Kemppi Kempact Pulse 3000 User Manual

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Kempact Pulse™

3000

KempactCool™

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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.

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

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

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

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.

2.13 SHIELDING GAS

The MIG shielding gas consists of carbon dioxide, mixed gases and argon. Shielding gas ow rate is determined by the amount of welding current. The typical ow rate of gas in the welding steel is 8–15 l /min.

Parts of gas ow regulator

A. Gas bottle valve B. Press regulation screw C. Connecting nut D. Hose spindle E. Jacket nut F. Gas bottle pressure meter G. Gas hose pressure meter

The following installation instructions are valid for most gas ow regulator types:

1. Step aside and open the bottle valve (A) for a while to blow out possible impurities.

2. Turn the press regulation screw (B) of the regulator until no spring pressure can be felt.

3. Close the needle valve if there is one in the regulator.

4. Install the regulator onto bottle valve and tighten the connecting nut (C) with a wrench.

5. Install the hose spindle (D) and jacket nut (E) into the gas hose and tighten with a hose clamp.

6. 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. Note! Do not use the whole contents of the bottle. The bottle pressure should be lled 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) displays the required ow (or pressure). When regulating the ow amount, the power source should be switched on and the "GAS PURGE" -switch pressed simultanously.

Close the bottle valve after welding is nished. If the machine will not be in use for a long time, unscrew the pressure regulation screw.

NOTE! Always fasten the gas cylinder securely in an upright position on a wall rack intended for the

purpose or on a cylinder cart. Always close the cylinder valve after you have nished welding.

E D

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

2.14 COOLING UNIT KEMPACTCOOL 10

NOTE! Cooling liquid is injurious! Avoid also contact with skin or eyes. In case of injury, seek for

medical advice.

Cooling unit KempactCool 10 together with MIG-gun of Kemppi's PMT-W and MMT-W range enables MIG welding with water-cooled gun.

The cooling unit is installed beneath the power source with screws and mounting plate. Electrical connections are on the bottom of power source.

Electrical connection for the cooling unit:

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

The bottom of power source

1. 400 V

2. Control connector

3. Equipment earth

NOTE! Only an authorised electrician is allowed to install electrical connection!

Installation of cooling unit:

Filling the reservoir:

Fill the reservoir with a 20 – 40 % mixture of etanol and water, or with any other suitable antifreeze. The capacity of the reservoir is 3 litres.

3. OPERATION

3.1 MAIN SWITCH AND SIGNAL LIGHTS

With the switch in the ‘I’ 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 o with the main switch; do not use the power plug for this purpose.

3.2 TO SELECT POLARITY FOR WELDING

Solid wire is usually welded in the +pole and gasfree ller wires in the - pole gun. When welding with other ller wires, check for the recommended polarity on the package or consult the supplier of the product. The welding of very thin steelplates (0.5 to 0.7 mm) a - polarity might also work best for solid wire.

3.2.1 Changing the polarity

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

- pole

+ pole

NOTE! Only a service shop authorised by Kemppi may change the polarity.

3.3 PANEL

3.3.1 Choosing start switch function

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

MIG welding by 4-function start switch, MIG 4T MIG welding by 2 function start switch, MIG 2T

3.3.2 Choosing the welding method

Normal MIG/MAG welding:

With a separate wire feed and voltage regulation can be chosen in the 1-MIG position. Curve number “00” provides a free wire feed range between 1-18 m/min. The voltage can be set between special pre-programmed limits depending on the wire feed. Curve number “01” wire feed speed and voltage are not depended on each other. When curve “01” is selected, the wire feed speed and voltage will be independent of one another.

Synergic MIG/MAG welding (1-MIG)

Synergic MIG/MAG welding (1-MIG): MIG welding in which the wire feed speed determines all the other welding parameter values, allowing the adjustment of welding power with a single knob. Choose the appropriate synergy curve for the ller wire and shielding gas to determine how the wire feed speed aects the pulse parametres.

Synergic Pulse MIG welding:

through this welding method, based on pulsing the welding current, the ller metal on the workpiece is kept spatter-free. The power source pulse parameters change automatically (synergy) enabling welding power regulation using a single knob. Choose the appropriate

synergy curve for the ller wire and shielding gas to determine how the wire feed speed aects the pulse parametres.

Double pulse:

The wire feed will become higher or lower according to the wire feed range. While the synergic welding parameters change to correspond to the momentary wire speed. The purpose is to get a goodlooking weld and a proper penetration while improving the controllability of the weld pool during position welding.

3.3.3 Selecting 1-MIG/Pulse MIG synergy curves

The program number of the synergy curve is selected using the plus-minus buttons and is displayed on "SYNERGIC PRG".

The middle display is actual material group display (eg. SS, AL, CUS, FE, GEN). Wire diameter (mm) can be seen on the right side. This information will only be displayed for a while.

The “PRG INFO” button gives more curve information: One press will revert to the material group and diameter display, a second will display the type

number of the material and a third run through the gas consistency components one by one.

KEMPACT PULSE 3000 Synergic programs 1-MIG Pulse Double

Wire, ø Material Gas Wire Feed Range

Pulse

00 All All All 1,0 - 18,0 01 All All All 0,5 - 18,0

SS-group

S1 S1 S1 0,8 mm SS 308 / 316 Ar + 2 % CO S2 S2 S2 0,9 mm SS 308 / 316 Ar + 2 % CO S3 S3 S3 1,0 mm SS 308 / 316 Ar + 2 % CO S4 S4 S4 1,2 mm SS 308 / 316 Ar + 2 % CO S5 0,9 mm SS 316 FC Ar + 18 % CO S7 1,2 mm SS 316 FC Ar + 18 % CO

Al-group

A1 A1 A1 1,0 mm AlMg5 / AlMg4,5Mn Ar A2 A2 A2 1,2 mm AlMg5 / AlMg4,5Mn Ar A6 A6 A6 1,0 mm AlSi5 / AlSi12 Ar A7 A7 A7 1,2 mm AlSi5 / AlSi12 Ar

Cu-group

C1 C1 C1 0,8 mm CuSi3 Ar C2 C2 C2 0,9 mm CuSi3 Ar C3 C3 C3 1,0 mm CuSi3 Ar C4 C4 C4 1,2 mm CuSi3 Ar C5 C5 C5 0,8 mm CuAl8 Ar C6 C6 C6 0,9 mm CuAl8 Ar C7 C7 C7 1,0 mm CuAl8 Ar C8 C8 C8 1,2 mm CuAl8 Ar

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

² ² ² ²

² ²

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

Fe-group

F1 F1 F1 0,8 mm Fe Ar + 18 % CO F2 F2 F2 0,9 mm Fe Ar + 18 % CO F3 F3 F3 1,0 mm Fe Ar + 18 % CO F4 F4 F4 1,2 mm Fe Ar + 18 % CO F5 0,8 mm Fe CO F6 0,9 mm Fe CO F7 1,0 mm Fe CO F8 1,2 mm Fe CO FA FA FA 1,0 mm FeMC Ar + 18 % CO FB FB FB 1,2 mm FeMC Ar + 18 % CO FD 1,2 mm FeFC Ar + 18 % CO

² ² ² ²

² ² ²

Auto

20 20 1,0 mm CuSi3-A Ar 1,1 – 2,0 1 21 21 1,0 mm CuSi3-A Ar 2,0 – 2,6 2 22 22 1,0 mm CuSi3-A Ar 2,4 – 3,1 3 23 23 1,0 mm CuSi3-A Ar 3,0 – 3,6 4 24 24 1,0 mm CuSi3-A Ar 3,5 – 4,1 5 25 25 1,0 mm CuSi3-A Ar 4,0 – 4,6 6 26 26 1,0 mm CuSi3-A Ar 4,5 – 5,1 7 27 27 1,0 mm CuSi3-A Ar 5,0 – 5,5 8 28 28 1,0 mm CuSi3-A Ar 5,5 – 6,0 9 29 29 1,0 mm CuSi3-A Ar 6,0 – 6,5 10 30 30 1,0 mm CuSi3-A Ar 6,4 – 7,0 11 31 31 1,0 mm CuSi3-A Ar 6,9 – 7,6 12 32 32 1,0 mm CuSi3-A Ar 7,4 – 8,1

3.3.4 Adjustments, display and weld data

Display for welding current and welding material thickness. Changing can be made using the button behind the display. There is a percentage display (eg. gas consistency) and seconds display (see timer). The relative length of arc will be displayed when adjusted. Otherwise the predicted current value is displayed (not in 2-MIG).

Process Manager™ for setting all welding parameters. The display for wire feed speed, welding voltage or material group. This can be switched using

the button under the display (wire feed speed/length of arc). The voltage can be adjusted in the normal and 1-MIG position (wire feed range/the length of arc). During pulse welding the voltage is determined by the wire feed speed while the length of arc aects some other parameters.

When pressed simultaneously, the weld data buttons recall the wire feed speed on the display, the welding voltage and welding current values which have been used when welding was stopped.

3.3.5 Timer

intermittent welding spot welding The spot time is set immediately after pressing the switch button, on the display SPt. The

pause time is set accordingly, on the PSE display. The time is set using the Process Manager.

3.3.6 Adjustment of welding dynamics

For adjusting of MIG/MAG welding dynamics, the adjustment value dyn -9...0...9 is displayed. The welding stability and quantity of spatter are aected by the welding dynamics control, the 0-position is the recommended reference range. Values -9...-1 give a smoother arc and less spatter, while values 1...9 give a rougher arc and increased stability, when using a 100% CO₂ shielding gas when welding steel.

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

3.3.7 Remote control

Gun control, wire feed speed or welding power control is changed using RMT 10. Control of the welding voltage or the length of the welding arc can be adjusted using the potentiometer on the panel. Panel control, adjustments using the potentiometer on the panel.

3.3.8 MIG extra functions

Crater lling, 1-MIG and pulse MIG: Crater lling reduces welding mistakes caused by end craters. By pressing the 4T-trigger

continuously at the end of weld, a descending welding power is achieved which lls end craters in a controlled manner. The descending time is kept constant using the 2T function, and the welding power and end level can be changed using the SETUP-function.

Wire range/ power/Welding current

Start switch 4T

The Hot Start:

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

The Hot Start function is used with 1-MIG and pulse MIG welding. The Hot Start time by 4T Hot Start time is determined by trigger function (see picture) and while by 2T function it is determined by the SETUP parameters. The level of Hot Start can be changed by SETUP function.

The Hot Start level, Hot Start time by 2T, crater ll level and downslope time can be easily adjusted using the ‘QUICK SETUP’ function:

1. Select the gun trigger function: 4T or 2T.

2. First, press the SETUP button and then , while still pressing the SETUP button, press the extra function button.

3. Adjust the Hot Start level.

4. Repeat step 2, upon which the display will show the next adjustable parameter, depending on the switch mode.

Exit by pressing any button (except SETUP)

Hot Start

Crater lling

3.3.9 Use of gas test

If you press the gas test button, gas will begin to ow without any starting power source or wire feed. Gas ow can be measured by using an external measuring device.

Cut o the gas ow by pressing the same button again, or the gun trigger. If the trigger is not pressed again, the gas ow will end within 20 seconds.

The display will show “GAS” and the time.

3.3.10 Testing wire feed

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. The wire feed range will be 5m/min but can be adjusted as desired.

3.3.11 Memory channels, MEMORY

The pulse panel has 100 channels for dierent welding options. Memory channels can be chosen on the lower part of the panel using the memory block. Both welding values and functions can be saved. Do the following:

1. Press twice if needed and and the SET light will start blinking if the channel is not in use, while the light will stay on if the channel is in use.

2. Select the memory channel you want by pressing CH button

3. Make settings and save by pressing SAVE button.

4. Press twice. ON light turns on.

5. Start welding and set the values.

To change the values, the light must be switched from the ON to SET and then you can choose the parameters, pressing the SAVE button afterwards. It is also possible to save the used parameters by pressing SET when memory function is OFF (no lights). The channel can be

emptied by pressing and SET button in SET simultaneously.

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

Using saved settings

1. Press button.

2. Select the memory channel by pressing the CH button.

3. Start welding.

Memory channels in control device

Select memory channels by pressing the CH REMOTE button simultaneously and the gun control light will start to blink. Use the saved values through the gun’s remote control.

You can use ve channels.

3.3.12 SETUP

Using the SETUP function, the user can change welding parameters which do not have their own panel functions. These parameters can be set separately for 1-MIG and Pulse MIG. SETUP settings are separate for each memory channel.

Setup functions on pulse panel

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

Parameter Name Nr Display 1-MIG Pulsed

MIG PostGasTime PreGasTime

HotStartLevel

HotStartTime 2T CraterFillLevel CraterFillSlope

CreepStartLevel CreepStartSlope

DoubleFrequency

DoubleAmpiltude

StartPower

PulseCurrent

ArcLength

1 PoG X X Cur ve s PostGas time 0.0 – 9.9 s 2 PrG X X Curve s PreGas time, functions by 2T

11 Hot X X 30 % Hot start ratio to welding power

12 H2t X X 1.2 s 2T Hot start timer 0.1 – 9.9 s 14 CFL X X 30 % Welding end level 10 – 90 % 15 CFS X X 1 s/10m Wire slowing-down

17 CSL X X Syn Wire speed start value 10 – 90 18 CSS X X 0 s/10m Wire speed up time

21 dFr X Curve Hz Double pulse frequency control

22 dA X Curve m/min Double pulse power variation

31 StP X X 0 Start power control

33 PuC X 0 % Pulse top current control

41 ALr X X 0 % Arc length adjustment range

AdjRange Calibration

WFS

Gun

GunRemote

Water Cooler

42 CAL X X 1 V/100A Setting mid value of arc length

51 FS 18 m/min Wire feed maximum

53 Gun On Liquidcooled thermal protection

54 GrE On Disabling of gun remote control

55 Coo On Set OFF after each power up if

On/Off Selection

Display reset time PRG INFO - feeld

81 dLY X X 5 s 1 – 20 s 82 diS X X 1 1, 2, 3

selection Restore

99 FAC X OFF Restoring factory settings

Factory value

Unit Explanation

0.0 – 9.9 s

-50 ... +75%

1 – 20 s/10m

0 – 50 s/10m

0.4 – 8.0 Hz

control 0.1 – 3.0 m/min

-9 ... 0 ... +9

-10 ... +15%

-50 ... +75%

ne adjustment

0.0 – 10.0 V/100A

18 or 25 m/min

on/o

automatic identication

cooler is connected with gas cooled gun.

(OFF=no reset, Pan=panel and setup ALL= also memory channels)

Changing parameters

By pressing the 2T/4T (SETUP) selection switch a little longer the machine will enter the SETUP state. The display will show the set parameter’s runnning number (blinking), its abbreviation and value. Select the parameter number using the “SYNERGIC PRG” + and - buttons or the “SETUP” button (which will jump by tens). Change the value using the control button (in some cases, the value can be found from the synergy curve). “Syn” and the curve value will blink by turns on the right of the display. Set the value by turning the button anticlockwise.

Exit for SETUP using a long press. Frequency and amplitude of double pulse can be set in the separate ‘SET’ mode, obtained

by rst pressing the 2T/4T (SETUP) and, without releasing it, the method button. “dFr” and the frequency in Hz will be displayed. “Syn” will appear if the frequency is based on synergy curves. Change this value by turning the control button anticlockwise. Press it twice to display “dA” i.e. the amplitude (m/min). Adjust this accordingly and exit SETUP by pressing any button other than SETUP.

3.3.13 Error codes

Error codes are among others the following: Err 3: Overvoltages in the mains supply. Also the pilot light of overvoltage is lighting. Err 4: The thermal protection of power suorce has stopped welding. Also the pilot light of

thermal protection is lighting. Err 5: The cooling device has stopped welding. Err 6: The terminal voltage has rised. Take the device to service. Err 153: Liquid cooled PMT- or WS-gun is overheated. Or torch-PTC or RMT10 has beeb

installed, but the jumber inside the torch is in FU-position, look also instruction of torch. Err 154: Overloading of the wire feed motor Error code is eliminated when the reason is aborted, except Err 6, which demands to turn

down the machine.

3.4 COOLING UNIT OPERATION KEMPACTCOOL 10

The operation of cooling units KempactCool 10 is controlled by the power source. The cooling unit pump starts automatically when welding starts. Proceed as follows:

• Start power source.

• Check water level and input ow of the reservoir, add liquid if needed.

• If you use a water-cooled gun you can ll it with cooling liquid by pressing TEST-button

(on cooling unit).

The pump operates for 5 another minutes after welding has been nished to cool the liquid to the same temperature as in the machine surrounds. This reduces the need of service.

Thermal overload

The thermal overload light is lit, the machine stops and display shows Err 5 when temperature control of the machine has detected cooling water overheating. The cooling unit fan cools down the water, and when the light goes out welding can be started again.

Water ow signal

Display shows Err 5 when water does not ow.

4. MAINTENANCE

4.1 DAILY MAINTENANCE

NOTE! Be careful of mains voltage when handling electric cables!

Clean the wire channel of the gun 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 qualied electrician should remove or install the mains cable!

4.2 REGULAR MAINTENANCE

Kemppi-service workshops sign special service contracts with customers for regular maintenance. All parts are cleaned, checked and if necessary, repaired. The operation of the welding machine is also tested.

5. 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.

6. ORDERING NUMBERS

Item Ordering number Kempact Pulse 3000 KempactCool 10 GH 30 Gun holder PMT 25 PMT 25 PMT 27 PMT 27 PMT 32 PMT 32 PMT 30W PMT 30W PMT 35 PMT 35 WS 35 WS 35 WS 30W WS 30W MMT 25 MMT 25 MMT 27 MMT 27 MMT 30W MMT 30W Remote Control Unit Earth cable 35 mm² Transport unit ST 7 Transport unit P20 Transport unit P250 Lift hook Gas hose Wire spool pole 5 kg spool adapter

621830002

6218600

6256030

3 m 6252513

4.5 m 6252514

3 m 6252713

4.5 m 6252714

3 m 6253213

4.5 m 6253214

6253043

6253044

3 m 6253513

4.5 m 6253514

6 m, Al 1.2 6253516A12

6 m, Ss 1.0 6253516S10

6 m, Al 1.2 6254206A12

6 m, Ss 1.0 6254206S10

3 m 6252513MMT

4.5 m 6252514MMT

3 m 6252713MMT

4.5 m 6252714MMT

3 m 6253043MMT

4.5 m 6253044MMT

RMT 10 6185475

5 m 6184311

for power source and gas bottle 6185290

power source, cooling unit and gas bottle 6185261

power source 6185268

4298180

6 m W000566

4289880

4251270

Parts of the DuraTorque™ 400 metal feed rolls

W000731 gear ring 1 driving 2 pcs per unit W000732 gear ring 2 pressing 2 pcs per unit W000711 drive ring V groove 1,2/1,2 optional 4 pcs per unit W000718 drive ring V groove 1,0/1,0 optional 4 pcs per unit W000891 drive ring V groove 1,0/1,2 4 pcs per unit 9420507 washer 10.5x30x2.5 2 pcs per unit

7. TECHNICAL DATA

Kempact Pulse 3000

Connection voltage Rated power

Supply current

Connection cable Fuse (delayed) Duty cycle 40 °C

Welding range Wire feed speed Open circuit voltage Power factor at max. current Efficiency at max. current Filler wires

Shielding gas Wire spool (max. ø) Feed roll ø Thermal class External dimensions Weight Gun connection Wire feed mechanism Operating temperature range Storage temperature range EMC class Degree of protection

3~, 50/60Hz 400V ±15%

40% ED 12 kVA 250A

60% ED 10 kVA 207A

100% ED 7.5 kVA 160A

1max

1eff

HO7RN-F 4G1.5 (5 m)

40% ED 250A /26.5V

60% ED 207A /24V

100% ED 160A /22V

Fe, Ss 0.6 – 1.2 mm

Cored wire 0.9 – 1.2 mm

Al 0.9 – 1.2 mm

CuSi 0.8 – 1.2 mm

LxWxH 580x280x440 mm

17 A

11 A

16A

8 – 30V

1 – 18 m/min

56 V

0.69 (250A / 26V)

0.84 (250A / 26V)

CO₂, Ar, Ar & CO₂ mixed gases

300 mm (15 kg)

32 mm

H (180 °C) / B (130 °C)

22 kg

EURO

4 roll

- 20 °C ...+ 40 °C

- 40 °C ...+ 60 °C

IP23S

Cooling unit KempactCool 10 Operating voltage Connection capacity Cooling power Start pressure, max Cooling liquid Tank volume External dimensions (LxWxH) Weight Operating temperature range Storage temperature range EMC class Degree of protection

400 V - 15% ... 10%

250 W

1 kW

0.4 MPa

20% – 40% etanol/water

3 l

580x280x300 mm

13 kg

- 20 °C ...+ 40 °C

- 40 °C ...+ 60 °C

IP23S

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Kemppi Kempact Pulse 3000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual