Kempoweld 3200, 3200W User Manual
Contents
1. The wire feed is adjusted from the potentiometer on the control panel of the wire feeder unit Kempoweld WIRE 400 The adjustment has been described in the operation instructions of the wire feeder unit VOLT AMPERE METERING UNIT MSD 1 For the mounting of the MSD 1 remove the cover plate on the front panel of the unit The connector of flat cable fastened to the cover plate is connected to the corresponding connector of the MSD 1 From the metering unit you can with lever switch select momentary display for either voltage or current By open circuit only voltage value is displayed because there is no welding current present The voltage value is the voltage between the unit s welding connectors or terminal voltage The value of the open circuit voltage has not very much importance for the welding so that the display of the metering unit is adjusted according to the welding situation The display of the open circuit voltage differs 2 3 V from the true voltage During welding the terminal voltage is varying and the arc voltage differs from the terminal voltage due to cable etc losses Accuracy of voltage true value in respect to real value is 4 0 0 2V by welding values according to the norm Accuracy of current true value in respect to real value is 2 5 96 2 A The metering unit does not show wire feed values The MSD 1 does not need any calibration in the Kempoweld power source The switch positions V voltage display A cur2. KEMPPI The Joy of Welding Kempoweld 3200 3200W Operating manual English K ytt ohje Suomi Bruksanvisning Svenska Bruksanvisning Norsk Brugsanvisning Dansk Gebrauchsanweisung Deutsch Gebruiksaanwijzing Nederlands Manuel d utilisation Francais Instrukcja obstugi Polski VAHCTpyKLUU no akcnnyataynn Flo pyccka EN H SV DA DE NL FR PL RU ZLLL AQ 1dduiey MOOCE O07 plemodusy OPERATING MANUAL English Kempoweld 3200 3200W Kemppi Oy 1117 EN CONTENTS 1 PREFACE o ee tenni 3 Il General RAP EP A SO V E OD O O OL P 3 L2 Product introduction Se ae halo roi ia 3 13 ee TE A 1 3 1 Operation control and copnpechors eene 4 1 3 2 Parts of cooling unit Kempoweld 3200W eee 4 1 3 3 Rear plate of Kempoweld 3200 3200W sss 5 1 4 Wire feeder panels 5 ES Font Panel ebrio ont beo menia uaa 5 142 EE 6 143 Cooling unit conpnectlons rennen 6 144 Rear panel EE ee GAA ae ae ORI 6 14 5 Inside wire feeder unft eterne 6 2 INSTALLATION 7 2 1 Positioning of the machine surement 7 22 Distribution net WO nemis titu utes rore p t neslo tact erepti neca 7 2 3 Connection to the mains supply 2 eeeeeeeeeeeeeeeeeeeeeeeeeeeeneeeeeeeeeeeteeeneeeeienc 7 24 Welding and return current cables 8 2 5 Operation and use of controls 9 2 5 1 Main switch fait 9 2 5 2 Adjustment of welding voltage sss 9 215 3 Pilot EI cae eerie ter iren er i eret
3. Do not use faulty cables Make sure that the mains connection cables in use are safe and according to regulations The repair and mounting of mains connection cables should be carried out only by an authorized electrician Power source NOTE Disconnect the plug of the power source from the mains socket before removing the cover plate Check at least every 6 months twice a year Electric connections of the unit clean the oxidized parts and tighten the loosened ones NOTE You must know correct tension torques before starting the repair of the joints Clean the inner parts of the machine from dust and dirt e g with soft brush and vacuum cleaner Do not use compressed air there is a risk that dirt is packed even more tightly into gaps of components Do not use pressure washing device Only authorized electrician shall carry out repairs to the machines Regular maintenance Kemppi service repair workshops make regular maintenance according to agreement The major points in the maintenance procedure are listed as follows Cleaning of the machine Checking and maintenance of the welding tools Checking of connectors switches and potentiometers Checking of electric connections Metering units checking Checking of mains cable and plug Damaged parts or parts in bad connection are replaced by new ones Maintenance testing Operation and performance values of the equipment are checked and adjusted when necessary by m
4. 10 6787 1282 Telefax 86 10 6787 5259 sales cn kemppi com BAD 1tR ARAA BLA TRA ZK ZR ERR 12 5 fil Bt KBR X420 100176 FIG 86 10 6787 6064 4 86 10 6787 1282 f Ei 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 Tt6L ZLLL OLOC
5. O i e OE 9 2 5 4 Control fuse EI 9 2 5 5 Adjustment for arc roughness u eeeeee eee eee eee etno n 9 2 5 6 Operation of cooling fan 9 2 5 7 Accessory E ose eoi cpi HR HO RO HER ER anea ai 10 2 5 8 Adjustment for wire feed 10 2 6 Volt ampere metering unit msd 1 10 2 7 COM RV a GE 10 2 7 1 Installation of cooling 10 2 7 2 Operation switches nene KRKA KAR K KK nennen 11 3 OPERATION DISTURBANCES cscs 12 4 MAINTENANCE 13 4 1 Disposal of the machine 13 5 ORDERING NUMBERS een 14 6 TECHNICAL DATA ttennennnnnnnnnenit 16 1 1 1 2 PREFACE GENERAL Congratulations on choosing the Kempoweld power source 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 th
6. volume before starting to weld Use the cooling liquid according to recommendations or the one you know as good beforehand Watch over liquid material s quality and possible sediments in hoses of the gun Do not swallow cooling liquid If somebody has swallowed the liquid take him immediately to medical care Avoid contact with skin and eyes wash the liquid from your skin with clean water Operation switches In zero O position of the power source s main switch also all operations of the cooling unit are stopped Cooling unit s main switch O 1I The electric supply for the pump motor is switched on by main switch key O I where the pilot lamp indicates the standby state I In zero O position of the main switch the pump motor cannot get started but the switches and pilot lamps are operating Fuse F2 The fuse on the front wall of the cooling unit is short circuit protection Use the fuse size and type according to markings If the fuse is blowing again send the unit to service Selecting switch for gun s cooling mode Sw1 The Kempoweld equipment are suitable to be used with both air and water cooled guns Select cooling mode and correct use and protection functions with switch on the cooling unit s panel If your choice is GAS but you are using water cooled gun no protection is operating The pilot lamp is illuminated in position I of the cooling unit s main switch However the control does not start the pump The w
7. 00 V In order to change the mains voltage remove the side plate of the machine Change the connections according to the enclosed diagram You find the corresponding wiring diagram on the instruction label which is under terminal block WELDING AND RETURN CURRENT CABLES Use only copper cables with cross sectional area of at least 50 mm In enclosed table are shown typical loading capacities of rubber insulated copper cables when ambient temperature is 25 C and conductor temperature is 85 C cable cross section duty cycle ED voltage loss 10 m Cu 100 60 40 96 for 100 A 50 mm 285A 370A 450A 0 35 V Fasten the earthing press of the return current cable carefully preferably direct onto the piece to be welded The contact surface area of the press should always be as large and steady as possible Do not overload welding cables over permissible values due to voltage losses and heating Clean the contact surface from paint and rust 2 5 2 5 1 2 5 2 2 5 3 2 5 4 2 5 5 2 5 6 OPERATION AND USE OF CONTROLS See the page for Kempoweld PANELS and COOLING UNIT Main switch S1 In zero position all control and welding current circuits of the equipment are dead without voltage In position the control circuits of the machine become live get voltage The primary and welding circuits are dead if the welding mode has not been started with the gun trigger NOTE Always switch on and switch off the machine from t
8. 10m 6m 6m 6m 8m 8m 8m 621532002 621632002 621740001 6219150 6185666 6185265 6185247 6260351 6260353 4289880 3151360 6253033 6253034 6253213MMT 6253214MMT 6253513MMT 6253514MMT 6253516A12 6253516510 6257306 6257310 6255046 6255047 6253043MMT 6253044MMT 6257406 6257410 6253046A12 6253046510 6253046512 6253048412 6253048510 6253048512 Air cooled interconnection cables Mounting cables for short distance KW 50 1 3 GH Interconnection cables for long distance Multimig 50 5 GH Multimig 50 10 GH Liquid cooled interconnection cables Mounting cables for short distance KW 50 1 5 WH Interconnection cables for long distance KW 50 5 WH KW 50 10 WH Return current cable 5m 50mm 6260350 626010401 626010601 6260352 626035401 626035601 6184511 15 Kempoweld 3200 3200W Kemppi Oy 1117 EN Kempoweld 3200 3200W Kemppi Oy 1117 EN 6 16 TECHNICAL DATA Kempoweld Connection voltage Connection capacity 230 V 400 V Main cable fuses Connection to wire feeder unit Fuse delayed Loading capacity nominal values Control range 40 steps Open circuit voltage 40 steps Open circuit power Efficiency Power factor Temperature dass Operation temperature range Storage temperature range Degree of protection EMC dass Minimun short circuit power Ssc of supply network Cooling unit power Fuse delayed External dimensions W
9. 2 X1 02 Adjustment for wire feed Welding gun connector EURO Trigger function mode continuous hold Welding mode selection continuous spot cycle arc Adjustment for welding mode timing spot or cycle time Kempoweld 3200 3200W Kemppi Oy 1117 EN Kempoweld 3200 3200W Kemppi Oy 1117 EN 1 4 2 1 4 3 1 4 4 1 4 5 Accessories KMW sync K3 Wire feed adjustment selection panel or push pull gun X1 Control connector for push pull gun Cooling unit connections 01 Return water connector for gun 02 Feed water connector for gun 04 Inlet of water hoses Rear panel X3 X2 03 04 03 Shielding gas connector X2 Control cable connector Kempoweld or interconnection cable X3 Welding current connection Kempoweld or interconnection cable Inside wire feeder unit R3 K4 04 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 latch 06 Box door lock 07 Wire feed mechanism 2 1 2 2 2 3 INSTALLATION POSITIONING 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 Preferably site the machine above floor level for example on a suitable carriage unit Notes for positioning the machine The surface inclination should not exceed 15 degrees Ensure the
10. 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 Strafe 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 plakemppi 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 KEMTITIM 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
11. able and push pull gun KMW timer controls continuous spot and cycle arc welding Accessory unit KMW sync is needed for connection and use of push pull guns Kempoweld 3200 3200W Kemppi Oy 1117 EN Kempoweld 3200 3200W Kemppi Oy 1117 EN 1 3 KEMPOWELD PANELS 1 3 1 Operation control and connectors S1 S2 S3 H2 X1 X2 05 MSD 1 S1 H1 05 H2 S2 S3 X1 X2 Main switch pilot lamp H1 Voltage selecting switch coarse grading Voltage selecting switch fine grading Pilot lamp for overheating power source Return current connector coarser arc Return current connector softer arc Accessory drawer V A metering unit accessory 1 3 2 Parts of cooling unit Kempoweld 3200W Sw1 F2 S4 Sw2 Hw4 Hw3 MSD 1 a di 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 1 4 1 4 1 F2 02 03 04 Fuse for cooling unit 2 A delayed Water circulation return connector Water circulation output connector Filler hole for water tank Rear plate of Kempoweld 3200 3200W 01 F1 X3 X4 02 03 01 X3 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 Front panel R1 X1 K1 K2 R2 K3 X1 01 K1 K2 R
12. at require particular attention in order to minimise damage and personal harm are indicated with the VOTE notation 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 PRODUCT INTRODUCTION The power sources Kempoweld 3200 and 3200W with wire feeder unit WIRE 400 makes together 320 A MIG welding equipment which is suitable for heavy industrial use To the product range belong in addition also the power sources Kempoweld 4200 4200W and 5500W Kempoweld 3200W has inbuilt water cooling unit Power source Supply voltage of the power source is 3 230 V 400 V Voltage of power source is adjusted with turn type switches together 40 steps The Volt Ampere metering unit MSD 1 accessory which is included in the power source displays voltage or welding current Wire feeder unit The wire feeder unit WIRE 400 is a 4 roll driven unit which is suitable for air or liquid cooled guns The unit may be turnable above the power source or it may be locked at its place You can use the WIRE 400 wire feeder unit equipped also with interconnection c
13. connectors on the front plate The connector marked with shorter symbol gives a rougher arc which is used for welding of thin sheets and ferrous metals by 0 6 1 0 mm wires and especially with CO shielding gas The connector marked with longer symbol is suitable for thicker wires and especially for aluminium and stainless materials The most suitable roughness is however most dependent on the welding case You will find the best position by testing the different positions Operation of cooling fan The cooling fan on the rear plate of the Kempoweld 3200 equipment is started and stopped according to use The cooling fan is controlled by the gun trigger and control circuits The cooling fan is started after ca 15 s after weld start and stopped after ca 10 min after weld end or release of the overheat protection NOTE Do not switch off the unit with the main switch before the cooling fan has automatically stopped By open circuit the cooling fan does not get started Kempoweld 3200 3200W Kemppi Oy 1117 EN Kempoweld 3200 3200W Kemppi Oy 1117 EN 2 5 7 2 5 8 2 6 2 7 2 7 1 10 Accessory drawer In the accessory drawer in the cover part of the unit are by delivery the plastic guide tubes needed for welding of aluminium and stainless steels In the drawer are also the screw and the insulation bushings needed for locking of rotation of the wire feeder Kempoweld WIRE 400 Adjustment for wire feed
14. e is always counted from the latest trigger release 11 Kempoweld 3200 3200W Kemppi Oy 1117 EN Kempoweld 3200 3200W Kemppi Oy 1117 EN 12 OPERATION DISTURBANCES By the operation or functional disturbances take the measures according to the following list If the disturbance cannot be eliminated check the equipment according to the paragraphs Installation and Maintenance and take contact with Authorized Kemppi repair workshop The pump does not get started by test switch check the fuse on the front plate of the cooling unit e check the fuse on the rear plate of the power source e check position for cooling mode selecting switch check positions for main switches The water does not circulate by lever switch check the tank filling volume disconnect the connector for the return water hose of the gun from the rear wall of the cooling unit and use thet test switch If the water is pumped close the connector and run again by the test switch A good tip Blow compressed air into the tank closing the filling opening by hand is enough The water is pumping but does not return back to the tank or the return flow is weak filling of interconnection cable can take several minutes e if you have lifted the gun or interconnection cable for the filling time many meters higher than the power source the filling will happen considerably slower Fill the hoses on the floor position e check the whole flowin
15. eans of test equipment 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 By applying this European Directive you will improve the environment and human health 13 Kempoweld 3200 3200W Kemppi Oy 1117 EN Kempoweld 3200 3200W Kemppi Oy 1117 EN 5 ORDERING NUMBERS Units Kempoweld 3200 Kempoweld 3200W Wire feeder unit Kempoweld WIRE 400 Accessories KMW sync 2 MSD 1 P500 transport unit feeder KV400 swing arm KV400 50 1 5 GH KV400 50 1 7 WH Hub for wire reel Branch cable KMP Kempoweld MIG guns Air cooled KMG 32 KMG 32 MMT32 MMT32 MMT35 MMT35 WS 35 Al 1 2 WS 35 SS 1 0 KMP 300 KMP 300 Liquid cooled MT51W MT51W MMT 30W MMT 30W 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 14 230V 400V 230V 400V 3m 45m 3m 45m 3m 45m 6m 6m 6m 10m 3m 45m 3m 45m 6m
16. eight See paragraph 2 2 3 400V 3 230V 40 ED 60 ED 100 ED 220 240V 380 415V 40 ED 60 ED 100 ED 320A 32V 320A 32V lenght width height 3200 380V 10 415V 6 220V 10 240V 6 13 6 kVA 10 0 kVA 6 6 kVA 4x2 5 mm 20 A delayed 4x2 5 mm 16 A delayed 30V 250VA 8A 320A 32V 265A 27V 205A 24V 40 320 A 15 32V 15 40V lt 50W 7596 0 95 H 180 C 20 60 C 40 60 C IP23S A 0 9 MVA 990 mm 530mm 880 mm 106 kg 3200W 380V 10 415V 6 96 220V 10 240 V 6 13 6 kVA 10 0 kVA 6 6 KVA 4x 2 5 mm 20 A delayed 4x2 5 mm 16 A delayed 30V 250VA 8A 320A 32V 265A 27V 205A 24V 40 320 A 15 32V 15 40V lt 50W 7596 0 95 H 180 C 20 60 C 40 60 C IP23S A 0 9 MVA 230V 250 VA 2A 990 mm 530mm 1090 mm 118 kg ZLLL AQ 1dduiey MO0ZE O07 Pjamodway EN 17 KEMPPI OY 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 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
17. free circulation of the cooling air There must be at least 20 cm of free space in front of and behind 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 aim metallic grinding spray sparks towards the equipment 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 This equipment complies with IEC 61000 3 12 provided that the short circuit power Ssc is greater than or equal to 0 9 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 0 9 MVA CONNECTION TO THE MAINS SUPPLY NOTE Connection and change of the mains cable and the plug must be carried out only by a competent electrician Remove for the mounting of the mains cable the left side plate seen from the front of the power source The Kempoweld power source is equipped with 5 m supply cable without plug The mains cable is according to
18. g line connector by connector The water is pumping but during welding the red pilot lamp for the water pressure is lit and the equipment is stopped check the cooling water volume and return flow to the tank e in the system are air bubbles or leakages especially check the connections of the cooling unit the pressure switch set value ca 1 bar is unsuitable for the gun you are using 1 Open the side plate In the middle at the upper end of the pressure guard connected to the pump is the adjusting screw for limit value Use the pump during the adjustment by the test switch After ca 5 s use twist the screw carefully until the pilot lamp is switched off Check the result by welding If the adjustment and checkings do not eliminate the disturbance take contact with the Authorized Kemppi repair workshop Urge wg M During welding the yellow pilot lamp for overheating is lit and the equipment is stopped e release the trigger When the lamp is switched off the operation has been reset automatically e check if the gun is suitable for power you are using check condition of connectors and connections in the welding current circuit 4 1 MAINTENANCE The amount of use and the working environment should be taken into consideration when planning the frequency of maintenance of the machine Careful use and preventive maintenance will help to ensure trouble free operation Cables Check the condition of welding and connection cables daily
19. he main switch Never use the mains plug for switching on or switching off the units and equipment Adjustment of welding voltage Table of adjustments switch positions coarse control fine control open circuit voltage 1 4 1 10 10 10 15 5 18 2V 2 4 1 10 10 10 18 6 22 5 V 3 4 1 10 10 10 23 1 29 3V 4 4 1 10 10 10 30 4 41 6V The welding voltage is adjusted with two turn switches The S2 is the 4 step switch for coarse control where voltage value of each step can be fine adjusted with the 10 step switch S3 Pilot lamps Pilot lamps of the machine report about electric function The green pilot lamp H1 indicating that the machine is ready for operation is always lit when the machine is connected to mains voltage and the main switch is on position I The yellow pilot lamp H2 is lit when thermal protection of the welding circuit has released due to overheating The protection releases if the power source is continuously loaded over rated values or the cooling air circulation has been obstructed Control fuse F1 On the rear plate of the power source the fuse F1 8 A delayed is the short circuit protection Use the fuse size and type according to markings Damage caused by a wrong type fuse is not covered by the guarantee If the fuse is blowing again send the unit to service Adjustment for arc roughness JAN NN Arc roughness is adjusted by connecting the return current cable to the applicable one of the two dix
20. rent display COOLING UNIT Kempoweld 3200W power source has inbuilt cooling unit Installation of cooling The cooling unit is connected to the gun by means of water hoses which are mounted to the wire feeder unit The interconnection cable contains also the water hoses which are mounted to the gun through the wire feeder unit without any extension parts See operation instruction for Kempoweld WIRE feeders Before connection check that in the hoses are no dirt metal powder rubber waste etc The connectors for hoses and cooling unit are marked with red or blue identification rings or spots Blue is colour for water supplied from cooling unit to gun and red is colour for water returning back from gun to cooling unit The cooling unit s tank is filled with 40 96 antifreeze according to British Standard BS3151 If the circumstances do not require frost resistance you can use a more dilute mixture or some other mixture of which you have good experriences Tank volume is ca 3 litres volume of gun and interconnection cable is 0 3 1 5 litres Filling of hoses takes 5 s 3min time Check the return flow to the tank Before filling check that tank cooling water pouring tank etc are clean and that there is no metal powder waste etc 2 7 2 NOTE If the water does not start circulating see paragraph Operation disturbances The water does not circulate etc Do not let any waste and dirt into the water circulation Check filling
21. rong choice will destroy the gun in short time If your choice is A water but you are using air cooled gun the pump gets started by pressing on the trigger if the cooling unit s main switch is in position I Test switch Sw5 By TEST switch on the panel of the cooling unit you can circulate water without starting welding It is used for filling the gun and interconnection cable with cooling water before starting welding By disturbance situations you can always test the water circulation Always check entry of return water into the tank before welding Pilot lamps Pilot lamp for overheating Hw4 If the cooling water in the tank is overheating the thermal protection will stop the power source Operation of the cooling unit is continued for ca 5 7 min automatically The pilot lamp will switch off after the water in the tank has cooled down after which the welding will start from the gun triggering Pilot lamp for lacking liquid pressure Hw3 If the pump does not step up sufficient supply pressure e g when the water is running out or by disturbances in the pump the whole equipment will stop after ca 5 s and the red pilot lamp illuminates Check the equipment like by the installation See paragraph for OPERATION DISTURBANCES Operating control The water circulation gets automatically started when you are pressing on the gun trigger The post circulation of water will continue for ca 5 7 min after the weld end The tim
22. the marking HO7RN F of the norm CENELEC HD22 The mains cable must be changed if it does not meet local regulations Mounting of the mains cable Kempoweld 3200 3200W Kemppi Oy 1117 EN Kempoweld 3200 3200W Kemppi Oy 1117 EN 2 4 The cable is entered into the machine through the inlet ring on the rear wall of the machine and locked with a cable clamp 05 The phase conductors of the cable are coupled to connectors L1 L2 and L3 The earth protection coloured green yellow is coupled to connector marked with earth protection symbol If you are using 5 conductor cable you must cut the zero conductor to the level of the cable s protective shield Sizes of mains cables and fuse ratings for the machine at 100 ED duty cycle are specified in the table below Kempoweld 3200 3200W Connected voltage 230V 400V Voltage range 220 240 V 380 415V Fuses delayed 20A 16A Connected cable 4x 2 5 S mm 4x 2 5 Smm In cables of S type there is protective grounding conductor coloured green yellow NOTE This equipment electromagnetic compatibility EMC is designed for use in an industrial environment Class A equipment is not intended for use in residential location where the electrical power is provided by the public low voltage supply system Change of mains voltage Connection 3 230 or 3 400 V of mains voltage By delivery from the factory the machine has been connected for mains voltage 3 4
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