Kemppi Kempact Pulse 3000 User Manual

Kempact Pulse™

3000

KempactCool™

Operating manual • English

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OPERATING MANUAL

English

Kempact Pulse 3000, KempactCool 10 / © Kemppi Oy / 1136

CONTENTS

1. PREFACE ........................................................................................................................................................3

1.1 General ................................................................................................................................................................. 3

1.2 Product introduction ................................................................................................................................. 3

2. BEFORE YOU START USING THE UNIT .................................................................. 3

2.1 Unpacking ......................................................................................................................................................... 3

2.2 Placement of the unit ................................................................................................................................ 3

2.3 Serial number .................................................................................................................................................. 3

2.4 Distribution network .................................................................................................................................4

2.5 Connection to the mains supply ....................................................................................................... 4

2.6 Ground cable ................................................................................................................................................... 4

2.7 DuraTorque™ 400, 4 wheel wire feed mechanism ...............................................................4

2.8 Installation of welding gun ................................................................................................................... 5

2.9 Mounting and locking of wire reel .................................................................................................. 5

2.10 Automatic wire feed to gun ..................................................................................................................6

2.11 Adjustment of pressure ...........................................................................................................................6

2.12 Adjustment of tightness of spool brake ......................................................................................6

2.13 Shielding gas ................................................................................................................................................... 7

2.14 Cooling unit (Kempactcool 10) ..........................................................................................................8

Kempact Pulse 3000, KempactCool 10 / © Kemppi Oy / 1136

3. OPERATION ............................................................................................................................................... 9

3.1 Main switch and signal lights .............................................................................................................. 9

3.2 To select polarity for welding .............................................................................................................. 9

3.2.1 Changing the polarity .........................................................................................................................9

3.3 Panel ...................................................................................................................................................................10

3.3.1 Choosing start switch function .................................................................................................... 10

3.3.2 Choosing the welding method .................................................................................................... 10

3.3.3 Selecting 1-MIG/Pulse MIG synergy curves ............................................................................. 11

3.3.4 Adjustments, display and weld data ..........................................................................................12

3.3.5 Timer ...................................................................................................................................................... 13

3.3.6 Adjustment of welding dynamics ............................................................................................... 13

3.3.7 Remote control ..................................................................................................................................13

3.3.8 MIG extra functions .......................................................................................................................... 14

3.3.9 Use of gas test .....................................................................................................................................14

3.3.10 Testing wire feed ...............................................................................................................................14

3.3.11 Memory channels, MEMORY .........................................................................................................15

3.3.12 SETUP .....................................................................................................................................................16

3.3.13 Error codes ...........................................................................................................................................17

3.4 Cooling unit operation (KempactCool 10) .............................................................................. 18

4. MAINTENANCE .................................................................................................................................. 18

4.1 Daily maintenance .................................................................................................................................... 18

4.2 Regular maintenance ............................................................................................................................. 18

5. DISPOSAL OF THE MACHINE ..........................................................................................18

6. ORDERING NUMBERS ...............................................................................................................19

7. TECHNICAL DATA ...........................................................................................................................20

1. PREFACE

1.1 GENERAL

Congratulations on your choice of the Kempact Pulse™ series power source. Reliable and durable, Kemppi products are aordable 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 specications of the device can be found at the end of the manual. Please read the manual carefully before using the equipment for the rst 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 specications 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. Please also read the safety instructions in this manual and respect them.

Disclaimer

While every eort 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 specication 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.

Kempact Pulse 3000, KempactCool 10 / © Kemppi Oy / 1136

1.2 PRODUCT INTRODUCTION

The Kempact Pulse 3000 is a compact MIG inverter suitable for repair and installation use, and for light and medium industrial use.

2. BEFORE YOU START USING THE UNIT

2.1 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 it is accompanied by the appropriate instructions.

NOTE! The packaging material is suitable for recycling.

2.2 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.

2.3 SERIAL NUMBER

The serial number of the unit is marked on its 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.

2.4 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.

Kempact Pulse 3000:

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.

2.5 CONNECTION TO THE MAINS SUPPLY

The Kempact Pulse 3000 is delivered with a ve 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.

2.6 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 of paint and rust. Use at least two 35 mm² cables. Thinner cross sectional areas may cause the connectors to overheat.

2.7 DURATORQUE™ 400, 4 WHEEL WIRE FEED MECHANISM

Kempact Pulse 3000, KempactCool 10 / © Kemppi Oy / 1136

Wire guide tubes

Ss, Al, Fe, Mc, Fc

Fe, Mc, Fc ø 0.6 – 0.8 mm ø 1.0/67 mm,

ø 0.6 – 1.6 mm ø 2.5/64 mm,

W000762, silver, plastic

ø 1.6 – 2.4 mm ø 3.5/64 mm,

W001430, silver, plastic

W001432, white, steel

ø 0.9 – 1.6 mm ø 2.0/64 mm,

W001433, orange, steel

ø 1.6 – 2.4 mm ø 4.0/63 mm,

W001434, blue, steel

ø 2.5/33 mm, W000956, silver, plastic

ø 3.5/33 mm, W001431, silver, plastic

ø 2.0/33 mm, W001435, orange, steel

ø 4.0/33 mm, W001436, blue, steel

ø 2.0 mm, W000624, plastic

ø 3.5 mm, W001389, plastic

ø 2.0 mm, W000624, plastic

ø 3.5 mm, W001389, plastic

ø 3.5 mm, W001391, brass

Wire feed rolls

Fe, Ss, Al, V-groove

Fe, Fc, Mc, knurled

Fe, Fc, Mc, Ss, Al, U-groove

ø mm colour drawing pressing

0.6 pale grey W001045 W001046

0.8/0.9 white W001047 W001048

1.0 red W000675 W000676

1.2 orange W000960 W000961

1.4 brown W001049 W001050

1.6 yellow W001051 W001052

2.0 grey W001053 W001054

2.4 black W001055 W001056

1.0 red W001057 W001058

1.2 orange W001059 W001060

1.4/1.6 yellow W001061 W001062

2.0 grey W001063 W001064

2.4 black W001065 W001066

1.0 red W001067 W001068

1.2 orange W001069 W001070

1.6 yellow W001071 W001072

2.8 INSTALLATION OF WELDING GUN

Make sure the gun wire conduit and the contact tip match the manufacturer’s recommendations for the type and diameter of wire you use. Too small a conduit may overload the wire feed device and impede the wire feeding. Tighten the gun’s quick connector to eliminate voltage loss. A loose joint will heat up the gun and wire heater.

NOTE! Never use defected gun.

2.9 MOUNTING AND LOCKING OF WIRE REEL

LOCKED OPEN

• 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!

• 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

Automatic wire feed makes change of wire reel more rapid. In reel change the pressure of feed rolls need not to be released and ller 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 o 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 (le o 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 sometimes 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

2.11 ADJUSTMENT OF PRESSURE

Adjust the pressure of the feed rolls with the control screw so that the wire is fed into the wire guide tube evenly and allows a little braking when emerging from the contact tip, without

slipping on the feed rolls.

NOTE! Excessive pressure will cause the ller wire to atten and damage its coating, as well as

undue wear and tear of the feed rolls and friction damage.

2.12 ADJUSTMENT OF TIGHTNESS OF SPOOL BRAKE

Brake force can be adjusted through the hole in the spool hub’s locking device of spool hub by screwing the control screw with a screwdriver. Adjust the braking force so that it is sucient to prevent the wire from becoming too loose on the spool and spilling when the spool stops rotating. The greater the wire feed speed, the greater the braking force required. Do not keep the brake unnecessarily tight, since this will impose a strain on the motor.

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