Kemppi 4000R User Manual
1922430E
2 KEMPOMIG 4000R, 4000WR - 0409 © COPYRIGHT KEMPPI OY
KEMPOMIG 4000R, 4000WR - 0409 3
© COPYRIGHT KEMPPI OY
CONTENTS
1. PREFACE ......................................................................................................................3
1.1. Introduction ..........................................................................................................3
1.2. Product introduction .............................................................................................3
1.3. Operation safety...................................................................................................3
2. INSTALLATION .............................................................................................................4
2.1. Transport and lifting of the equipment..................................................................4
2.2. Siting the machine ...............................................................................................4
2.3. Connection to the mains supply...........................................................................4
2.4. Welding and return current cables .......................................................................5
3. OPERATION AND USE CONTROLS............................................................................5
3.1. Main switch ..........................................................................................................7
3.2. Signal lamps ........................................................................................................7
3.3. Adjustment for MMA dynamics ............................................................................7
3.4. Control fuse..........................................................................................................7
3.5. Operation of cooling fan.......................................................................................7
3.6. Adjustment for MIG/MAG welding........................................................................7
4. ACCESSORIES .............................................................................................................8
4.1. V/A meter unit MSD 1 ..........................................................................................8
4.2. Cooling unit functions in Kempomig 4000WR......................................................8
4.2.1. Installation of cooling................................................................................................8
4.2.2. Operation .................................................................................................................9
4.2.3. Operation disturbances of the cooling unit...............................................................9
5. MAINTENANCE...........................................................................................................10
5.1. Cables................................................................................................................10
5.2. Power source .....................................................................................................10
5.3. Regular maintenance.........................................................................................10
6. ORDERING NUMBERS...............................................................................................11
7. TECHNICAL DATA ......................................................................................................12
KEMPOMIG 4000R, 4000WR - 0409 3
© COPYRIGHT KEMPPI OY
1. PREFACE
1.1. INTRODUCTION
Congratulations on having purchased this product. Properly installed Kemppi products should
prove to be productive machines requiring maintenance at only regular intervals. This manual is
arranged to give you a good understanding of the equipment and its safe operation. It also contains
maintenance information and technical specications. Read this manual from front to back before
installing, operating or maintaining the equipment for the rst time. For further information on
Kemppi products please contact us or your nearest Kemppi distributor.
The specications and designs presented in this manual are subject to change without prior
notice.
In this document, for danger to life or injury the following symbol is used:
Read the warning texts carefully and follow the instructions. Please also study the Operation safety
instructions and respect them when installing, operating and servicing the machine.
1.2. PRODUCT INTRODUCTION
Kempomig 4000R and 4000WR are DC power sources for demanding professional use in MIG/
MAG welding.
They are inverter power sources for 400 V 3-phase electric mains. Kempomig 4000WR is equipped
with inbuilt cooling unit for water-cooled MIG guns. Parameter adjustments for MIG/MAG
welding are made from Feed 420R wire feeding control unit, which is connected to Kempomig
power sources.
1.3. OPERATION SAFETY
Please study these Operation safety instructions and respect them when installing, operating and
servicing the machine.
Welding arc and spatter
Welding arc hurts unprotected eyes. Be careful also with reecting arc ash. Welding arc and
spatter burn unprotected skin. Use safety gloves and protective clothing.
Danger for re or explosion
Pay attention to re safety regulations. Remove ammable or explosive materials from welding
place. Always reserve sufcient re-ghting equipment on welding place. Be prepared for hazards
in special welding jobs, e.g. for the danger of re or explosion when welding container type work
pieces. Note! Fire can break out from sparks even several hours after the welding work has been
nished!
Mains voltage
Never take welding machine inside a work piece (e.g. container or truck). Do not place welding
machine on a wet surface. Always check cables before operating the machine. Change defect cables
without delay. Defect cables may cause an injury or set out a re. Connection cable must not be
compressed, it must not touch sharp edges or hot work pieces.
Welding power circuit
Isolate yourself by using proper protective clothing, do not wear wet clothing. Never work on a
wet surface or use defect cables. Do not put MIG gun or welding cables on welding machine or
on other electric equipment. Do not press MIG gun’s switch if the gun is not directed towards a
work piece.
Welding fumes
Take care that there is sufcient ventilation during welding. Take special safety precautions when
welding metals which contain lead, cadmium, zinc, mercury or beryllium.
4 KEMPOMIG 4000R, 4000WR - 0409 © COPYRIGHT KEMPPI OY
KEMPOMIG 4000R, 4000WR - 0409 5
© COPYRIGHT KEMPPI OY
EN 60974-1
60°
max
15°
rain water
– Preferably site the machine above oor level.
– See to that in front of the machine as well as at the rear of the machine there is at least 20 cm
free space to allow good circulation of the cooling air through the machine.
– Protect the machine against heavy rain and in hot circumstances against direct sunshine. Ensure
free circulation of the cooling air.
Degree of protection IP23 of the machine allows a water jet coming in 60 ° angle at its maximum
to hit machine´s outer covering.
Do not direct particle spray of grinding tools towards the machine.
2.3. CONNECTION TO THE MAINS SUPPLY
As standard, Kempomig power sources are delivered with 5 m mains cable without plug. If the
mains cable does not meet local electric regulations, you must change the cable to meet them.
Connection and change of the mains cable and plug must be carried out only by a
competent electrician.
During mounting of mains cable, remove the right side plate of the machine, seen from the
front.
When mounting the mains cable ensure the following: The cable is entered into the machine
through the inlet ring on the rear wall of the machine and locked with a cable clamp. The phase
conductors of the cable are coupled to connectors L1, L2 and L3.
Sizes of mains cables and fuse ratings for the machine at 100 % ED duty cycle are specied in the
table Technical data. In cables of S type there is protective grounding conductor coloured greenyellow.
2. INSTALLATION
2.1. TRANSPORT AND LIFTING OF THE EQUIPMENT
On the power source´s front panel and above the wire feeder unit there are handles for moving the
units on the oor.
Make sure that the unit is kept between lifting linens during lifting. When necessary,
use additional binding round the lifting linens and the unit´s upper part. Use protection
between the lifting device and the unit in order to eliminate impacts and shocks.
2.2. SITING THE MACHINE
Site the machine on a stationary, horizontal, dry and clean base from which there does not come
any dust etc. into inlet air through the rear grate.
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