself by using proper protective clothing do not wear wet c
4. 33 34 60 10 e mail sales no 9 kemppi com KEMPPI DANMARK A S Literbuen 11 DK 2740 SKOVLUNDE DANMARK Tel 44 941 677 Telefax 44 941 536 e mail sales dk 9 kemppi com KEMPPI BENELUX B V Postbus 5603 NL 4801 EA BREDA NEDERLAND Tel 076 5717 750 Telefax 076 5716 345 e mail sales nl 9 kemppi com Ver 8 SEBES SS KEMPPI The Joy of Welding KEMPPI UK Ltd Martti Kemppi Building Fraser Road Priory Business Park BEDFORD MK443WH ENGLAND Tel 0845 6444201 Fax 0845 6444202 e mail sales uk 9 kemppi com KEMPPI FRANCE S A S A au capital de 5 000 000 F 65 Avenue de la Couronne des Pr s 78681 EPONE CEDEX FRANCE Tel 01 30 90 04 40 Telefax 01 30 90 04 45 e mail sales fr kemppi com KEMPPI GmbH Otto Hahn StraBe 14 D 35510 BUTZBACH DEUTSCHLAND Tel 06033 88 020 Telefax 06033 72 528 e mail sales de 9 kemppi com KEMPPI SP z o o Ul Pitsudskiego 2 05 091 ZABKI Poland Tel 48 22 781 6162 Telefax 48 22 781 6505 e mail info pl 9 kemppi com KEMPPI WELDING MACHINES AUSTRALIA PTY LTD P O Box 404 2 58 Lancaster Street Ingleburn NSW 2565 Australia Tel 61 2 9605 9500 Telefax 61 2 9605 5999 e mail info kemppi com au www kemppi com
5. Operation instructions english 1921440E Gebrauchsanweisung deutsch 0531 Gebruiksaanwijzing nederlands Manuel d utilisation francais KEMPOMAT 1 01 2100 EM KEMPPI The Joy of Welding GE CONTENTS 1 PREFACE 3 Ld ene eelerer et RS N 3 e iProducpbIDUOQUG MON siio coa bieten irato aded aestu dde le ent 3 Eos TEE 3 Ld Switches And ONTOIS RL M nent elite 4 1 5 Mains conne DIU DE di dde pate ei a Sd un 4 Wo Locatie the machine soos uec ed ond ael edm ides lec mob Coup CL eria 4 Wie Ee E Does up ERR NIME DEM EINE UE RC MM I I ME 4 2 INSTALLATION OF WELDING GUN AND WIRE sees eere nnn nennen nenne nennen 5 2 1 Welding sun main component Sasss tH gege Seege ege AER Ce 5 2 2 Ware feeding mechanishi component oo deo eR TE ee een 5 E dE e Ben et EE 6 Zo TO HORS we POET ose ann le erint esa Ue ns ul ne don 6 2 5 eet 6 3 OPERATING WELDING EQUIPMENT cccceccseseseeeesseensessnnnnnnnnnnnnnnnnnnnnssnnseesseeeeseeeenseeeees 6 Bri PAGES OL USSR E EL t 6 32 VEIT SW E 7 3595 Polay JOE Wel CIO ooo aesti un bsc e uu MEE MEM E DI MM aD Pid 7 3 4 Adjustment of arc roughness Kempomat 2100 7 2o Oud re ee 7 3 6 o select weldite Tode ocn ibn N ar te M MD m I Du UTI 7 3 1 Forelle 8 99 MMS MONS E 8 Sek SCI DAS m 8 LOS ICE T TR 9 3 11 Storage 9 4 MAINTENANCE OF WELDING UNIT 1 leere elec ccce ecce e cree eene e nennen nn
6. Release the reel latch claws by turning them 1 4 of a turn 2 Insert the reel so that the hole in the reel will be at the pin of the device Use reel supports when required 3 Insert the reel N B The wire travels from the top of the roll to the wire feed unit 4 Secure the reel by turning the latch 2 5 To install the welding wire Before installing the welding wire check that the feed roll the wire conduit and the flow nozzle match the wire 1 Fitin the feed roll and check once more that the correct groove is in line with the wire 2 Round the end of the wire and push it through wire guide into burner s wire tube 3 Check that the wire is in the groove and set clamping lever on its place Tighten only a little 4 Feed the wire into the gun by pressing the gun switch Wire clamping force to the feed roll is correct when wire coming out of flow nozzle can be lightly slowed down with fingers 5 Regulate braking power of wire roll by turning the adjustment screw in the centre of latch with a screw driver Do not tighten too much as the brake puts an additional load on motor Note Not wire nor wire reel must touch the unit body as it creates a danger of short circuit When using aluminium wire it might be advisable to totally remove the spiral part of the back guide If you use cored wire check the wire manufacturer s instructions on use and safety first en Ai d 3 OPERATING WELDING EQUIPMENT A
7. actor When overheating pilot lamp lights welding is not possible There is an appr 3 min delay before the light goes out and welding can be normally continued by starting from the trigger The light can also signify low supply voltage or an overtly long welding period 3 9 Shield gas A Handle gas bottle with care it might explode if it falls down Because the danger of falling the gas bottle must not be higher than 1600 mm Shield gas shields the arc and in MAG welding it is also used for reinforcing the weld seam Shield gas for steel wire is carbon dioxide CO or mixed gas where main component is argon Ar and the rest is carbon dioxide When welding aluminium wire pure argon is used as shield gas Flow meter must be suitable for gas type Usually suitable flow is 8 to 10 l min If flow is too slow or too big the weld seam becomes porous Your dealer will give you advice on choosing gas and equipment Note Always mount the gas bottle in upright position in a specially made rack A on the wall or in a bottle trolley Always close the bottle valve after finishing welding 8 KEMPOMAT 1701 KEMPOMAT 2100 0531 KEMPPI OY 3 10 Welding Never look at the flame arc without a face shield for arc welding Protect yourself and your surroundings from the flame arc and hot spatter You can start welding when selections and adjustments demanded by the work have been done Welding begins when wire 1s pressed to the work
8. heel Aufziehrad aandrijfrol galet d entrainement 4265240 028mm 0 6 mm 0 8 mm 0 9 1 0 mm 1 2 mm 1 4 1 6 mm 0 030 0 035 0 045 52 1 16 FE Silea slat 3133810 3133210 3133820 ss Slett glat XA Valkoinen vit hvit Punainen r d red Keltainen gul gul plain glatt hvid white r d red rot gul yellow gelb AL glad lisse weiss wit blanc rood rouge geel jaune ek Pyalletty rafflat 3133940 3133990 riflet riflet NF Se Punainen rod r d Keltainen gul gul FC knurled gerillt V r d red rot gul yellow gelb gekarteld crant rood rouge geel jaune U ura U sp r 3133960 U spor U spor 4 Punainen r d r d Bu groove U Nut rad red rot U groef gorge U rood rouge KEMPPI OY KEMPOMAT 1701 KEMPOMAT 2100 0531 5 Ge 2 3 Installation of welding gun To ensure trouble free welding use only original Kemppi welding guns Do not use a damaged gun Make sure the gun wire conduit and the flow nozzle match the manufacturer s recommendations for the type and diameter of the wire you use Too small a conduit may overload the wire feed device and disturb wire feeding Tighten the gun quick connector to eliminate voltage losses A loose joint will make the gun and the wire feeder warm After this check that the conduit inside the wire liner does not touch the feed rolls 2 4 To fit the wire reel 1
9. ire feed speed Wires with filler Fe SS Cored wire Al Wire reel maximum weight maximum diameter Gun connection Thermal class Range of temperature for use Storage temperature range Degree of protection Measurements length width height Weight The unit fulfils the CE marking demands KEMPPI OY 1 230 V 50 60 Hz 3x1 5 mm 16 A delayed 220 V 10 240 V 6 6 5 kVA 3 0 kVA 2 3 kVA 170 A 2 V 85 A 18 5 V 76 A1 17 5 V 30A 14 V 170A 22 5 V 8 steps 40 V 70 9o 170A 21 V 0 85 170A 21 V 0 16 m min stepless 0 6 1 0 mm 0 9 1 2 mm 1 0 mm 20 kg 300 mm Euro H 180 C 20 40 C 40 60 C IP 23 C 850 mm 392 mm 750 mm 47 kg KEMPOMAT 1701 KEMPOMAT 2100 0531 11 Ge Kempomat 2100 3 230 400 Welding machine Rated voltage Mains cable fuse Mains connection Connected load 25 ED 60 ED 100 ED Load capacity 25 ED 60 ED 100 ED Adjustment range Voltage adjustment Idle voltage max Efficiency Power ratio Wire feed speed Wires with filler Fe SS Cored wire AI Wire reel maximum weight maximum diameter Gun connection Thermal class Range of temperature for use Storage temperature range Degree of protection Measurements length width height Weight The unit fulfils the CE marking demands 12 KEMPOMAT 1701 KEMPOMAT 2100 0531 3 230 V 50 60 Hz 3 400 V 50 60 Hz 3x1 5 mm
10. lothing Never work on a wet surface or use defect cables Do not put MIG gun or welding cables on welding machine or on other electric equipment Do not press MIG gun switch if the gun is not directed towards a work piece Welding fumes Take care that there is sufficient ventilation during welding Take special safety precautions when welding metals which contain lead cadmium zinc mercury or beryllium 4 KEMPOMAT 1701 KEMPOMAT 2100 0531 KEMPPI OY 2 INSTALLATION OF WELDING GUN AND WIRE Select the flow nozzle the wire conduit and the feed roll to match the wire The machine is supplied with 0 6 and 0 8 mm dia wires 2 1 Welding gun main components fi QV Un BW N 2 2 Wire feeding mechanism components 3134140 1 mm FE 0 6 0 8 Valkoinen vit hvit hvid p 4285900 FEMC Hu white weiss wit blanc Messinki Messing pene 3133700 o2mm ng SSFC 0 9 1 6 Messing mm Oranssi orange oransje orange emm a Massing orange orange oranje orange Brass Messing 134290 o 2mm Messing SS 08 1 6 AL mm Hopea silver s lv s lv la Laiton silver Silber zilveren argent D Handle Trigger Neck Gas nozzle Gun connector Wire conduit 4102283 901 8 mm gt Muovi plast plast plastic plastic Kunststoff plastic plastique Vetoratas drivhjul trekktannhjul drivhjul gearw
11. lso see section 1 Before you start using the welding machine A Welding in fire or explosion hazard sites is absolutely forbidden Note When welding in other than industrial surroundings the unit might cause disturbance in radio equipment Taking necessary precautions is the responsibility of the user 3 1 Places of use Kempomat is a basic welding machine for MIG MAG welding in maintenance servicing and repair works It is suitable for both normal MIG MAG welding as well as for welding without shield gas 6 KEMPOMAT 1701 KEMPOMAT 2100 0531 KEMPPI OY 3 2 Main switch In position I control circuit of the unit is live and indicator light of main switch is on Power source and welding circuit become active when gun trigger is pressed Note If mains power is shut off or triggered you must wait 10 to 15 sec before switching power back on Always switch the unit on and off from the main switch Do not use the mains plug as a switch A Beware that neither you yourself gas bottles nor electric equipment become a part of the welding electric circuit 3 3 To select polarity for welding Solid wire is usually welded in pole and cored wire in pole gun Check for the recom mended polarity on package or product seller When welding very thin plates 0 5 to 0 7 mm polarity might also work best for solid wire 3 4 Adjustment for arc roughness MNIIMM Kempomat 2100 Arc roughness is set by connecting the return curre
12. n nnmnnn mennaan 9 Zl WE Gay el VS HEEN 9 22 IRepular mantenin E ER dre tete trees noie no mines 9 5 DISPOSAL OF THE MACHINE asian aid eod va avv e vov cei twv ev ca ava 10 6 ORDERING NUMBERS zispis a 10 7 TECHNICAL INFORMATION gees 11 8 ERNEIEREN 13 2 KEMPOMAT 1701 KEMPOMAT 2100 0531 KEMPPI OY OOOO 1 PREFACE 1 1 Introduction Congratulations on having purchased this product Properly installed Kemppi products should prove to be productive machines requiring maintenance at only regular intervals This manual is arranged to give you a good understanding of the equipment and its safe operation It also con tains maintenance information and technical specifications Read this manual from front to back before installing operating or maintaining the equipment for the first time For further informa tion on Kemppi products please contact us or your nearest Kemppi distributor The specifications and designs presented in this manual are subject to change without prior notice In this document for danger to life or injury the following symbol is used AN Read the warning texts carefully and follow the instructions Please also study the Operation safety instructions and respect them when installing operating and servicing the machine 1 2 Product introduction Kempomat 1s a welding machine with integrated welding current supply and wire feeder The power supply converts the mains voltage suitable for welding The wire feedi
13. nd when the switch is released shield gas flow ends Wire inch will be in cycles if timer potentiometer is set on time scale range Q Spot welding procedure Shield gas flow and wire inch start when gun switch is pressed all the way and end when time set by the timer potentiometer ends or when the gun switch 1s released If the timer potentiometer is in 0 range this procedure will not start TIMER potentiometer Welding can be spaced by selecting a time for welding period on timer potentiometer Wire feed and gas flow will be automatically interrupted after set time and automatically restarted KEMPPI OY KEMPOMAT 1701 KEMPOMAT 2100 0531 7 3 7 To select welding parameters Select adjustment step of voltage switch 2 Set adjustment potentiometer of wire inch speed on the same number 3 Test the weld and make necessary adjustments in wire inch If fusion power 1s not suitable for the target set the voltage anew Also adjust wire feed if necessary Repeat until the values suit the target Kempomat 1700 Kempomat 2100 Voltage step Open circuit voltage Voltage step Open circuit voltage l i l 16 9 V 2 17 5 V 2 18 2 V 3 192 V 3 19 6 V 4 21 1 V 4 21 1 V 5 23 6 V 5 22 8 V 6 26 4 V 6 24 6 V 7 30 1 V 7 264 V 8 34 7 V g 28 5 V 9 30 8 V 10 33 1 V 3 8 Thermostat Thermal protection of the unit prevents the power source from over heating Thus the unit will not be damaged even 1f load during weld ing exceeds load f
14. ng mechanism feeds wire from a roll through the welding gun nozzle into the arc A weld is made by moving the welding gun 1 3 Main components gt Housing Door plate Handle Earth cable socket Gun connector Polarity selector Switches and controls Wire feed mechanism Feed roll latch Roll brake control Gas bottle holder yu C SB UH Et EE gy B G j H i E nm _ D A This equipment s electromagnetic compatibility EMC is designed for use in an industrial environment Class equipment is not intended for use in residential location where the electrical power is provided by the public low voltage supply system KEMPPI OY KEMPOMAT 1701 KEMPOMAT 2100 0531 3 Ge 1 4 Switches and controls Main switch and pilot light Overheat control lamp Voltage selector Polarity selector Un A N I Return current dix connector coarser arc only Kempomat 2100 6 II Return current dix connector softer arc 7 Welding method selector 2 way spot or 4 sequence 8 Wire feed rate adjustment potentiometer 9 Timer potentiometer 1 5 Mains connection The machine is supplied with the mains cable installed The cable may be disconnected and the plug installed only by an authorised electrician See under Maintenance The fuse rating and the cable diameter are given in the chapter Technical data in the end of this document 1 6 Locating the machine Use the front panel handles to
15. nt cable or polarity selector cable to the one of the two dix connectors on the front plate The connector marked with symbol I gives a rougher arc which is used for welding of thin sheets and ferrous metals by lower currents Consider especially with CO shielding gas The connector marked with symbol IT is suitable for greater currents and especially for alumin ium and stainless materials The most suitable roughness is however most dependent on the welding case You will find the best position by testing 3 5 Earthing If possible always fix the earth clamp of return current cable directly on the welding target Clean earth clamp touch surface of paint and rust Secure clamp so that the surface it 1s touch ing 1s as large as possible Finally check that clamp sits tightly 3 6 To select welding mode Also see section 1 4 Switches and controls Use the welding mode selecting switch to select how to regulate shield gas flow and wire feed in welding gun switch You have three welding modes to select from c 2T sequence procedure Gas flow and wire inch start when gun switch is pressed and end when the switch is released Wire feed 1s in cycles if timer potentiometer is set on time scale range CT DN i e 4 T sequence procedure d a Gas flow starts when gun switch 1s pressed all the way ox When the switch is released wire inch starts and welding en begins When the gun switch is pressed again wire inch is interrupted a
16. piece by pressing the gun switch Arc forms shield gas starts to flow and wire feed inches welding wire out of the gun nozzle Note It 1s advisable to test welding first on something else than the work piece A Welding fumes are a possible health hazard make certain there is sufficient ventilation during welding 3 11 Storage Store the unit in a clean and dry place Shield it from rain and at temperatures exceeding 25 C from direct exposure to sun There must be sufficient free space in front and back of the unit for air circulation 4 MAINTENANCE OF WELDING UNIT 4 1 Daily maintenance VAN Be careful of mains voltage when handling electric cables Clean wire passage in gun and check contact tip regularly Always check condition of mains and welding cables before use change damaged ones Note Mains cable can be changed only by a qualified electrician Mains cable is changed as follows Kempomat 1701 l Detach back plate of wire reel 2 Connect mains cable to main switch pins with flat clamps 3 Connect green and yellow earth to the body plug marked as earth U1 230V 001 S002 1001 Kempomat 2100 By delivery from the factory the Kempomat machine has been connected for mains voltage3 400V In order to change the mains voltage loosen the right side plate of the machine change the connections according to the enclosed diagram 4 2 Regular maintenance KEMPPI service workshops make service contracts
17. with customers about regular mainte nance All parts are cleaned checked and if necessary repaired Also the operation of welding machine 1s tested KEMPPI OY KEMPOMAT 1701 KEMPOMAT 2100 0531 9 5 DISPOSAL OF THE MACHINE In observance of European Directive 2002 96 EC on Waste Electrical and Electronic Equipment and its implementation in accordance with national law electrical equipment that has reached the end of its life must be collected separately and returned to an environmentally compatible recycling facility As the owner of the equipment you should get information on approved collection systems from our local representative S Do not dispose of electrical equipment together with normal waste By applying this European Directive you will improve the environment and human health 6 ORDERING NUMBERS Part Ordering number Kempomat 1701 1 230 V welding machine 6214171 Kempomat 2100 3 230 400 V welding machine 621421001 Earth cable 16mm 3 m 4260000 MIG welding gun 3 m KMG 20 6251113 MIG welding gun 3 m MT 18 6251013 Hub for wire reel 4289880 10 KEMPOMAT 1701 KEMPOMAT 2100 0531 KEMPPI OY ME 7 TECHNICAL INFORMATION Kempomat 1701 1 230 V Welding machine Rated voltage Mains cable fuse Mains connection Connected load 15 ED 60 ED 100 ED Load capacity 15 ED 60 ED 100 ED Adjustment range Voltage adjustment open circuit voltage max Efficiency Power ratio W
Download Pdf Manuals
Related Search