Kempact 2530 User Manual - Rapid Welding and Industrial Supplies
Contents
1. By applying this European Directive you will improve the environment and human health ORDERING NUMBERS Kempact MIG 2530 621853002 GH 30 Gun holder 6256030 MMT 25 3m 6252513MMT MMT 25 45m 6252514MMT MMT 27 3m 6252713MMT MMT 27 45m 6252714MMT Earth cable 35 mm 5m 6184311 Transport unit ST 7 6185290 Transport unit P250 6185268 Lift hook 4298180 Wire spool pole 4289880 5 kg spool adapter 4251270 Gas hose 6m W000566 Kemppi Oy 1204 EN 11 EN 12 6 TECHNICAL DATA Kempact MIG 2530 Connection voltage 3 50 60Hz Rated power at max current 40 ED Supply current nie ler Connection cable HO7RN F Fuse delayed Output 40 C 40 ED 60 ED 100 ED Welding range Open circuit voltage Power factor at max current Efficiency at max current Wire feed speed Filler wires Fe Ss Cored wire Al Cusi Shielding gas Wire spool max Thermal class External dimensions LxWxH Weight Operating temperature range Storage temperature range EMC class Degree of protection Standards IEC EN 60974 1 IEC EN 60974 5 IEC EN 60974 10 See paragraph 2 5 Kempact MIG 2530 380 440V 10 250 12 kVA 17A 11A 461 5 5 m 16A 250 A 26 5 V 207 A 24V 160 A 22 V 10 30V 30 45V 0 64 87 1 18 m min 0 6 1 0 mm 00 9 1 2 mm 00 9 1 2 mm 00 8 1 0 mm CO Ar Ar amp CO mixed gases 300 mm 15 kg H 180 C B 130 C 580x280x440 20 kg 20 C2. 40 C 40 C 60 C A 1P235 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 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 dk kemppi 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 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 30 90 04 45 sales fr kemppi com KEMPPI GmbH Otto Hahn Stra e 14 D 35510 BUTZBACH DEUTSCHLAND Tel 49 6033 88 020 Telefax 49 6033 72 528 sales de kemppi com KEMPPI SP KA 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 B
3. ON signal light Thermostat signal light Selecting welding procedure 2T 4T MIG welding dynamics adjustment Wire feed adjustment Welding voltage adjustment OV UT Oh gt Selecting the welding procedure 2T AT 2T MIG welding with double action of the start switch of the gun 1 Switch closed welding starts 2 Switch open welding ends 4T MIG welding with quadruple action of the start switch of the gun 1 Switch closed flow of shielding gas starts 2 Switch open welding starts 3 Switch closed welding ends 4 Switch open flow of shielding gas ends O Kemppi Oy 1204 EN EN 10 3 5 Adjusting welding dynamics DYNAMICS sl aw 7 w The adjustment of MIG welding dynamics influences the properties of the welding arc and the amount of splatter The recommended basic setting is 0 The values gt min 1 9 provide a softer arc for diminishing the amount of spatter The values gt max 1 9 provide a coarser arc suitable when increased arc stability is desired and when using 100 CO shielding gas for welding steel 3 6 Thermostat The temperature control of the machine prevents the power source from over heating This means that the machine can not become damaged if loading exceeds the specified load factor during welding When the signal lamp indicating overheating is lit the welding circuit can not be activated The lamp will turn off after a pause of about three
4. when placing spare parts orders or when planning maintenance Kemppi Oy 1204 EN EN 2 4 2 5 2 6 2 7 Connection to the mains supply The Kempact 2520 is delivered equipped with a five metre mains cable without a plug Installation of the plug should be carried out only by a competent electrician For fuse and cable sizes see the technical data in the end of this document Distribution network All regular electrical devices without special circuits generate harmonic currents into distribution network High rates of harmonic current may cause losses and disturbance to some equipment WARNING This equipment does not comply with IEC 61000 3 12 If it is connected to a public low voltage system 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 may be connected Ground cable Fasten the earth clamp of the return current cable carefully preferably direct onto the piece to be welded The contact surface of the earth clamp should always be as large as possible Clean the fastening surface from paint and rust Use at least 35 mm cables Thinner cross sectional areas cause overheating of connectors Wire feeding mechanism components Clamp screw Clamping lever Feed rolls Gun connector Euro Wire guides UT NS Kempact MIG 2530 DuraTorque 400 4 wheel wire feed mechanism Wire guide
5. G 2530 is compact MIG inverter suitable for repair and installation use and for light and medium industrial use The power source and the wire feeding mechanism are contained in the device The power regulation of the power source is implemented with IGBT transistors operating at a frequency of approximately 30 kHz 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 BEFORE YOU START USING THE UNIT Unpacking The equipment is packed in durable packages designed specially for it Nevertheless before using the equipment always make sure it was not damaged during transport Also check that you have received what you ordered and that there are instructions for it NOTE The packaging material of the products is suitable for recycling Placement of the unit Place the unit on a horizontal solid and clean surface Shield it from heavy rain and scorching sun Make sure that cooling air circulates freely Serial number The serial number of the unit is marked on the rating plate of the unit The serial number makes it possible to trace product manufacturing series You might need the serial number
6. Kempact MIG 2530 Operating manual K ytt ohj D Bruksanvisning Bruksanvisning Brugsanvisning Gebrauchsanweisung Gebruiksaanwijzing Manuel d utilisation Manual de instrucciones Instrukcja obstugi HCTpykumu NO 3Kcnnyarauu REF 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 IT Kemppi Oy 1204 OPERATING MANUAL English EN EN CONTENTS 1 1 1 1 2 2 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 29 2 10 2 11 2 12 2 13 3 3 1 32 3 3 3 4 3 5 3 6 3 7 4 4 1 4 2 4 3 SA 6 Preface ERE ao ak pe tn a n a ae a kan ap eat ek afe UNSER 3 ET 1 REE EN ERE 3 Product aurora EE 3 Before you start using the unit sasa 3 Nr 3 Placement of the unit une nern inne 3 Serial number 3 Connection to the mains supply css on 4 Distribution network nenne 4 Eeer FR NO 4 Wire feeding mechanism components 4 Installation OF welding QUA urn 6 Mounting and locking of wire reel 6 Automatic wire feed to gun 6 Adjustment of presse une een ee 6 Adjustment of tightness of reel brake 7 SMA orina aiii 2 0191317211 ee Do iene 8 Mainswitceh and signal O arca ni a 8 To select polarity for welding o oo cccccessstesssessseesssesssecsseessecsneessecsseessisssseesseesseesneests 8 3 21 Changing the polatity oc iion atn D eed tm Dx OE 8 A PN 9 Selecting the w
7. d disturb the wire feeding Tighten the gun quick connector to eliminate voltage losses A loose joint will make the gun and the wire feeder warm NOTE Do not use a damaged gun Mounting and locking of wire reel LOCKED Release locking nails of wire reel hub by turning locking knob a quarter round 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 2 10 Automatic wire feed to gun 2 11 Automatic wire feed makes change of wire reel more rapid In reel change the pressure of feed rolls need not to be released and filler wire goes automatically to correct wire line Make sure that groove of feed roll matches the diameter of welding wire used 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 Do not 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 in grooves of both feed roll pairs Press still the gun switch until wire has come through contact tip Automatic feed may s
8. elding procedure OT A3T 9 Adjusting welding dynamics 10 bR ale ee EE EE 10 Wire feed switch 10 Ea L MANY A 11 DAN LAA a EN AN NG s pab siy ak ay ak ss en ea ane ok ep ae ie kode sey asi 11 Regular maintenance 11 Disposal of the machine ansasen sanson ooo sanson 11 Ordering AUMDES nenne 11 Technical id 12 Kempact MIG 2530 1 1 1 2 2 1 2 2 2 3 PREFACE General Congratulations on your choice of the Kempact series power source Reliable and durable Kemppi products are affordable to maintain and they increase your work productivity This user manual contains important information on the use maintenance and safety of your Kemppi product The technical specifications of the device can be found atthe end of the manual Please read the manual carefully before using the equipment for the first time For your 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 Product introduction The Kempact MI
9. minutes and welding can be started again in the usual way by pressing gun switch 3 7 Wire feed switch The wire feed switch will start the wire feed motor without opening the gas valve The power source will start up but without providing welding power Kempact MIG 2530 4 1 4 2 4 3 MAINTENANCE Daily maintenance NOTE Be careful of mains voltage when handling electric cables Clean the wire channel of the electrode and check the contact tip regularly Always check the condition of the mains and welding cable before operation and replace defective cables NOTE Only a competent electrician is allowed to remove or install the mains cable Regular maintenance KEMPPI service workshops sign special service contracts with customers for regular maintenance All parts are cleaned checked and if necessary repaired Also the operation of the welding machine is tested Disposal of the machine 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
10. n The following installation instructions are valid for most gas flow regulator types ARGOMAG 2 ym Parts of gas flow regulator Gas bottle valve Pressure regulation screw Connecting nut Hose spindle Jacket nut Gas bottle pressure meter Gas hose pressure meter pmm Qn L Step aside and open the bottle valve A for a while to blow out possible impurities Turn the press regulation screw B of the regulator until no spring pressure can be felt Close the needle valve if there is one in the regulator Install the regulator on bottle valve and tighten the connecting nut C with a wrench Install the hose spindle D and jacket nut E into the gas hose and tighten with a hose clamp Connect the hose with the regulator and the other end with the wire feed unit Tighten jacket nut 7 Open the bottle valve slowly The gas bottle pressure meter F shows bottle pressure PWN a Kemppi Oy 1204 EN EN 3 1 3 2 NOTE Do not use the whole contents of the bottle Bottle should be filled when bottle pressure is 2 bar 8 Open the needle valve if there is one in the regulator 9 Turn the regulation screw B until the hose pressure meter G shows the required flow or pressure When regulating the flow amount the power source should be switched on and the gun switch pressed simultanously NOTE Close the bottle valve after welding is finished If the machine will not be in use for a long time u
11. nscrew the pressure regulation screw Always fasten the gas ottle tightly in vertical position to a wall stand or bottle cart specially designed for it For safety reasons always remove the gas bottle from the transport stand of the machine before lifting of transport of the machine by car OPERATION Main switch and signal lights With the switch in the T position the primary and control circuits of the machine become live and the ON signal light on the panel lights up The welding circuit receives voltage when the gun switch is operated or when the wire feed test switch is pressed Always use the main switch to turn the machine on and off with the main switch do not use the power plug for this purpose To select polarity for welding Solid wire is usually welded in pole and cored wire in pole gun Check for the recommended polarity on the package or consult th esupplier of the product The welding of very thin plates 0 5 to 0 7 mm polarity might also work best for solid wire 3 2 1 Changing the polarity KEMPACT 7 1 pole 2 pole NOTE Only a service shop authorised by Kemppi may change the polarity Kempact MIG 2530 3 3 3 4 Panel Adjusting voltage and wire feed speed The welding voltage can be adjusted from 10 to 30 V and the wire feed speed from 1 to 18 m min Adjust the values appropriately by using the table of guideline values on the door of the wire compartment and by testing KEMPPI
12. ometimes fail with thin wires Fe Fc Ss 0 6 0 8 mm Al 0 8 1 0 mm In that case you might have to open feed rolls and feed wire manually through feed rolls NOTE Check that the wire or wire reel does not touch the equipment body there is a danger of short circuit Adjustment of pressure Adjust the pressure of feed rolls with the control screw 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 Kempact MIG 2530 2 12 2 13 Adjustment of tightness of reel brake 2 x2 Stell RARA Brake force is adjusted through hole in locking device of reel hub by screwing the control screw A 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 Shielding gas The MIG shielding gas consists of carbon dioxide mixed gases and argon Shielding gas flow rate is determined by the amount of welding current The typical flow rate of gas in the welding of steel is 8 15 mi
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14. tubes Ss Al Fe 90 6 1 6 mm g 2 5 64 mm 92 5 33 mm g 2 0 mm Mc Fc W000762 W000956 W000624 silver plastic silver plastic plastic 1 6 2 4 mm g 3 5 64 mm 63 533 mm 03 5 mm W001430 W001431 W001389 silver plastic silver plastic plastic Fe Mc Fc 90 6 0 8mm 9 1 0 67 mm g 2 0 33 mm g 2 0 mm W001432 W001435 W000624 white steel orange steel plastic 80 9 1 6 mm 9 2 0 64 mm 83 5 mm W001433 W001389 orange steel plastic g 1 6 2 4 mm 9 4 0 63 mm 9 4 0 33 mm g 3 5 mm W001434 W001436 W001391 blue steel blue steel brass Wire feed rolls mm Colour Drawing Pressing Fe Ss Al 0 6 pale grey W001045 W001046 V groove 08 09 white W001047 W001048 1 0 red W000675 W000676 12 orange W000960 W000961 14 braun W001049 W001050 1 6 yellow W001051 W001052 2 0 grey W001053 W001054 24 black W001055 W001056 Fe Fc Mc 10 red W001057 W001058 knurled 12 orange W001059 W001060 1 4 1 6 yellow W001061 W001062 2 0 grey W001063 W001064 2 4 black W001065 W001066 Fe Fc Mc 1 0 red W001067 W001068 Ss Al 12 orange W001069 W001070 U groove 1 6 yellow W001071 W001072 Kemppi Oy 1204 EN 2 8 2 9 Installation of welding gun Make sure the gun wire conduit and the flow nozzle match the manufacturers recommendations for the type and diameter of wire you use Too small a conduit may overload the wire feed device an
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