Kempact RA User Manual - Rapid Welding and Industrial Supplies Ltd
Contents
1. Neck 4153040 45 Wire liner 4188573 0 60 8 mm W006453 0 9 1 2 mm W006457 eum 0 8 1 0 mm Al Ss W006459 eo 10 16mm Mss 4188576 0 6 0 8 mm W006454 TTO 0 9 1 2 mm W006458 cc 0 8 1 0 mm Al Ss W006460 ex 1 0 1 6 mm Al Ss Kempact 251R 253R 323R 181A 251A 253A 323A FE 25 6602503 3 5 m 6602504 5 0 m C Gas nozzle Ax Bx C Insulating bush Contact tip M6 Contact tip adapter M6 Insulating ring Locking spring Neck Wire liner Kemppi Oy 1135 9580101 958010101 4113470 9580101E 9591010 9876634 9876635 9876633 9876636 9876637 9580173 9591079 4275240 4153040 4188573 W006453 W006457 W006459 4188576 W006454 W006458 W006460 60 5 x 18 x 14 mm standard 60 5 x 18x 14 mm with insulating bush 9580101 9591079 60 5 x 18x 14 mm for spot welding 60 5 x 20 x 14 mm thick wall 00 6 mm 0 8 mm 0 9 mm 1 0mm 1 2mm 45 Gm 0 0 6 0 8 mm 0 9 1 2 mm gt 0 8 1 0mm Al Ss eo 1 0 1 6 mm Al Ss 0 6 0 8 mm CEO 0 9 1 2 mm 0 8 1 0 mm Al Ss 1 0 1 6 mm Al Ss 3 5m 3 5m L 35m 5 5m sm a sm a EN 29 EN 30 FE 27 6602703 3 5 m 6602704 5 0 m FE 32 6603203 3 5 m 6603204 5 0 m L sa Gas nozzle 4295760 Ax Bx 4295760L A 4295760C 4294970 B Contact tip 9876634 M6 9876635 9876633 9876636 9876637 9876639 M8 9580122 9580121 9580123 9580124 9580125 9580126 95801237R 95801247R2. ii 17 Using control panels 18 Regular control 18 Adaptive control panel i 20 Parameter GUNG SS vesenet 24 MIG MAG welding cesses eere 24 26 Maintenance oce eps eee eee 97 27 Gun spare balls 28 33 StOFAG Ip O OR E R 34 Disposal 34 Error CORSA 34 Ordering codes rni te o epi S HEP HERE PUNIRE RESO 35 Technical data 36 Kempact 251R 253R 323R 181A 251A 253A 323A 1 1 1 2 1 2 1 INTRODUCTION General Congratulations on choosing Kempact RA welding 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 For Kemppi s standard safety instructions and warranty terms and conditions please visit our web site at www kemppi com The specificatio
3. First present the welding gun nozzle to a practice work piece The gun nozzle should be approximately 15 mm away from the surface of the work piece and weld joint If welding a T fillet joint the gun should be held at an angle of approximately 45 degrees bisecting the 90 degree joint at the midway point Starting at the right hand side of the joint right handed operators only lean the gun backwards slightly so the gun nozzle is pointing forwards towards the centre of the work piece This is called a pushing technique and is suitable for most applications Pull the welding gun trigger The filler wire will move forward and a short circuit will occur and the arc will be established Keeping the gun trigger depressed the molten weld pool will start to form Begin to travel the gun forwards in a controlled manner and travel speed Providing you have correctly set your equipment the quality of your weld deposit is now determined by your skill and technique The resulting weld deposit width and shape should be consistent in appearance and quality If you are welding too fast the weld bead may be too thin or even intermittent in appearance Try to slow your travel speed slightly and maintain an even approach to the joint If you are welding too slowly you may find the weld deposit is too heavy the weld piece overheats and possibly burns a hole through the plate All that may be required to ensure a successful result here is an increase in for
4. to ensure by consultation with the distribution network operator if necessary that the equipment is connected only to a supply with a short circuit power Ssc greater than or equal to 1 1 MVA EN EN 2 4 3 1 Kempact 323 MVU This equipment complies with IEC 61000 3 12 provided that the short circuit power Ssc is greater than or equal to 1 5 MVA at the interface point between the user s supply and the public supply network It is the responsibility of the installer or user of the equipment to ensure by consultation with the distribution network operator if necessary that the equipment is connected only to a supply with a short circuit power Ssc greater than or equal to 1 5 MVA Serial number The serial number of the unit is marked on the rating plate The serial number makes it possible to trace product manufacturing series You might need the serial number when placing spare parts orders or when planning maintenance MACHINE INTRODUCTION General view of the machine Supply voltage cable Main switch Shielding gas hose connector Welding gun and cable Earth return clamp and cable pm WY 3 2 Cable connections Connection to the mains Kempact RA models are available in either 1 phase 230 V 3 phase 400 V or multi voltage units Machines supplied with a mains power cable are not equipped with a plug so you must select and fit a suitable mains plug before you use the machine for the first time Check
5. 6787 1282 EE 86 10 6787 5259 sales cn kemppi com KEMPPI INDIA PVT LTD LAKSHMI TOWERS New No 2 770 First Main Road Kazura Garden Neelankarai CHENNAI 600 041 TAMIL NADU Tel 91 44 4567 1200 Telefax 91 44 4567 1234 sales india kemppi com SELL 060666 KEMPPI The Joy of Welding
6. 95801257R 9580123AG 9580124AG Contact tip 4294890 adapter 4295740 Gas diffuser 4294880 4294880CER Neck 3146780 Wire liner 4188573 W006453 W006455 W006457 W006459 4188576 W006454 W006456 W006458 W006460 M6 M8 76x20x 14 mm standard M8 79 x 20x 14 mm long M8 76x20x 12 mm conical M8 70x20x 14 mm standard M6 0 6 mm 0 8 mm 0 9 mm 1 0mm 1 2mm 1 6mm 0 8 mm 9580122A 0 9 9580121A 1 0 9580123A 1 2 9580124A 1 4 9580125A 1 6 9580126A 1 0 CuCr1Zr 958012255 12 CuCr1Zr 958012155 14 CuCr1zr 958012355 1 0 CuAg 958012455 12 CuAg 958012655 M6 M8 50 wo 6 0 6 0 8 mm Cm 0 9 1 2 mm KO 1 4 1 6 mm ew 08 10mm Al Ss eo 10 16mm Al Ss ao 0 6 0 8m m TUO 0 9 1 2mm 0 1 4 1 6 mm eo 0 8 1 0mm Al Ss eo 310 1 6mm Al Ss Kempact 251R 253R 323R 181A 251A 253A 323A 0 8 mm 0 9 1 0 12 1 4 1 6 0 8 0 9 1 0 1 2 1 6 3 5m 3 5m 3 5m 3 5m 3 5m 5m 5m 5m 5m 5m SP004585 FE 35 6603503 3 5 m 6603504 5 0 m C SP600317 Gas nozzle 4300260 AxBxQ 4300260L 4300260C 4307050 Insulating bush 4307020 Contact tip M8 9580122 9580121 9580123 9580124 9580125 9580126 95801237R 95801247R 95801257R 9580123AG 9580124AG Contact tip 4295740 adapter Gas diffuser W004390 Insulator W004165 Neck SP004585 SP600317 Wire liner 4188573 W006453 W006455 W006457 W006459 4188576 W006454 W006456 W006458 W006460 77x22x 16 mm s
7. DO cll Qi o AF O O P O Wire feed rolls NOTE Orange part code colour denotes standard delivery specification GT 02 and DuraTorque mm driving pressing Fe Ss Al V groove 0 6 W001045 W001046 0 8 0 9 W001047 W001048 GT 02 1 0 T W000675 W000676 DuraTorque 1 2 El W000960 W000961 Fe FC MG knurled V groove 1 0 a W001057 W001058 1 2 W001059 W001060 Fe FC MC Ss AL U groove 1 0 E W001067 W001068 1 2 m W001069 W001070 For aluminium filler wires select the correct feed roll type from the chart supplied and adjust for the minimum pressure necessary for reliable filler wire drive without deformation of the wire itself For flux cored filler wires select a knurled feed roll to achieve better wire grip NOTE Slight slippage is recommended in the case of aluminium filler wires This ensures that the soft wire is not deformed and flattened and that the feed rolls skid over the soft wire if it stops when passing through the gun liner or contact tip For aluminium and stainless steel filler wires always use Kemppi DL Teflon gun liners These liners are especially developed by Kemppi and significantly reduce friction losses so improving welding performance and quality EN 15 EN 16 4 8 Changing the feed rolls Kempact RA machines are factory fitted with wire feed rolls as part of the delivery packages Howev
8. correctly adjusted e Check gun liner is not blocked Replace if necessary Check correct gun liner is fitted for the filler wire size and type e Check contact tip for size type and wear e Check gun is not over heating for the application e Check cable connections and earth return clamp Check welding parameter settings Filler wire won t feed e Check wire feed mechanism Adjust as necessary e Check welding gun switch function Check euro gun connector is correctly fitted Check gun liner is not blocked e Check contact tip size type wear Check filler wire diameter for correct size High spatter volume Check welding parameter values Check inductance dynamics values e Check gas type and flow Check welding polarity and cable connections Check filler material selection Check filler wire delivery system Check power supply Are all electrical phases present Check that operator maintains correct technique arc length travel speed gun angle NOTE Many of these checks may be carried out by the operator However certain checks relating to mains power must be completed by an authorised trained electrician EN 33 EN 34 7 4 7 5 Storage Store the unit in a clean and dry place Shield it from rain and in temperatures exceeding 25 C from direct exposure to sun Disposal of the machine Do not dispose of electrical equipment with normal waste In observance of European Directi
9. minor arc voltage adjustment for fine tuning the welding arc 4 Timer button for spot welding and cycle arc welding z CYCLE FE The spot and cycle arc timer offers two modes of function By pressing and selecting the SPOT timer you regulate the time duration for one single SPOT welding cycle from either 0 1 to 9 9 seconds of arc time By selecting the CYCLE arc timer you regulate the machine to a repeating cycle of arc time and pause time The pause time offered is 0 1 to 3 seconds Select function by depressing button 4 Regulation and adjustment of SPOT and CYCLE arc values are adjusted by the voltage control item 3 Function selection is confirmed by either one dot SPOT TIME or dash line CYCLE TIME under the word Timer in the display 5 Selection of 2T 4T gun operating mode 2T 4T This button offers you two modes of welding gun functions The selected mode is indicated as either 2T or 4T in the display In 2T mode the welding arc is started by a single press and hold of the welding gun trigger Welding continues whilst the trigger is held and stops when the trigger is released In 4T mode the gun trigger is pressed and gas starts to flow When the trigger is released the arc ignites Welding continues unti the trigger is pulled and released for a second time This mode is useful for long welding durations EN 21 EN 22 6 Selection for MANUAL AUTOMATIC or HOT SPOT function Pa eran n Thi
10. needs routine maintenance or the friction plates in the spool brake need adjustment or maintenance the Spanner service symbol will illuminate indicating that maintenance is required Welding is not prevented when the WireLine service symbol is active Adaptive control panel iL d2 13 m 5 6 gt TERI WIRE cas CRATER nae 27147 MODE A 15 ua LAT rost cas J HOT SPOT m e EXER Dn Art SR N ss 2 BBAUTOMATIC 7 8 9 tt XV 9 16 Wi LILI s 10 1 2 3 Models featuring the adaptive A control panel offer the following control functions Dynamics control Control knob for wire feed speed or power adaptive mode Control knob for voltage or arc length adaptive mode Timer button for spot welding and cycle arc welding Selection of 2T 4T gun operating mode Selection for MANUAL AUTOMATIC or HOT SPOT function Parameter display Overheating indicator 9 WireLine service indicator 10 Post gas symbol 11 Selection for materials type or display of amperes wire feed speed adaptive mode 12 Selection for filler wire diameter adaptive mode 13 Selection for shielding gas or post gas function adaptive mode 14 Selection of crater fill function adaptive mode 15 Selection for memory function 16 Material thickness and weld shape display ODE e UNS 1 Dynamics control Dynamics function controls the rate of rise of current when the filler wir
11. working environment frequently carries airborne metallic dust particles due to fabrication practices it is recommended that you install a filter casette to the machine Particle filter cassette s ordering code W005852 Fitting the particle filter cassette provides additional protection to your welding machine and lengthens its service intervals Filter maintenance Once fitted the filter should be removed checked and cleaned with dry compressed air weekly Every six months wash the filter in a solution of warm soapy water Allow to dry thoroughly before replacing EN 17 EN 18 5 5 1 USING CONTROL PANELS Regular control panel 6 7 4 5 f AM GAS Spore ara Tuc AT Bl MANUAL POST GAS UT Tu oy 4 10 V Vi LI DYNAMICS 2 U 1 2 3 Models featuring the regular R control panel offer the following control functions and features Control knob for welding dynamics Control knob for wire feed speed Control knob for welding voltage Shielding gas button Timer button for spot welding and cycle arc welding 2T 4T gun switch latching button Selection for MIG MAG or HOT SPOT function Parameter display Overheating indicator 0 WireLine service indicator 20 po ON du um 1 Control knob for welding dynamics Dynamics function controls the rate of rise of current when the filler wire is in short circuit with the welding plate This control adjustm
12. 0 60 C IEC 60974 1 IEC 60974 5 IEC 60974 10 EN 37 EN 38 Kempact Connection voltage Rated power at max current Supply current Connection cable Fuse Welding range No load voltage Idle power Power factor at max Efficiency at 10096 ED Wire feed speed adjustment range Voltage adjustment range Filler wires Wire spool Shielding gases External dimensions Weight 3 phase models MVU 3 50 60 Hz 40 EDI 250 A 230 V 40 ED mar 250 A 400V 40 EDI 250 A 230 V 40 ED lynas 250 A 400 V 100 ED hyer 150 A 230V 100 ED hug 150 A 400 V HO7RN F Type C 230V Type C 400V 250A 26 5V 230V 250A 26 5V 400V 150A 21 5V 230V 150A 21 5V 400V Fe solid Fe cored wires Ss Al Brazing max LxWxH Not including gun and cables 253 MVU 230V 1596 400V 15 9 KVA 8 5 kVA 22 2 A 12 3 A 10 8 A 6 2 461 5 1 5 mm 5 m 16A 10A 10V 20A 31V 250A 46V 35W 0 94 0 93 0 79 0 82 1 0 18 0 m min 8 0 31 0V 0 8 1 2mm 0 8 1 2mm 0 8 1 2mm 1 0 1 2mm 0 8 1 0 mm 300 mm 20 kg 0 Ar Ar C0 mixed 623 x 579 x 1070 mm 44 kg 3 50 60 Hz 35 ED limo 320A 230V 35 ED 320A 400 V 35 ED limo 320A 230V 35 ED 320A 400 V 100 ED I 190A 230V 100 ED le 190A 400V HO7RN F Type C 230 V Type C 400 V 320A 30V 230V 320A 30V 400V 1
13. 717750 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 uk kemppi com KEMPPI FRANCE S A S 65 Avenue de la Couronne des Pr s 78681 EPONE CEDEX FRANCE Tel 33 1309004 40 Telefax 33 1 3090 04 45 sales fr kemppi 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 0 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 KEMITIIM yn Nonkosaa 1 crpoenue 6 127018 MockBa Tel 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 BARI tr ARAA PB ILRA RRA R ZR JUR 125 blir KEB Z X420 100176 Hik 86 10 6787 6064 86 10
14. 904 23 5V 230V 1904 23 5V 400V LxWxH Not including gun and cables 323 MVU 230V 1596 400V 15 13 5 kVA 12 5 kVA 33 3 A 17 8 A 14 8 A 83A 461 5 1 5 mm 5 m 16A 10A 10V 20A 32 5V 320A 50V 35W 0 94 0 94 0 80 0 83 1 0 20 0 m min 8 0 32 5V 0 8 1 2mm 0 8 1 2mm 0 8 1 2mm 1 0 1 2mm 0 8 1 0 mm 300 mm 20 kg 0 Ar Ar C0 mixed 623 x 579 x 1070 mm 44kg Temperature class EMC dass Degree of protection Operating temperature range Storage temperature range Standards F 155 C A Ip235 20 40 C 40 60 C IEC 60974 1 IEC 60974 5 IEC 60974 10 F 155 C A Ip235 20 440 C 40 60 C IEC 60974 1 IEC 60974 5 IEC 60974 10 EN 39 KEMPPI OY Kempinkatu 1 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 5 194 27 UPPLANDS V SBY SVERIGE 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 T NSBERG 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 dk kemppi com KEMPPI BENELUX B V Postbus 5603 NL 4801 EA BREDA NEDERLAND Tel 31 765
15. FE32 5m Kempact 181A FE20 3 5m Kempact 181A FE20 5m Kempact 251A FE25 3 5m Kempact 251A FE25 5m Kempact 253A FE32 3 5m Kempact 253A FE32 5m Kempact 323A FE32 3 5m Kempact 323A FE32 5m Welding guns FE 20 3 5m FE 25 3 5m FE 27 3 5m FE 32 3 5m FE 35 3 5m FE 42 3 5m P2203 P2204 P2207 P2208 P2211 P2212 P2201 P2202 P2205 P2206 P2209 P2210 P2214 P2215 6602003 6602503 6602703 6603203 6603503 6604203 Consumables for guns see pages 27 34 Consumables for wire feed mechanism see pages 14 15 Earth return cable and clamp Shielding gas hose Particle filter 253RMV 323RMV 253AMV 323AMV Kempact 323RMV FE 27 3 5m Kempact 323RMV FE 27 5m Kempact 323RMV FE 32 3 5m Kempact 323RMV FE 32 5m Kempact 253AMV FE 27 3 5m Kempact 253AMV FE 27 5m Kempact 323AMV FE 32 3 5m Kempact 323AMV FE 32 5m FE20 5 0 m FE25 5 0 m FE27 5 0 m FE 32 5 0 m FE 35 5 0 m FE 42 5 0 m 25 mm 5 m 181 251 253 253MV 35 mm 5 m 323 323MV 1 5m P2216 P2215 P2219 P2220 P2218 P2217 P2221 P2222 6602004 6602504 6602704 6603204 6603504 6604204 6184211 6124311 4292020 W005852 EN 35 EN 36 1phase models Kempact Connection voltage Rated power at max current Supply current Connection cable Fuse Welding range No load voltage Idle power Power factor at max Efficiency at 10096 ED Wire feed speed adjustment range Voltage adjustment ra
16. IC is selected from the mode selection button 6 the material thickness and weld shape is displayed based on your input selections for plate thickness in mm and weld shape Adjust these values though control knobs 2 and 3 As you adjust the power control 2 you will see the graphic indicating plate thickness become thicker or thinner and as you adjust the arc length control 3 you will see the weld shape change from convex flat and concave Select the desired settings and you are ready to weld Parameter guides Fe 0 8 mm 5 18 96 CO Ar PlateThickness mm 0 5 0 8 1 1 5 2 2 5 3 WireFeedSpeed m min 2 25 3 5 5 8 10 13 SetVoltage V 145 15 155 16 17 18 20 MeanCurrent A 40 50 65 97 130 155 185 Fe 1 0 mm 5 25 C0 Ar Plate Thickness mm 0 7 1 5 2 3 4 5 Wire Feed Speed m min 14 32 4 5 6 5 8 5 11 0 Set Voltage V 150 175 184 214 238 288 Mean Current A 40 100 150 180 200 240 Fe 1 2 mm 5 25 60 41 Plate Thickness mm 1 1 5 2 3 4 6 Wire Feed Speed m min 1 5 2 2 32 5 0 6 0 7 2 Set Voltage V 146 170 178 210 227 26 3 Mean Current 75 100 140 180 220 250 MIG MAG WELDING NOTE Welding fumes may be dangerous to your health Ensure that there is ample ventilation during welding Never look at the arc without a face shield specifically designed for arc welding Protect yourself and your surrounding area from the arc and hot welding spatter NOTE Always wear protective clothing gloves face and eye shields suitable for welding It i
17. Kempact 251R 253R 323R 181A 251A 253A 323A Operating manual K ytt ohje Bruksanvisning Bruksanvisning Brugsanvisning Gebrauchsanweisung Gebruiksaanwijzing Manuel d utilisation Manual de instrucciones Instrukcja obstugi 1 414 no 3KCNAYaTaLVN ERE at Manual de utilizac o Manuale d uso KEMPPI The Joy of Welding EN FI SV NO DA DE NL FR ES PL RU ZH PT OPERATING MANUAL English EN CONTENTS 1 1 1 1 2 2 2 1 2 2 23 2 4 3 3 1 3 2 4 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 5 5 1 5 2 5 3 6 6 1 7 7 1 4 2 73 7 4 7 5 8 9 10 Introduction 3 ciclici 3 About Kempact RA ici 3 1 21 Popes 3 12 2 About welding T 4 Preparations sees ee eee 4 4 Positioning and location of the Machine sss 4 Distribution NEtWOfk Luria 5 Serial 6 Machine introduction sese sese 6 General view of the machine sse 6 Cable COMME CHONS REE 7 Before you start using the unit inn 10 10 Mounting and locking of filler wire spool sss 10 Setting the spool brake force 11 Loading the welding wire to feed mechanism 11 VJ 12 Setting the pressure of the feed rolls 13 Wire guide tubes and feed rolls 14 Changing the feed rolls sss 16 Reversing 17 49 1 Dusty work environments
18. Zr CuAg CuAg 9580122A 9580121A 9580123A 95801244 9580125A 9580126A 958012255 958012155 958012355 958012455 958012655 00 8 mm 0 9 1 0 1 2 1 4 1 6 0 8 0 9 1 0 1 2 1 6 50 neck includes temperature protection spring as standard 6 0 6 0 8 mm 0 9 1 2 mm 14 1 6 mm 0 8 1 0 mm 1 0 1 6 mm 0 6 0 8 mm 0 9 1 2 mm 14 1 6 mm 0 8 1 0 mm 1 0 1 6 mm Al Ss Al Ss Al Ss Al Ss 3 5m 3 5m 3 5m 3 5m 3 5m 5m 5m 5m 5m 5m 7 3 Troubleshooting Welding performance can be effected by a number of issues including the welding gun and or other parts of the welding system The following information will help you to check identify and rectify possible causes of welding malfunction NOTE The problems listed and the possible causes are not definitive but serve to suggest some standard and typical situations that may present during normal use when using the MIG MAG process Dirty poor quality weld Check that spatter is not blocking the nozzle or contact tip adapter Check shielding gas supply Check and set gas flow rate Check gas type for application Check gun polarity Example Fe solid filler wire Earth return socket should be connected to the pole wire feed gun connection to the pole Check power supply Phase down Variable welding performance e Check wire feed mechanism is correctly adjusted Check correct drive rolls are fitted Check wire spool hub overrun tension is
19. applied so avoiding filler wire slippage in the feed rolls NOTE Too much wire feed roll pressure may flatten the filler wire damage its coating increase friction and result in the filler wire sticking in the welding gun liner or contact tip Also excessive pressure will result in increased wear to wire drive roll bearings reducing their life EN 13 EN 14 4 7 Wire guide tubes and feed rolls Wire guide tubes A front tube B centre tube C rear tube D wire spiral guide GT 02 models 251R 181A 251A Ss Al Fe MG FC 90 6 1 6mm 2 5 97mm W006164 plastic 2 0mm W006019 brass D A C W006410 T d 2 5 125mm steel A O O O O S O O DuraTorque models 253R 323R 253A 323A Ss Al Fe MG FC 90 6 1 6mm 2 5 75mm 2 5 33mm W006369 plastic W000956 plastic Fe MC FC 0 6 0 8mm 1 5 75mm 2 0 33mm 2 0mm W006421 steel W001435 steel W005784 brass 1 0 1 6mm 2 0 75mm W006422 steel D A B C W006410 cL X 2 5 125mm steel A B C D O O ofl To t Io 3 O Removing front tube Release pressure tension arm Push the front tube out of its housing with a piece of filler wire
20. ax current Supply current Connection cable Fuse Welding range No load voltage Idle power Power factor at max Efficiency at 10096 ED Wire feed speed adjustment range Voltage adjustment range Filler wires Wire spool Shielding gases External dimensions Weight Temperature class EMC dass Degree of protection Operating temperature range Storage temperature range Standards 3 50 60Hz 40 ED 2504 1max 40 ED limax 250 A 100 ED l e 150 A HO7RN F Type C 250A 26 5V 150A 21 5V Fe solid Fe cored wires Ss Al Brazing max LxWxH Not including gun and cables 253R 253A 400 V 15 8 5 kVA 11 9A 6 1A 461 5 1 5 mm 5 m 10A 10V 20A 31V 250A 41V 25W 0 93 88 1 0 18 0 m min 8 0 31 0V 0 8 0 8 0 8 1 0 0 8 300 mm 20 kg CO Ar Ar C0 mixed 623x579x1070mm LxWxH 44 kg F 155 A IP235 20 4 40 C 40 60 C 1 2 mm 1 2 mm 1 2 mm 1 2 mm 1 0 mm IEC 60974 1 IEC 60974 5 IEC 60974 10 35 ED lima 320A 100 ED lies 1904 Not including gun and 323R 323A 400 V 15 12 KVA 172A 82A 461 5 1 5 mm 5 m 10A 10V 20A 32 5V 320A 45V 25W 0 94 8696 1 0 20 0 m min 8 0 32 5 V 0 8 1 2 mm 0 8 1 2mm 0 8 1 2 mm 1 0 12 mm 0 8 1 0 mm 300 mm 20 kg CO Ar Ar CO mixed 623 x 579 x 1070 mm 44 kg F 155 C A 1P235 20 40 C 4
21. cated in front of the air intake grill Press your foot firmly downwards and pull back the machine at the same time so lifting the machine and gas cylinder to a position for movement To move the machine and a large cylinder 1 Load and secure the gas cylinder with straps provided 2 With one hand firmly grip the top of the cylinder and with the other hand grip one of the machine handles 3 Place one foot to the foot base plate located in front of the air intake grill Press your foot firmly downwards and pull back the machine at the same time so lifting the machine and gas cylinder to a position for movement Additional safety notes NOTE In both cases listed above you will quickly feel the fulcrum point mechanical advantage and the point of balance You are now ready to move your machine and gas cylinder to a new location However caution should be observed at all times when moving heavy equipment and local safety conditions and laws must be respected NOTE Be careful when lowering the cylinder to its resting position Whilst maintaining a firm grip ensure that you keep your back straight and extend your arms Maintain firm pressure to the foot base plate and slowly lower the machine and cylinder to its resting position You will feel the weight increase as you move forwards over the point of balance Ensure you keep a firm grip and your weight as far back as possible as you lower the cylinder and machine chassis carefully to the
22. ce a short circuit occurs forming the needed closed electrical circuit A welding arc is formed and welding commences Unrestricted current flow is possible only when the earth return clamp is properly attached to the workpiece and the fixing point of the clamp to the workpiece is clean and free from paint and rust PREPARATIONS NOTE Please read the separate safety instruction booklet provided before you commence welding Pay particular attention to the risks associated with fire and explosion Unpacking When the machine leaves the factory the wire drive system and gun it is set for use with ferrous filler wire 181 251 models WHITE 0 8 wire feed rolls and 253 323 models RED 1 0 wire feed rolls If you wish to use an alternative thickness filler wire or type make sure that you select appropriate feed rolls groove size welding gun contact tip and gun liner and also ensure that the machine polarity is correctly set for the material filler type used If using aluminium or stainless steel filler wire we recommend you change the wire liner to a Kemppi plastic type which is better suited for the material Before using the equipment always make sure it was not damaged during transportation Also check that you have received what you ordered and that there are instructions for it The packaging material of the products is suitable for recycling Environment The machine is suitable for both indoor and outdoor use but it should be protec
23. e feed rolls their groove shape and size and the wire liner inside the welding gun cable are suitable for the wire you are using Also check that you are using the correct polarity for the filler wire Mounting and locking of filler wire spool To mount the wire spool 1 Turnthe locking knob of the spool holder so that the locking clips are opened 1 2 Checkthe rotating direction of the wire spool and push the spool into its place so that it rotates in the right direction 2 3 Turnthe locking knob of the spool holder to close the locking clips 3 NOTE Check that the filler wire spool is correctly mounted and locked into position Ensure the spool is not damaged or deformed in such a way that it can rub or chaff against the internal surface of the wire feed unit chassis or door This may result in increased drag impacting on weld quality This may also result in long term wire feed unit damage rendering the unit unserviceable or unsafe to use Kempact 251R 253R 323R 181A 251A 253A 323A 4 3 Setting the spool brake force 4 4 To prevent the filler wire from uncoiling on overrun following use at high feed speeds you can change the brake force of the welding spool Adjust the spool brake force through the hole in the spool locking mechanism Increase the force by turning the screw clockwise and decrease it by turning it anticlockwise NOTE Do not over tight
24. e is in short circuit with the welding plate This control adjustment is necessary due to the alternative welding parameters materials wire sizes gas types and current values used The welding dynamics scale is 9 to 9 Negative values make the rise of current slower which results in a hotter and more fluid weld characteristic Positive values make the rise of current faster which results in a colder welding condition This can result in more spatter during welding depending on the filler wire size and type used How to find the optimal dynamics setting Start by setting 0 and make a test weld after selecting the correct wire feed speed and voltage values Fine tune the welding arc by trying different values in the negative and positive sides of the dynamics scale 2 Control knob for wire feed speed or power adaptive mode This control knob increases and reduces the speed of filler wire delivery or power to the welding arc The scale is regulated in meters per minute or amperes There is also a graphical display bar indicating the proportion of motor speed or power selected 3 Control knob for voltage or arc length adaptive mode This control knob increases and reduces the available output voltage of the machine to the welding arc The scale is regulated in volts and is also supported by a graphical display bar that indicates the proportion of the available output voltage selected In adaptive mode this control knob offers
25. e symbol will illuminate indicating that maintenance is required Welding is not prevented when the WireLine service symbol is active 10 Post gas symbol POST GAS This symbol indicates that the post gas function is active Kempact Regular R models have fixed post gas function but in Kempact Adaptive A models the post gas time can be changed through a long press of button 13 In both models the words POST GAS on the display identify that the function is active 11 Selection for materials type or display of amperes wire feed speed adaptive mode When operating in adaptive mode and AUTOMATIC is selected from the mode selection button 6 a selection of filler materials types is presented through short presses of button 11 Materials selection includes FE BRAZING FCAW MCAW When selecting a suitable filler material POWER regulation is achieved through POWER selection knob 2 A long press 5 secs of button 11 also switches the display from m min to amperes 12 Selection for filler wire diameter adaptive mode When operating in adaptive mode and AUTOMATIC is selected from the mode selection button 6 you can select from the filler wire diameter options Following your materials selection through button 11 press button 12 briefly to select the filler wire diameter Not all materials have alternative choices 13 Selection for shielding gas or post gas function adaptive mode D When operating in adaptive mode and AUTOMATIC
26. en and reduce the pressure for light filler wire types Loading the welding wire to feed mechanism O O o AE O GT02 DuraTorque NOTE Always ensure that ALL wire guide tubes are correctly selected and installed before connecting the welding gun 1 Release the pressure lever s and open the pressure arm s carrying the top wire feed roll lifting clear on its pivot 2 Draw some loose filler wire from the spool and carefully push it through the liner and bronze guide at the back of the wire feed mechanism Push the filler wire over the feed roll groove and through the wire guide s tubes and Euro connector block exposing about 150 mm of filler wire from the front of the machine 3 Closethe top feed roll s lever s over the filler wire and close the pressure arm s EN 11 EN 12 4 Cut away any deformed filler wire section and dress the sharp wire tip 0 JER 5 Connect the welding gun and tighten the collar 6 Pressthe welding gun trigger and allow the filler wire to feed through the gun cable to the contact tip Check once again that the filler wire is still properly seated in the grooves of both top and bottom feed rolls 4 5 Welding gun Connect the welding gun connector to the Euro adapter socket located below the wire feed mechanism and hand tighten only Do not over tighten the gun collar NOTE Remember to re
27. ent is necessary due to the alternative welding parameters materials wire sizes gas types and current values used The welding dynamics scale is 9 to 9 Negative values make the rise of current slower which results in a hotter and more fluid weld characteristic Positive values make the rise of current faster which results in a colder welding condition This can result in more spatter during welding depending on the filler wire size and type used How to find the optimal dynamics setting Start by setting 0 and make a test weld after selecting the correct wire feed speed and voltage values Fine tune the welding arc by trying different values in the negative and positive sides of the dynamics scale 2 Control knob for wire feed speed This control knob increases and reduces the speed of filler wire delivery to the welding arc The scale is regulated in meters per minute There is also a graphical display bar indicating the proportion of motor speed selected 3 Control knob for welding voltage This control knob increases and reduces the available output voltage of the machine to the welding arc The scale is regulated in volts and is also supported by a graphical display bar that indicates the proportion of the available output voltage selected 4 Shielding gas button This button sets the machine s dynamics range for either mixed Ar C0 or carbon dioxide C05 shielding gas A single press of the button changes the set u
28. er it may be necessary to select alternative feed rolls to suit different filler wire sizes used So you may occasionally need to replace the feed rolls Kemppi feed rolls and gun liners are colour coded in order to make identification easy To change the feed rolls Pull and release the pressure tension arm Lift the upper feed roll on its pivot to the maximum open position Pull out mounting pin of the upper feed pressure roll and replace the roll with a new one Open the locking screw of the lower feed roll and replace the roll with a new one Return the upper pressure feed roll to its down position and replace the pressure tension arm Adjust the pressure tension as instructed in the earlier section oP c o 4 9 4 9 1 Reversing polarity Some filler wires are recommended to be welded with the gun in the minus pole so the polarity should be reversed Check the recommended polarity from the filler wire package 1 Disconnect the machine from the mains 2 Exposethe terminal connections by bending the protective rubber covers away from the terminal 3 Remove the terminal tightening nuts and washers Note the correct order of the washers 4 Interchange the cables Install the washers in place and re tightening the securing nuts 6 Replacethe rubber terminal covers The rubber covers must always protect the terminals during use d Dusty work environments If the
29. face or others in the vicinity NOTE Kempact RA models are fitted as standard with both over temperature and WireLine service indicators described earlier in the manual f If the overheating indicator is displayed this may be due to welding durations exceeding the set duty cycle The machine will reset after a cooling rest period However if the optional cooling air intake filter is fitted to the machine this may be contaminated restricting cooling airflow and require cleaning See section 4 9 1 AS If the WireLine service indicator is illuminated this indicates that the wire delivery system is not running efficiently Checks adjustment or cleaning is required to the spool hub friction assembly wire feed mechanism or gun liner assembly Welding is not prevented when the WireLine service symbol is active and is maintenance advice only EN 27 EN 28 7 2 Gunspare parts NOTE Orange part code colour denotes standard delivery specification FE 20 6602003 3 5 m 6602004 5 0 m C Gas nozzle 9580101 60 5 x 18x 14 mm standard AxBxC 958010101 60 5 x 18 x 14 mm with insulating bush A 9580101 9591079 4113470 60 5 x 18 x 14 mm for spot welding 9580101E 60 5 x 20 x 14 mm thick wall Insulating bush 9091010 Contact tip M6 9876634 0 6 mm 9876635 0 8 mm 9876633 0 9 mm 9876636 1 0 mm 9876637 1 2 mm Contact tip 9580173 adapter M6 a Insulating ring 9591079 Locking spring 4275240
30. floor NOTE The chassis is designed to provide stability in the upright position when loaded with or without a gas cylinder Reasonable effort is required to raise and lower the machine and cylinder to a position of movement If you are light in weight or in any way unsure about moving the machine and cylinder you should consider an alternative method or process A local Health and Safety audit and risk assessment may be necessary before heavy or new equipment is taken into use including the usefor carrying or transporting compressed shielding gas cylinders Kemppi Oy 1135 EN EN 10 4 1 4 2 NOTE In all cases the chassis design is not recommended for lifting its weight clear of the ground by the handles or any other means with or without a gas cylinder loaded in place When transporting the machine between sites welding gas cylinders must be removed from the chassis secured and transported by other means BEFORE YOU START USING THE UNIT Installing filler wire Kempact RA is designed for 300 mm wire spools and the following filler wire types solid wires flux cored wires self shielded flux cored wires stainless steel wires aluminium wires brazing wires When choosing appropriate filler materials remember that the wire must have approximately the same melting point as the base material to be welded MIG brazing process is an exception to this rule NOTE When changing the filler wire always check that th
31. he HOT SPOT carbon and holder replacing the standard FE welding gun parts ready to continue welding NOTE HOT SPOT function is only possible in 2T gun trigger mode If 4T selection is made the function will automatically revert to 2T operation 7 1 MAINTENANCE NOTE Be careful when handling electrical cables In maintaining the unit take into consideration the rate of use and the environment it is used in When the unit is used properly and serviced regularly you will avoid unnecessary disturbances in use and production Daily maintenance Remove welding spatters from the welding gun s tip and check the condition of the parts Change damaged parts to new ones immediately Only use original Kemppi spare parts Change damaged insulation parts to new ones immediately Checkthe tightness of the welding gun s and earth return cable s connections Check condition of mains and welding cables and replace damaged cables See that there is enough space around the unit for ventilation Service the wire feed mechanism at least every time the spool is changed Check the wear of the feed roll groove and change the feed roll when necessary Carefully clean the welding gun wire liner with dry compressed air NOTE When using compressed air pistols ensure you are wearing adequate safety equipment including suitable work clothing gloves and eye protection Never direct compressed air pistols or the end of the liner at your skin
32. ing durations 7 Selection for MIG MAG or HOT SPOT welding function Pa This button switches the machine from standard MIG MAG welding mode to a specialised process function for localised spot heating and stress relieving for metal panels This function is normally used in the automotive industry and light sheet fabrication To switch between functions press and hold the button for 5 seconds See further information on HOT SPOT function later in this manual 8 Parameter display The large illuminated parameter display is designed to provide excellent visibility of welding values and machine settings in a variety of welding situations The display is protected by a polycarbonate lens fitted into the control panel housing EN 19 EN 20 5 2 9 Overheating indicator Under normal working conditions the overheating indicator is not visible However should the machine exceed its working duty cycle welding will cease and the thermometer symbol will illuminate indicating that the machine has overheated The cooling fans of the machine will continue to operate When normal operating temperature is regained the machine will reset and welding can continue The overheating indicator will no longer be visible 10 WireLine service indicator A Under normal working conditions the WireLine service indicator is not visible However if the welding gun contact tip or liner becomes dirty and blocked or the wire feed mechanism
33. is selected from the mode selection button 6 you can select from the shielding gas option for the filler material type set Shielding gas options are displayed with a short press of button 13 When operating in either MANUAL or AUTOMATIC mode you can also select POST GAS function and make adjustments to the POST GAS time value with adjustment knob 3 The POST GAS adjustment range is from 0 1 second to 3 0 seconds 14 Selection of crater fill function adaptive mode CRATER FILL When operating in adaptive mode and AUTOMATIC is selected from the mode selection button 6 you can select CRATER FILL function CRATER FILL function activates a pre set slope timer at the end of the welding cycle and operates in either 2T or 4T gun switch mode when the off signal is given 15 Selection for memory function When operating in either MANUAL or AUTOMATIC mode you can store your welding parameters using the MEMORY function There are four MEMORY locations to choose from and you can store either MANUAL or AUTOMATIC welding setup in any channel location To store your welding settings simply press and hold a MEMORY button for 5 seconds To recall the welding settings for future use simple short press the MEMORY buttons To record new weld settings to a channel repeat the long press sequence EN 23 EN 24 5 3 16 Material thickness and weld shape display 7 mm A 3n JL When operating in adaptive mode and AUTOMAT
34. lection of plate thickness and weld profile All Kempact RA models feature a large and clear orange backlit LCD display for easy and fast reference of parameter settings All models include stepless control of voltage and wire feed speed spot and cycle arc timer and 2T 4T gun switch selection WireLine maintenance alert indicator Brights cabinet lighting GasMate chassis design and HOT SPOT carbon arc function EN EN 1 2 2 About welding 2 1 2 2 In addition to the welding machine welding outcome is influenced by the work piece to be welded welding technique and the welding environment Therefore recommendations in this manual must be followed During welding an electric welding circuit is created between the filler wire and the welded piece On delivery the welding gun euro connector is connected to the positive pole The terminals are located inside the wire feed case door and should not be changed unless you intend to run a filler wire that is directed to be used in reverse polarity electrode negative When a filler wire is loaded to the machine and the gun trigger is pressed the wire feed mechanism drives the filler wire through the wire liner to the contact tip mounted in the welding gun The earth return socket on the back of the machine is set as the negative terminal and when connected to the workpiece via the earth return lead it completes the welding circuit When the filler wire touches the work pie
35. move the sharp cut tip of the filler wire before loading the wire to the welding gun so preventing damage to the liner inside the welding gun cable This is particularly important for soft filler wires such as aluminium It will also improve feed quality and increase the service life of your gun liner Kempact 251R 253R 323 4 6 Setting the pressure of the feed rolls To ensure the filler wire runs smoothly into the welding gun wire liner you should adjust the pressure of the feed rolls of the wire drive mechanism Turn the orange coloured pressure adjustment knob s in a clockwise direction to increase the pressure applied to the welding filler wire and anticlockwise to decrease it NOTE Periodically remove and clean the short wire spiral located at the back of the wire feed mechanism See item D O O OQ fo opg O Ox O E O There is a graduation scale marked on the pressure arm above or below the orange adjustment knob depending on the Kempact RA used For models fitted with the two roll GTO02 wire drive system the more pressure applied the greater the number of graduation marks visible For models fitted with the four roll DuraTorque wire drive system the more pressure applied the fewer number of graduation marks visible For hard steel and stainless steel filler wires make sure there is sufficient pressure
36. nge Filler wires Wire spool Shielding gases External dimensions Weight Temperature dass EMC dass Degree of protection Operating temperature range Storage temperature range Standards 10 TECHNICAL DATA 1 50 60 Hz 50 ED lina 180A 50 96 ED I max 180A 100 ED I 140A HO7RN F Type C 180A 23V 140A 21V Fe solid Fe cored wires Ss Al Brazing max LxWxH Not including gun and cables 181A 230V 15 5 kVA 22A 16A 361 5 1 5 mm 5 m 16A 10V 20A 26V 180A 36V 35W 0 99 82 1 0 14 0 m min 8 0 26 0V 0 8 1 2 mm 0 8 1 2 mm 0 8 1 2 mm 1 0 1 2 mm 0 8 1 0 mm 300 mm 20 kg C0 Ar Ar C0 mixed 623x579x 1070 mm 44 kg F 155 C A Ip235 20 440 C 40 60 C IEC 60974 1 IEC 60974 5 IEC 60974 10 IEC 61000 3 12 1 50 60Hz 30 ED ma 250A 3096 ED I HO7RN F Type C 250 A 26 5V 150 A 21 5V LxWxH Not including gun and cables imma 100 96 ED lg 150A 251R 251A 240V 15 8 5 kVA 36A 17A 362 5 2 5 mm 5 m 20A 10V 20A 29V 250A 36V 35W 0 99 82 1 0 18 0 m min 8 0 29 0V 0 8 1 2mm 0 8 1 2mm 0 8 1 2mm 1 0 1 2mm 0 8 1 0mm 300 mm 20 kg C0 Ar Ar C0 mixed 623x579 x 1070 mm 44 kg F 155 C A Ip235 20 40 C 40 60 C IEC 60974 1 IEC 60974 5 IEC 60974 10 IEC 61000 3 12 3 phase models Kempact Connection voltage Rated power at m
37. ns presented in this manual are subject to change without prior notice NOTE Items in the manual that require particular attention in order to minimise damage and personal harm are indicated with this symbol Read these sections carefully and follow their instructions Disclaimer While every effort 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 About Kempact RA Kempact RA MIG MAG welding machines are designed for professional industrial use Before use or doing any maintenance work on the machine read the operating manual and keep it for further reference Welding and earth return cables are supplied in the delivery package including gun earth clamp and connections Properties Kempact RA family sets new standards for the compact MIG MAG equipment class and offers many innovative features designed to make welding more accurate and productive All models are suitable for welding a wide range of filler wire materials including Fe FCAW MCAW and MIG brazing Kempact Adaptive models include a memory function for saving frequently used weld settings They also feature automatic power regulation adjusted through se
38. p for the intended gas type The selected shielding gas type is shown in the LCD display panel If using argon shielding gas for aluminium or CuSi MIG brazing filler wires use the mixed gas setting Ar C0 5 Timer button for spot and cycle arc welding CYCLE The spot and cycle arc timer offers two modes of function By pressing and selecting the SPOT timer you regulate the time duration for one single SPOT welding cycle from either 0 1 to 9 9 seconds of arc time By selecting the CYCLE arc timer you regulate the machine to a repeating cycle of arc time and pause time The pause time offered is 0 1 to 3 seconds Select function by depressing button 4 Regulation and adjustment of SPOT and CYCLE arc values are adjusted by the voltage control item 3 Function selection is confirmed by either one dot SPOT TIME or dash line CYCLE TIME under the word Timer in the display 6 2T 4T gun switch latching button 27 4T This button offers you two modes of welding gun functions The selected mode is indicated as either 2T or 4T in the display In 2T mode the welding arc is started by a single press and hold of the welding gun trigger Welding continues whilst the trigger is held and stops when the trigger is released In 4T mode the gun trigger is pressed and gas starts to flow When the trigger is released the arc ignites Welding continues until the trigger is pulled and released for a second time This mode is useful for long weld
39. s recommended that you make practice welds before you commence welding your main work piece NOTE The work piece will be very hot Protect yourself and others at all times You can start welding after you have made the necessary preparation described throughout these instructions Providing you ensure that the equipment is correctly prepared and set for the material type and joint to be welded you will achieve exceptionally high quality welding results Ensure that the correct filler wire type and size is selected for the work piece Ensure that the correct wire liner and contact tip size is fitted to the welding gun Ensure that the correct shielding gas type is connected and the flow rate adjusted before welding starts Ensure the earth return clamp is connected to the work piece Ensure that you are wearing the correct safety equipment before you start welding including suitable welding clothing the correct welding face shield with a suitable shade welding lens welding gloves and when necessary a welding mask NOTE Please read section 1 2 2 before proceeding further Having checked that the equipment is prepared in the correct way for the welding task ahead and that you are wearing the necessary protective equipment you are ready to commence welding MIG MAG welding can be performed down hand vertically and overhead either right to left right handed operators or left to right left handed operators
40. s button switches the machine from standard MIG MAG welding mode to a specialised process function for localised spot heating and stress relieving for metal panels This function is normally used in the automotive industry and light sheet fabrication To switch between functions press and hold the button for 5 seconds See further information on HOT SPOT function later in this manual 7 Parameter display The large illuminated parameter display is designed to provide excellent visibility of welding values and machine settings in a variety of welding situations The display is protected by a polycarbonate lens fitted into the control panel housing 8 Overheating indicator F Under normal working conditions the overheating indicator is not visible However should the machine exceed its working duty cycle welding will cease and the thermometer symbol will illuminate indicating that the machine has overheated The cooling fans of the machine will continue to operate When normal operating temperature is regained the machine will reset and welding can continue The overheating indicator will no longer be visible 9 WireLine service indicator A Under normal working conditions the WireLine service indicator is not visible However if the welding gun contact tip or liner becomes dirty and blocked or the wire feed mechanism needs routine maintenance or the friction plates in the spool brake need adjustment or maintenance the Spanner servic
41. tandard 80x 22x 16 mm long 71 x22x 13 mm conical 77 x 22x 16 mm standard spatter protection bush 0 8 mm 0 9 1 0 1 2 1 4 1 6 1 0 1 2 1 4 1 0 1 2 M8 50 cucr1Zr CuCr1Zr uCr1Zr CuAg CuAg 9580122A 9580121A 9580123A 9580124A 9580125A 9580126A 958012255 958012155 958012355 958012455 958012655 0 8 mm 0 9 1 0 1 2 1 4 1 6 0 8 0 9 1 0 12 1 6 50 neck includes temperature protection spring as standard 0 6 0 8 mm 0 9 1 2mm 1 4 1 6mm 0 8 1 0 mm 1 0 1 6 mm 0 6 0 8 mm 0 9 1 2 mm 1 4 1 6mm 0 8 1 0 mm 1 0 1 6 mm Al Ss Al Ss Al Ss Al Ss 3 5m 3 5m 3 5m 3 5m 3 5m 5m 5m 5m 5m 5m EN 31 EN 32 FE 42 6604203 3 5 m 6604204 5 0 m C Gas nozzle 4300380 AxBxC 4300380L A 43003806 4307070 B 4308190 Insulating bush 4307030 Contact tip 9580122 M8 9580121 9580123 9580124 9580125 9580126 95801237R 95801247R 95801257R 9580123AG I 9580124AG Contact tip 4304600 adapter A Gas diffuser W004505 m Insulator W004579 SP004585 SP600317 Neck SP004578 18 ig SP600316 Wire liner 4188573 W006453 W006455 W006457 W006459 4188576 W006454 W006456 W006458 W006460 80x 25 x 18 mm standard 83 x 25 x 18 mm long 80x 25 x 14 mm conical 80x 25 x 18 mm standard spatter protection bush 89 5 x 25x18 mm special long 00 8 mm 0 9 1 0 1 2 1 4 1 6 1 0 1 2 1 4 1 0 1 2 M8 50 CuCr1Zr CuCr1Zr CuCr1
42. ted from rain and sunshine Store the machine in a dry and clean environment and protect it from sand and dust during use and storage The recommended operating temperature range is 20 40 C Place the machine in such a way that it does not come in contact with hot surfaces sparks and spatters Make sure the air flow into the machine is unrestricted Positioning and location of the machine Place the machine on a firm dry and level surface Where possible do not allow dust or other impurities to enter the machines cooling air flow Notes for positioning the machine The surface inclination should not exceed 15 degrees Ensure the free circulation of the cooling air There must be at least 20 cm of free space around the machine for cooling air to circulate Protect the machine against heavy rain and direct sunshine NOTE The machine should not be operated in the rain as the protection class of the machine IP23S allows for outside preserving and storage only NOTE Never use a wet welding machine 2 3 NOTE When locating and siting the machine prior to and during operation it is important to ensure that the metal chassis of the machine does not come into contact with the welding circuit and or surfaces so connected l NOTE Never aim metallic grinding spray sparks towards the equipment Distribution network All regular electrical devices without special circ
43. that the mains cable complies with the local electrical regulations and replace the cable if necessary See Technical data NOTE The mains cable or mains plug may be installed or replaced only by an electrical contractor or installer authorised to perform such operations Welding gun Kempact RA welding machines are supplied with Kemppi FE range welding guns as standard These guns are designed for industrial applications and if used and maintained correctly will provide productive and reliable service NOTE The gun is set at the factory for use with ferrous filler wires Should you wish to use the gun with an alterative filler wire size or type please select the appropriate contact tip and wire liner EN EN Shielding gas Hd silla l Shielding gas is used for replacing air around the welding arc For steel wires use CO carbon dioxide or a mixture of Ar argon and CO for shielding gas Welding performance will be improved when using mixed gas products For stainless steel filler wires use a mixture of Ar and CO 2 96 and for aluminium and Cui filler wires use pure argon The required flow rate of the shielding gas is determined by the thickness of the welded sheet and the used welding power Alternative gas mixtures are available Contact your gas supplier for further advice The machine is delivered with a 1 5 m gas hose Connect the gas hose to the machine s male connector at the back of
44. the machine Connect the other end of the gas hose to the gas cylinder via a suitable and approved single stage regulator valve where outlet flow rates can be adjusted NOTE Never attempt to connect directly to a compressed gas cylinder Always use an approved and tested regulator and flow meter Connecting the gas hose to a typical welding regulator control valve 1 Connect the hose to the welding machine 2 Open the regulator valve of the gas cylinder 3 Measure the gas flow 4 Adjust the flow with the adjustment knob 12 18 lpm NOTE Use a suitable shielding gas for the welding application Always secure the gas cylinder in an upright position with either a specially made wall rack or the Kempact RA GasMate chassis securing the cylinder in place with the webbing and metal buckles provided Always close the cylinder valve after welding Moving the machine and gas cylinder The Kempact RA is designed to provide safe gas cylinder storage and movement in satisfactory workshop conditions The floor surface should be sound level and free from obstructions These notes must be followed and an adequate risk assessment completed prior to use of the equipment Cylinder size and weight vary and therefore affect the total weight and balance of equipment movement To move the machine and a small cylinder 1 Load and secure the gas cylinder with straps provided 2 Gripthe machine handles and place one foot to the foot base plate lo
45. uits generate harmonic currents into distribution network High rates of harmonic current may cause losses and disturbance to some equipment Kempact 181A 251R 251A Equipment complying with IEC 61000 3 12 Kempact 253R 253A This equipment complies with IEC 61000 3 12 provided that the short circuit power Ssc is greater than or equal to 2 7 MVA at the interface point between the user s supply and the public supply network It is the responsibility of the installer or user of the equipment to ensure by consultation with the distribution network operator if necessary that the equipment is connected only to a supply with a short circuit power Ssc greater than or equal to 2 7 MVA Kempact 323R 323A This equipment complies with IEC 61000 3 12 provided that the short circuit power Ssc is greater than or equal to 2 1 MVA at the interface point between the user s supply and the public supply network It is the responsibility of the installer or user of the equipment to ensure by consultation with the distribution network operator if necessary that the equipment is connected only to a supply with a short circuit power Ssc greater than or equal to 2 1 MVA Kempact 251 MVU This equipment complies with IEC 61000 3 12 provided that the short circuit power Ssc is greater than or equal to 1 1 MVA at the interface point between the user s supply and the public supply network It is the responsibility of the installer or user of the equipment
46. ve 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 ERROR CODES Error 2 Mains under voltage The machine has detected mains under voltage that disturbs welding Check the quality of the supply network Error 3 Mains over voltage The machine has detected momentary voltage spikes or continuous overvoltage that can damage the machine if allowed to continue Check the quality of the supply network Error 4 Wire feed motor over current Wire feed motor current is higher than the designed limit Check condition of welding gun contact tip liner and wire feed mechanism Other error codes The machine can display alternative codes not listed In the event of an unlisted code appearing contact an authorised Kemppi service agent and report the error code shown 9 ORDERING CODES Kempact 251R 253R 323R 181A 251A 253A 323A Kempact 251R FE25 3 5m Kempact 251R FE25 5m Kempact 253R FE27 3 5m Kempact 253R FE27 5m Kempact 323R FE32 3 5m Kempact 323R
47. ward travel speed but you may also need to reduce the power setting slightly to achieve the desired result As with all craft skills practice will make perfect For more information visit the Welding ABC section in www kemppi com EN 25 EN 26 6 1 HOT SPOT function NOTE The HOT SPOT component kit is suitable for use with the FE 20 25 welding guns only Setting and function 1 10 Before using HOT SPOT function release the pressure tension arms at the wire feed mechanism Rotate the filler wire spool slowly clockwise removing the filler wire away from the FE welding gun contact tip and neck Fit the special HOT SPOT electrode adaptor and carbon electrode into the gun head as shown 9592106 holder 4192160 carbon electrode HE et aS E Select HOT SPOT mode with the control panel button 6 Select the required HOT SPOT power level There are 4 power level options depending on the machine type in use Place the carbon electrode to the work piece fixing or area requiring spot heating Pull the trigger to activate the HOT SPOT function The electrode will quickly heat up and depending on the power level set will glow red hot When sufficient heating effect is reached release the trigger and remove the electrode from the work piece When HOT SPOT process is complete press control panel button 6 to return the machine to standard MIG MAG mode When cool and safe to handle remove t
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