Kempoweld K400 User Manual - Rapid Welding and Industrial
Contents
1. KEMPPI The Joy of Welding Kempoweld WIRE 400 550 Operating manual English K ytt ohje Suomi Bruksanvisning Svenska Bruksanvisning Norsk Brugsanvisning Dansk Gebrauchsanweisung Deutsch Gebruiksaanwijzing Nederlands Manuel d utilisation Francais VIHCTPYKLIMU NO skcnnyarauM Flo pycckn EN FI SV NO DA DE NL FR RU 8cLL AO ddwy o OSS 00 3HIM PIPMOdway OPERATING MANUAL English Kempoweld WIRE 400 550 Kemppi Oy 1128 EN CONTENTS 1 PREFACE nn 3 TAN en 3 1 2 Product introduction E 3 2 PARTS OF WIRE FEED MECHANISMWIRE 4 3 KMEMROUNELDPANELS sscssssssssesnan 5 3 1 Operation control and conpnectors eene 5 3 2 Parts of cooling unit Kempoweld 4200W and BOU 6 EVENT 7 3 4 Inside wire feeder unt 9 4 ASSEMBLY OF KEMPOWELD EQUIPMENIT 9 5 INSTALLATION seen 11 5 1 Accessories corresponding to wire dameter sess 11 5 2 Mounting of MIG welding oun 11 5 3 Mounting and locking of wire reel sss 12 5 4 Accessory Odrawer nennen ttt tenerent entis 12 5 5 Automatic wire feed rogoun tata patan aa aa anana enonse soon osans 12 5 6 Adjustment of pressure nennen 12 5 7 Adjustment of tightness of reel Drake 13 5 8 Return current cable sesorrrrrrrrrrrrrrvrrsrvevevsvsssererersvrsserererssrsserevererrsrereveversssereveversssssernne 13 SC mm ele E EEE EE 13 510 SPE Be EE 13 5 10 1 te le tee EE EE EEEE 14 6 CONTROL PANELS AND ADI2. 6260354 6260356 626035401 626035601 6260393 6260394 6184511 6184921 19 Kempoweld WIRE 400 550 Kemppi Oy 1128 EN Kempoweld WIRE 400 550 Kemppi Oy 1128 EN 9 20 TECHNICAL DATA Working voltage safety voltage Connection power Loading capacity nominal values Operation principle Diameter of feed roll Wire feed speed Filler wires Wire reel Gun connector Operation temperature range Storage temperature range Degree of protection Dimensions Weight 40 96 ED 60 96 ED 100 96 ED I 9 Fe Ss 9 Filler wire AI max weight max size lenght width height WIRE 400 30 VAC 150 VA 400 260 4 roll drive 32 mm 0 18 m min 0 25 m min 0 6 1 2 mm 0 8 1 6 mm 1 0 1 6 mm 20 kg 9 300 mm Euro 20 40 C 40 60 C IP 23 570mm 210 mm 440 mm 12 kg WIRE 550 30 VAC 150 VA 550 430A 4 roll drive 32mm 0 18m min 0 25 m min 0 6 2 4 mm 1 0 1 6 mm 1 0 1 6 mm 20 kg 9 300 mm Euro 20 40 C 40 60 C IP 23 570mm 210 mm 440 mm 13 kg 8cLL AO ddwy o OSS 00 3HIM PIPMOdway EN 21 KEMPPI 0Y Hennalankatu 39 PL 13 FIN 15801 LAHTI FINLAND Tel 358 3 899 11 Telefax 358 3 899 428 export kemppi com www kemppi com Kotimaan myynti Tel 358 3 899 11 Telefax 358 3 734 8398 myynti fi kemppi com KEMPPI SVERIGE AB Box 717 S 194 27 UPPLANDS VASBY SV
3. orange s 1 0 1 2 d 3133940 re 8 1 2 1 2 L 3137380 orange g1 2 1 2 L 3142210 orange 8 1 4 1 6 2 0 1 6 1 6 L yellow 1 4 1 6 2 0 8 1 6 1 6 L yellow 1 4 1 4 L brown B 1 6 1 6 L yellow 3133820 3141120 3133990 3141130 3142220 3142200 5 2 4 3133880 black 8 3 2 3133910 blue 92 4 3134030 black 83 2 3134060 blue B 2 0 2 0 L 3142230 grey 6 2 4 L 3142240 black W000574 3 KEMPOWELD PANELS 3 1 OPERATION CONTROL AND CONNECTORS S1 S2 53 H1 H2 X1 X2 05 MSD 1 MSD 1 KEMPOWELD Main switch voltage range Voltage selecting switch coarse grading Voltage selecting switch fine grading Pilot lamp for main switch Pilot lamp for overheating power source Return current connector coarser arc Return current connector softer arc Accessory drawer V A metering unit accessory for 4200 and 4200W V A metering unit included in delivery of 5500W Kempoweld WIRE 400 550 O Kemppi Oy 1128 EN Kempoweld WIRE 400 550 Kemppi Oy 1128 EN 3 2 PARTS OF COOLING UNIT KEMPOWELD 4200W AND 5500W Sw1 F2 54 Sw2 Hw4 Hw3 MSD 1 ger KEMPOWELD Main switch of cooling unit Selecting switch for gun s cooling mode Water cooling test switch Pilot lamp for overheating Pilot lamp for lacking water pressure Fuse for cooling unit 2 A delayed 4200W Fuse for cooling unit 4 A delayed 5500W Water circulation return
4. connector Water circulation output connector Filler hole for water tank 3 3 Rear plate of Kempoweld 4200 4200W and 5500W 01 F1 X3 X4 Inlet of mains cable Fuse of auxiliary transformer 8 A delayed Welding current connector for wire feeder unit pole Control connector for wire feeder unit WIRE FEEDER PANELS K1 K2 R2 K3 X1 01 02 Front panel R1 X1 Adjustment for wire feed Welding gun connector EURO Kempoweld WIRE 400 550 O Kemppi Oy 1128 EN Kempoweld WIRE 400 550 Kemppi Oy 1128 EN Accessories KMW timer Accessory for Kempoweld WIRE 400 Included in delivery of Kempoweld WIRE 550 K1 Trigger function mode continuous hold K2 Welding mode selection continuous spot cycle arc R2 Adjustment for welding mode timing spot or cycle time KMW sync Accessory K3 Wire feed adjustment selection panel or push pull gun X1 Control connector for push pull gun Binzel Hulftegger Cooling unit connections 01 Return water connector for gun 02 Feed water connector for gun 04 Inlet of water hoses Rear panel 03 Shielding gas connector X2 Control cable connector Kempoweld or interconnection cable X3 Welding current connection Kempoweld or interconnection cable 3 4 INSIDE WIRE FEEDER UNIT K4 Wire inch switch wire feed into gun R3 Burn back time adjustment according to filler material and wire feed 04 Locking device for wire reel 05 Box door lat
5. dangerous objects KMW TIMER FUNCTIONS 2 4 sequence procedure g The welding with the 2 sequence procedure 1 Switch pressed welding starts 2 Switch open welding stops The welding with the 4 sequence procedure Switch pressed shielding gas is flowing Switch open welding starts Switch pressed welding stops Switch open gas flow stops after the burn back time kN 15 Kempoweld WIRE 400 550 Kemppi Oy 1128 EN Kempoweld WIRE 400 550 Kemppi Oy 1128 EN 6 4 16 Spot cycle arc and continuous welding is operating only in the 2 seguence procedure position Spot welding 1 Set the spot time with the potentiometer R2 2 The gun switch pressed welding starts 3 Welding ends automatically after the set time Cycle arc welding m m 1 Set the welding cycle time with the potentiometer R2 The pause time is adjusted automatically 2 Thegun switch cycle welding is continued for so long as the switch is pressed KMW SYNC The push pull gun is most often used for feed of thin aluminium wires when over 5 m reach is required You can connect the gun equipped with the EURO adaptor to the KMW sync unit The push pull gun s potentiometer is connected to amphenol connector mounted onto front wall of the wire feeder You can connect to this connector also some other potentiometer which has suitable values for it With the unit s switch you can select the normal operation or
6. g chafe against chassis or door of wire feeder unit Dragging parts might expose chassis of wire feeder unit under voltage ACCESSORY DRAWER In the accessory drawer in the cover part of the power source there are in delivery Teflon guide tubes needed for welding of aluminium and stainless wires In the drawer are there also screw and insulation bushings designed for locking of rotation of the wire feeder unit as well as big gear wheel D40 AUTOMATIC WIRE FEED TO GUN Automatic wire feed in wire feeder unit makes change of wire reel more rapid In reel change the pressure of feed rolls need not released and filler wire goes automatically to correct wire line Make sure that groove of feed roll match the diameter of welding wire used Feed roll groove is selected by moving the groove selecting washer 28 Also the selector plate for changing the feed roll groove has to be moved similarly see table on page 4 Release the wire end from reel and cut off the bent length Be careful that the wire does not spill from the reel to sides Straighten about 20 cm of the wire and see that the end of it has no sharp edges file off if necessary A sharp edge may damage the wire guide tube and contact tip of the welding gun Draw a bit of loose wire from wire reel Feed wire through back liner to feed rolls Don t release pressure of feed rolls Press the gun switch and feed a bit wire until wire goes through feed rolls to gun See that wire is i
7. 53213MMT MMT 32 45m 6253214MMT MMT 35 3m 6253513MMT MMT 35 45m 6253514MMT WS 35 Al 1 2 6m 6253516A12 WS 35 SS 1 0 6m 6253516510 MMT 42 3m 6254213MMT MMT 42 45m 6254214MMT KMP 300 6m 6257306 KMP 300 10m 6257310 18 Liquid cooled MMT 30W MMT 30W MMI 42W MMI 42W MMI 52W MMI 52W MT 51W MT 51W KMP 400W KMP 400W WS 30W Al 1 2 1 6 WS 30W SS 1 0 WS 30W SS 1 2 WS 30W Al 1 2 1 6 WS 30W SS 1 0 WS 30W SS 1 2 WS 42W Al 1 2 1 6 WS 42W SS 1 0 WS 42W SS 1 2 WS 42W Al 1 2 1 6 WS 42W SS 1 0 WS 42W SS 1 2 Air cooled interconnection cables Mounting cables for short distance KW 50 1 3 K Interconnection cables for long distance Multimig 50 5 K Multimig 50 10 K Multimig 50 5 KH Multimig 50 10 KH Liquid cooled interconnection cables Mounting cables for short distance KW 50 1 5 W KW 95 1 5 W Interconnection cables for long distance KW 50 5 W KW 50 10 W KW 50 5 WH KW 50 10 WH KW 95 5 WH KW 95 10 WH Return current cable 5m 50 mm part 7 5 m 95 mm part 7 3 m 45m 3m 45m 3m 45m 3m 45m 6m 10m 6m 6m 6m 8m 8m 8m 6m 6m 6m 8m 8m 8m 6253043MMT 6253044MMT 6254203MMT 6254204MMT 6255203MMT 6255204MMT 6255046 6255047 6257406 6257410 6253046A12 6253046510 6253046512 6253048412 6253048510 6253048512 6254206A12 6254206510 6254206512 6254208412 6254208510 6254208512 6260350 6260104 6260106 626010401 626010601 6260352 6260391
8. ERIGE Tel 46 8 590 783 00 Telefax 46 8 590 823 94 sales se kemppi com KEMPPI NORGE A S Postboks 2151 Postterminalen N 3103 TONSBERG NORGE Tel 47 33 346000 Telefax 47 33 346010 sales no kemppi com KEMPPI DANMARK A S Literbuen 11 DK 2740 SKOVLUNDE DANMARK Tel 45 4494 1677 Telefax 45 4494 1536 sales dkakemppi com KEMPPI BENELUX B V Postbus 5603 NL 4801 EA BREDA NEDERLAND Tel 31 765717750 Telefax 31 765716345 sales nl kemppi com www kemppi com KEMPPI UK Ltd Martti Kemppi Building Fraser Road Priory Business Park BEDFORD MK44 3WH UNITED KINGDOM Tel 44 0 845 6444201 Telefax 44 0 845 6444202 sales ukakemppi com KEMPPI FRANCE S A S 65 Avenue de la Couronne des Pr s 78681 EPONE CEDEX FRANCE Tel 33 1 30 90 04 40 Telefax 33 1 30 90 04 45 sales frakemppi com KEMPPI GmbH Otto Hahn StraBe 14 D 35510 BUTZBACH DEUTSCHLAND Tel 49 6033 88 020 Telefax 49 6033 72 528 sales de kemppi com KEMPPI SPOLKA Z 0 0 Ul Borzymowska 32 03 565 WARSZAWA POLAND Tel 48 22 7816162 Telefax 48 22 7816505 info pl kemppi com KEMPPI AUSTRALIA PTY LTD 13 Cullen Place P O Box 5256 Greystanes NSW 2145 SMITHFIELD NSW 2164 AUSTRALIA Tel 61 2 9605 9500 Telefax 61 2 9605 5999 info au kemppi com 000 KEMPPI Polkovaya str 1 Building 6 127018 MOSCOW RUSSIA Tel 7 495 739 4304 Telefax 7 495 739 4305 info ru kemppi com 000 KEMNMN yn NonkoBaa 1 crpoenue 6 127018 MockBa T
9. USTMENTS oo 15 6 1 Wire feed speed potentiometer HILL 15 02 Burn Daci ANN E 15 gt UTNE hr 15 OA GE EEE EE 16 7 OPERATION DISTURRBANCES ee 17 7 1 Regular maintenance of eouipment sess 17 7 1 1 Disposaloftbhemachine cee cescesccscesceseceecesecsecsecescseecssessssseesesuesesseeeenees 18 8 ORDERING NUMBERS sess 18 9 TECHNICAL DATA senten 20 1 1 1 2 PREFACE GENERAL Congratulations on choosing the Kempoweld WIRE equipment Used correctly Kemppi products can significantly increase the productivity of your welding and provide years of economical service This operating manual contains important information on the use maintenance and safety of your Kemppi product The technical specifications of the equipment can be found at the end of the manual Please read the manual carefully before using the equipment for the first time For your own safety and that of your working environment pay particular attention to the safety instructions in the manual For more information on Kemppi products contact Kemppi Oy consult an authorised Kemppi dealer or visit the Kemppi web site at www kemppi com The specifications presented in this manual are subject to change without prior notice Important notes Items in the manual that require particular attention in order to minimise damage and personal harm are indicated with the NOTE notation Read these sections carefully and follow their instructions Disclaimer While every effor
10. ch 06 Box door lock 07 Wire feed mechanism ASSEMBLY OF KEMPOWELD EOUIPMENT Kempoweld power source Read the paragraph INSTALLATION in the operation instructions for the power source Wire feeder 1 Mountthe wire feeder unit into pin on the power source s cover When necessary you can lock the wire feeder to the support piece on the power source s cover 2 Mount the control cable and welding current cable to connectors on the rear walls and the return current cable to the connector on Kempoweld s front panel 3 Welding current polarity By the connection made according to markings the gun has positive voltage In order to change the polarity interchange the welding and return current cable ends connected to the power source with each other 4 Ifthe MIG gun is water cooled mount the water hoses to the wire feeder unit 5 Mountthe interconnection cable to the same connections NOTE The hoses of the water cooled interconnection cable go also through the wire feeder unit 6 Thewire feeder must be mounted to boom without galvanic contact to lift hook and boom See the paragraph ACCESSORIES 7 TheMIG gun is mounted to the EURO connector Use guide tubes and contact tips according to manufacturer s operation instructions Accessories which are too narrow or otherwise unsuitable for the wire type used by you will cause disturbances and excessive wear for accessories Kempoweld WIRE 400 550 O Kemppi Oy 1128 EN Kem
11. ear wall of the wire feeder Mountings to the gas bottle and the shielding gas flow adjustment see the paragraph Shielding gas KMW sync see the paragraph ACCESSORIES 9 1 5 2 INSTALLATION ACCESSORIES CORRESPONDING TO WIRE DIAMETER The wire feed rolls are available with plain groove knurled groove and with trapezoidal groove for different purposes All rolls and accessories in tables fits both WIRE 400 and WIRE 550 wire feeders Feed rolls colour filler wire mm inch white 0 6 and 0 8 0 030 red 0 9 1 0 and 1 2 0 035 0 045 and 0 052 orange 1 2 0 052 brown 1 4 vellow 1 4 1 6 and 2 0 1 16 and 5 64 grey 2 0 5 64 black 2 4 3 32 Guide tubes colour filler wire mm inch orange 0 6 1 6 0 024 1 16 blue over 1 6 over 1 16 Feed rolls with plain groove 1 Universal feed roll for welding of all kinds of wires 2 Special feed rolls for heavy duty use Feed rolls with knurled groove Special feed roll for cored wires and steel wires Feed rolls with trapezoidal groove Special feed roll for aluminium wires The wire feed rolls have two grooves for different filler wire diameters Correct wire groove is selected by moving selecting washer 28 from one side to another in feed roll Feed rolls and wire guide tubes of wire feeder unit have colour codes in order to make identification easier see table on page 4 In delivery the Kempoweld WIRE 400 is equipped with red feed rolls with plain gro
12. el 7 495 739 4304 Telefax 7 495 739 4305 info ru kemppi com KEMPPI TRADING BEIJING COMPANY LIMITED Room 420 3 Zone Building B No 12 Hongda North Street Beijing Economic Development Zone 100176 Beijing CHINA Tel 86 10 6787 6064 86 10 6787 1282 Telefax 86 10 6787 5259 sales cn kemppi com BAD db APRA al HE dE RAAF AR EIER Dier A EBA KX 420 100176 Eig 86 10 6787 6064 86 10 6787 1282 ES 86 10 6787 5259 sales cn kemppi com KEMPPI INDIA PVT LTD LAKSHMI TOWERS New No 2 770 First Main Road KAZURA Gardens Neelangarai CHENNAI 600 041 TAMIL NADU Tel 91 44 4567 1200 Telefax 91 44 4567 1234 sales india kemppi com 8cll OvOCCOL
13. essure meter AnmopnN PW The following installing instructions are valid for most of the gas flow regulator types 1 Step aside and open the bottle valve A for a while to blow out possible impurities from the bottle valve Turn the press regulation screw B of the regulator until no spring pressure can be felt Close needle valve if there is one in the regulator Install the regulator on bottle valve and tighten connecting nut C with a wrench Install hose spindle D and jacket nut E into gas hose and tighten with hose clamp Connect the hose with the regulator and the other end with the wire feed unit Tighten the jacket nut 7 Open bottle valve slowly Gas bottle pressure meter F shows the bottle pressure NOTE Do not use the whole contents of the bottle The bottle should be filled when the bottle pressure is 2 bar oe ues que a 8 Open needle valve if there is one in the regulator 9 Turn regulation screw B until hose pressure meter G shows the required flow or pressure When regulating flow amount the power source should be in switched on and the gun switch pressed simultaniously Close bottle valve after having finished welding If the machine will be out of use for a long time unscrew the pressure regulation screw 6 1 6 2 6 3 CONTROL PANELS AND ADJUSTMENTS WIRE FEED SPEED POTENTIOMETER R1 The wire feed speed is adjusted steplessly with the potentiometer on the front panel see the parag
14. g surface from paint and rust Use in your Kempoweld equipment copper cables Too small cross sectional area might cause overheating of connectors and insulations Make sure that the welding gun in your use is designed for max welding current needed by you Never use a damaged welding gun COOLING UNIT The cooling unit is built in the power source All settings and operations needed for cooling are incorporated in the power source Read in the operation instructions the paragraph COOLING UNIT SHIELD GAS NOTE Handle gas bottle with care There is a risk for injury if gas bottle or bottle valve is damaged For welding stainless steels mixed gases are normally used Check that the gas bottle valve is suitable for the gas The flow rate is set according to the welding power used in the job A suitable flow rate is normally 8 10 l min If the gas flow is not suitable the welded joint will be sporous Contact your local Kemppi dealer for choosing gas and equipment 13 Kempoweld WIRE 400 550 O Kemppi Oy 1128 EN Kempoweld WIRE 400 550 Kemppi Oy 1128 EN 5 10 1 Installing gas bottle 14 NOTE Always fasten gas bottle properly in vertical position in a special holder on the wall or on a carriage Remember to close gas bottle valve after having finished welding Parts of gas flow regulator Gas bottle valve Press regulation screw Connecting nut Hose spindle Jacket nut Gas bottle pressure meter Gas hose pr
15. n grooves of both feed roll pairs Press still the gun switch until wire has come through contact tip Automatic feed may sometimes fail with thin wires Fe Fc Ss 0 6 0 8 mm Al 0 8 1 0 mm Then it might be possible that you must open feed rolls and feed wire manually through feed rolls 5 6 5 7 5 8 5 9 5 10 ADJUSTMENT OF PRESSURE Adjust the pressure of feed rolls with the control screw 20 so that the wire is fed into the wire guide tube evenly and allows a little braking when coming out from the contact tip without slipping at the feed rolls NOTE Excessive pressure causes flattening of the filler wire and damage to the coating It also causes undue wear of the feed rolls as well as friction ADJUSTMENT OF TIGHTNESS OF REEL BRAKE d o H A Ce XX NNNNNNP Va aas Brake force is adjusted through hole in locking device of reel hub by screwing the control screw 41 with screwdriver Adjust brake force as so big that the wire is not allowed to become too loose on the reel so that it would spill from the reel when the rotation of the reel stops Need for brake force is increased with increase of wire feed speed Since the brake loads for its part the motor you shouldn t keep it unnecessarily tight RETURN CURRENT CABLE Fasten earthing press of return current cable carefully preferably direct to welding piece Contact surface of press always should be as large as possible Clean the fastenin
16. nt of use and the working environment should be taken into consideration when planning the freguency of maintenance of the wire feeder unit Careful use and preventive maintenance will help to ensure trouble free operation The following maintenance operations should be carried out at least every six months Check e The wear of the grooves of the feed rolls Excessive wear of grooves causes problems in wire feed e The wear of the wire guide tubes of the wire feeder unit Badly worn feed rolls and wire guide tubes should be discarded The wire guide tube in the gun should be set as near the feed rolls as possible but not touching them and the wire must follow a straight line from the end of the tube to the groove of the feed roll e Reel brake adjustment e Electric connections e Oxidezed couplings must be cleaned e Loose couplings must be tightened Clean dust and dirt from the equipment In case of problems contact your Kemppi dealer NOTE When using compressed air always protect your eyes with proper eye protection REGULAR MAINTENANCE OF EQUIPMENT Kemppi service repair shops make regular maintenance according to agreement The major points in the maintenance procedure are listed as follows e Cleaning of the equipment e Checking and maintenance of the welding tools e Checking of connectors switches and potentiometers e Checking of electric connections e Metering units checking Checking of mains cable and plug e Damaged part
17. ove and with orange wire guide tubes for welding filler wires of 0 9 1 2 mm 0 035 0 045 and 0 052 Kempoweld WIRE 550 is equipped with ball beared orange feed rolls with plain groove and with orange wire guide tubes for welding filler wire of 1 2 mm 0 052 MOUNTING OF MIG WELDING GUN In order to ensure trouble free welding check in operation instructions of gun used by you that wire guide tube and contact tip of gun are according to manufacturer s recommendation suitable to be used for wire feed diameter and type in question Too tight a wire guide tube might cause for wire feeder unit a bigger stress than normally as well as disturbances in wire feed Screw snap connector of gun tight that there won t come any voltage losses on connecting surface Loose connection will heat gun and wire feeder unit When you are using liquid cooled gun mount water hoses according to ASSEMBLY OF KEMPOWELD EQUIPMENT 11 Kempoweld WIRE 400 550 O Kemppi Oy 1128 EN Kempoweld WIRE 400 550 Kemppi Oy 1128 EN 5 3 5 4 5 5 12 MOUNTING AND LOCKING OF WIRE REEL O ke LOCKED OPEN Release locking nails of wire reel hub by turning locking knob a quarter round e Mount the reel at its place Note rotating direction of reel e Lock the reel with locking knob locking nails of hub remain to outside position and will lock the reel NOTE Check that in filler wire reel are no parts sticking out which could e
18. poweld WIRE 400 550 Kemppi Oy 1128 EN 10 9 GO x L Lift hook DIX connector Push pull Amphenol connectors Sons tors Push pull connectors Locking DIX connector Bearing bushing 8 Max wire feed speed When the unit is delivered the max wire feed speed is 18 m min which is enough for most welding jobs If you need a higher speed you can increase the max wire feed speed to 25 m min by replacing the gear wheel on motor shaft to a bigger one The big gear wheel D40 is delivered in accessory drawer of the power source 21 23 24 21 22 25 22 When necessary speed is changed according to following Open tightening lever 20 Remove lower feed rolls 21 Release screw 23 and its washer Remove gear wheel D28 24 from motor shaft Loosen screws 25 3 pc 1 twist Mount the D40 gear wheel onto motor shaft Screw the screw 23 with its washer back Put feed rolls 21 back to their axles however don t fasten yet fastening screws of feed rolls 22 Lift the motor so that the tooth gap between gear wheel and both lower feed rolls is approx 0 2 mm Tighten screws 25 Check gear teeth gaps when necessary put the motor into a better position Screw on the mounting screws of feed rolls 22 NOTE Too small gap between gear wheel and feed rolls will overload motor Too big gap for its part might cause too rapid wearing for teeth of feed rolls and gear wheel 9 The shielding gas hose is mounted to the r
19. raph PANELS The potentiometer has the memory scale for max speeds of 18 m min and 25 m min BURN BACK TIME Different filler materials and shielding gases behave in different ways in the welding end so that you should switch off the welding current with a delay which is suitable for wire feed stopping according to the welding case If you try to end welding with an unsuitable burn back time the wire will burn in the contact tip there will be too big drop at the wire end or the wire will stick at the ending point BURN BACK WIRE INCH Factors influencing on the delay 1 Melting of aluminium is much quicker than by the other material so that the burn back time is clearly shorter 2 Steel and especially filler wires require longer time than the stainless materials 3 Thicker filler wires require longer time Also by increase of wire feed speed the required time should be longer In the instructions label are given points for starting with different materials The fine adjustment should be carried out according to each case in question 4 Memory scale for potentiometer Wire inch 5 The wire inch starts the wire feed motor and mechanism but not the power source The filler wire can be driven to the feeder unit gun and interconnection cable also with the welding gun s switch but then also the power source will get started and the wire becomes live gets voltage and this can cause a danger situation by accidental contact to
20. s or parts in bad connection are replaced by new ones e Maintenance testing Operation and performance values of the equipment are checked and adjusted when necessary by means of test equipment 17 Kempoweld WIRE 400 550 Kemppi Oy 1128 EN Kempoweld WIRE 400 550 Kemppi Oy 1128 7 1 1 DISPOSAL OF THE MACHINE H Do not dispose of electrical equipment with normal waste 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 taken to an appropriate environmentally responsible recycling facility The owner of the equipment is obliged to deliver a decommissioned unit to a regional collection centre per the instructions of local authorities or a Kemppi representative By applying this European Directive you will improve the environment and human health 8 ORDERING NUMBERS Wire feeder units Kempoweld WIRE 400 621740001 Kempoweld WIRE 550 621755001 Units Kempoweld 3200 230 400 V 621532002 Kempoweld 3200W 230 400 V 621632002 Kempoweld 4200 230V 6215422 Kempoweld 4200 400 V 6215424 Kempoweld 4200W 230V 6216422 Kempoweld 4200W 400V 6216424 Kempoweld 5500W 400V 6216554 Accessories KMW timer 6219200 KMW sync 2 6219150 MSD 1 6185666 Hub for wheel reel 4289880 Branche cable KMP Kempoweld 3151360 MIG guns Air cooled MMT 32 3m 62
21. t has been made to ensure that the information contained in this guide is accurate and complete no liability can be accepted for any errors or omissions Kemppi reserves the right to change the specification of the product described at any time without prior notice Do not copy record reproduce or transmit the contents of this guide without prior permission from Kemppi PRODUCT INTRODUCTION Kempoweld WIRE 400 and WIRE 550 wire feeders belong to the KEMPOWELD product range designed for demanding professional use both with water cooled or air cooled MIG guns Synchronization unit KMW sync for push pull guns can be easily mounted to the wire feeder unit Units have 4 roll drive You can also equip the Kempoweld power source and the wire feeder unit with air or water cooled interconnection cable You can hang the wire feeder unit onto boom with a specially designed lift hook Kempoweld WIRE 400 550 O Kemppi Oy 1128 EN Kempoweld WIRE 400 550 Kemppi Oy 1128 EN 2 Fe Fc Ss Al PARTS OF WIRE FEED MECHANISM WIRE WIRE 400 and WIRE 550 4 roll wire feed mechanism Wire guide tubes 0 6 0 8 mm 1 0mm 3134140 Sege white 2 0mm 3133700 g 0 9 1 6 mm orange 91 6 2 4mm 0 mm 3134130 blue 8 2 5mm 3134290 g 0 8 1 6 mm eler g1 6 2 4A mm P 3 0 mm 3134710 dudit yellow lul A pressure adjustment 82 0mm 3134120 orange 4 0mm 3134110 blue 8 2 5 mm 3134300 sil
22. the push pull gun operation For right connections in the gun contact your KEMPPI dealer Installation and mounting In the KMW sync accessories are included the electronics card switch protective cap of switch insulation bushings fastening screws and cable set 1 Remove the side plate 2 Fastenthe electronics card with screws and insulation bushings to fastening holes of the wire feeder uni s intermediate wall 3 Remove protection knob from cover plate by side of gun adapter on front wall of feeder and its underside cover plate totally 4 Mount the amphenol connector to lower fastening place and the switch to hole which has left on the upper cover plate 5 Connect the connector for wiring from the card to the control card A001 to connector KMW sync from which you have first removed the jumper piece 6 Mount the push pull gun to the feeder adaptor In order to verify the operation you can use even an ordinary welding gun 7 Connect the push pull gun s connector or a potentiometer which has been connected on a corresponding way to the amphenol mounted to the feeder 8 Test with the switch that the enclosed control is changed according to the enclosed operation description 9 Fasten the side plate back at its place Hanging onto the boom The lift hook is fastened to the handle on the cover of the feeder The wire feeder unit s position depends on the hole position 7 1 OPERATION DISTURBANCES The amou
23. ver 3 0mm 3134720 vellow 5 m Vetoratas drivhjul trekktannhjul drivhjul gearwheel Aufziehrad aandrijfrol galet d entrainement 8 28 mm 0 18 m min 4265240 40 mm 0 25 m min 4265250 Muovi plast plast plastic plastic Kunststoff plastic plastique 8 28 mm 0 18 m min 4287860 s 40 mm 0 25 m min 4297270 Ter s st l st l st l steel Stahl staal acier Fe Ss M Feed rolls Plain Knurled Ed Trapezoid T L Ball race 0 6 0 8 6 0 8 0 8 L white 3133810 3143180 1 0 1 2 5 2 0 mm plastic 5 2 0 mm plastic 4 0 mm plastic g 4 0 mm brass 5 2 0 mm plastic s 4 0 mm plastic 4267220 4266970 4270180 4267030 4267220 4210180 TN g2 4mm 4268210 yellow Promig 511 8 3 0mm 4268560 vellow pee Sy tt py ran uran valinta val av matarhjulspar valg av matehjul spor valg af spor i tradhjul selection of feed wheel groove Auswahl der Transportrollennut selectie van de draaddiameter groef s lection de la gorge du galet Ou 4292030 Vetorattaan valintalevyn siirto flyttning av distansbricka flytting av avstandsskive for matehjul hvordan flytter man justerskiven relocation of selection plate Versetzen der Wahlschalterplatte verplaatsing van selectie plaat remise en place de la rondelle de s lection 3133210 1 0 1 0 L 3138650 red 8 1 2 1 2 L 3137390
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