Kemppi MIG 2520 User Manual

KEMPACT

MIG 2520

1910183E

0635

2 – Kempact mig 2520 / 0635 © Kemppi oy

CONTENTS

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

1.1. INTRODUCTION .........................................................................................................

3

1.2. PRODUCT INTRODUCTION ...................................................................................... 3

1.3. SAFE OPERATION ..................................................................................................... 3

2. BEFORE YOU START USING THE UNIT ..................................................................... 4

2.1. UNPACKING ...............................................................................................................

4

2.2. PLACEMENT OF THE UNIT ....................................................................................... 4

2.3. SERIAL NUMBER ....................................................................................................... 4

2.4. CONNECTION TO THE MAINS SUPPLY ................................................................... 4

2.5. GROUND CABLE ........................................................................................................ 4

2.6. WIRE FEEDING MECHANISM COMPONENTS ........................................................ 4

2.7. FEED ROLLS .............................................................................................................. 5

2.8. INSTALLATION OF WELDING GUN ........................................................................... 5

2.9. MOUNTING AND LOCKING OF WIRE REEL ............................................................. 5

2.10. INSTALLING WELDING WIRE .................................................................................. 5

2.11. SHIELDING GAS ....................................................................................................... 6

3. OPERATION .................................................................................................................. 6

3.1. MAIN SWITCH AND SIGNAL LIGHTS ........................................................................

6

3.2. TO SELECT POLARITY FOR WELDING .................................................................... 7

3.2.1. CHANGING THE POLARITY ......................................................................... 7

3.3. PANEL ......................................................................................................................... 7

3.4. SELECTING THE WELDING PROCEDURE (2T/4T) ................................................. 8

3.5. ADJUSTING WELDING DYNAMICS ........................................................................... 8

3.6. THERMOSTAT ............................................................................................................ 8

3.7. WIRE FEED SWITCH ................................................................................................. 8

4. MAINTENANCE ............................................................................................................. 9

4.1. DAILY MAINTENANCE ...............................................................................................

9

4.2. REGULAR MAINTENANCE ........................................................................................ 9

5. ORDERING INFORMATION .......................................................................................... 9

6. TECHNICAL DATA ...................................................................................................... 10

7. DISPOSAL OF THE MACHINE ...................................................................................

10

8. TERMS OF GUARANTEE ............................................................................................11

Kempact mig 2520 / 0635 – 3 © Kemppi oy

1. PREFACE

1.1. INTRODUCTION

Congratulations on having purchased a KEMPPI product. Properly installed and used KEMPPI
products should prove to be productive machines requiring only a small amount of regular
maintenance.This manual is designed to give you a good understanding of the equipment and its safe
use. There is also information on maintenance of the unit and the machine´s technical data. Read

the instructions before bringing the machine into use or servicing it for the rst time. Additional

information on Kemppi products and their use can be obtained from Kemppi or a Kemppi dealer.

The specications and designs presented in this manual are subject to change without prior notice.
In this document, the following symbol is used the symbol is used to indicate a risk of injury or

death:

Read the warnings carefully and follow the instructions. Please also study the instructions for safe
operation and follow them when installing, operating and servicing the machine.

1.2. PRODUCT INTRODUCTION

The Kempact MIG 2520 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.

1.3. SAFE OPERATION

Read the warnings carefully and follow the instructions.

Welding arc and spatter

The arc and the reected radiation from it can damage unprotected eyes. Shield your eyes and
protect your surroundings appropriately before you start welding. The arc and welding spatter will
burn unprotected skin. When welding, use protective clothes and clothing.

Danger of re and explosion

Observe the re safety instructions. Remove ammable material in and near the location in which
you will weld. Have the necessary re extinguishing equipment at hand. Note the dangers posed
by special jobs, such as the risk of re and explosion when welding tanks. Note! Sparks may ignite
a re even hours later!
Welding is working with re, note the special instructions for such work.

Mains voltage

Never bring the welding machine inside the work piece (e.g. container or car). Never set the
welding machine on a wet surface. Replace faulty cables immediately, they create a danger to life
and can cause a re. See that the connecting cable does not stick, touch sharp edges, or come in
contact with a hot piece.

Welding current circuit

Isolate yourself from the welding current circuit by wearing dry and undamaged protective clothing.
Never work on a wet surface. Never use damaged welding cables. Never set the electrode holder,
earth clamp, or welding cables on top of the power source or other electrical equipment.

Welding fumes

Ensure adequate ventilation. Always take special measures when welding metals containing lead,
cadmium, zinc, mercury, or beryllium.

This equipment’s 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.

4 – Kempact mig 2520 / 0635 © Kemppi oy

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 that there are instructions for it. NOTE! The packaging material of

the products 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 the rating plate of the unit. 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. CONNECTION TO THE MAINS SUPPLY

The Kempact 2520 is delivered equipped 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.

2.5. 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 mm² cables. Thinner cross-sectional areas
cause overheating of connectors.

2.6. WIRE FEEDING MECHANISM COMPONENTS

Wire feed motor

Clamp screw

Clamping lever

Wire guide

Feed roll and screw

Gun connector (Euro)

Kempact mig 2520 / 0635 – 5 © Kemppi oy

2.7. FEED ROLLS

Choose feed roll according to ller wire.

2.8. INSTALLATION OF WELDING GUN

Make sure the gun wire conduit and the ow nozzle 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 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.

Do not use a damaged gun.

2.9. MOUNTING AND LOCkING OF WIRE REEL

1. Install the wire reel so that the hole in the reel is aligned with the pin on the reel holder. Use

a reel adaptor, if necessary.

2. Push the reel into its place. Note! Check the reel rotation direction.

3. Lock the reel by turning the locking latch.

2.10. INSTALLING WELDING WIRE

Before installing welding wire, check that the feed roll, wire conduit and contact tip are suitable
for the wire.

1. Install the feed roll, and check that the right groove is in the wire feed line.

2. Install the wire reel. Note! Do not tighten the locking screw of the reel trigger too much, the

reel must roll freely.

3. Round off the wire end and push it through the wire conduit into the wire drive tube.

4. Check that the wire is in the groove and turn press stick into its proper place. Tighten the
wire slightly.

5. Feed wire to the gun by pressing the switch until the wire has come through the contact tip.
Pressing force to the feed roll is suitable when the wire can be slightly restrained with the
ngers.

6. Adjust the wire reel braking force by turning the adjusting screw in the middle of the locking
latch. To avoid over-loading the wire feed motor, do not overtighten.

Note! Check that the wire or wire reel does not touch the equipment body, there is a
danger of short circuit

When using aluminium ller wire, removing rear guide tube may improve wire feed. When using
ux cored wire, always study the manufacturer’s operation and safety instructions before use.

Filler wires Wire Ø mm Groove

Fe, SS, CuSi

0.6/0.8, 0.8/1.0 V-groove

Flux cored

0.8/ 0.9, 1.0/1.2 knurled

Al

1.0/1.2 U-groove

6 – Kempact mig 2520 / 0635 © Kemppi oy

E

B

D

CAF

G

2.11. 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

of steel is 8-15 l / min.

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 on 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. Bottle 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) shows the required ow (or
pressure). When regulating the ow amount, the power source should be switched on and
the gun 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. 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!

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 off with the main switch; do not use the
power plug for this purpose.

Kempact mig 2520 / 0635 – 7 © Kemppi oy

3.2. 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

+ pole

- pole

Thermostat signal light

MIG welding dynamics adjustment

ON signal light

Selecting welding
procedure (2T/4T)

Wire feed adjustment

Welding voltage adjustment

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

3.3. 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.

8 – Kempact mig 2520 / 0635 © Kemppi oy

3.4. SELECTING THE WELDING PROCEDURE (2T/4T)

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 - ow of shielding gas starts.

2. Switch open - welding starts.

3. Switch closed - welding ends.

4. Switch open - ow of shielding gas ends.

3.5. ADJUSTING WELDING DYNAMICS

The adjustment of MIG welding dynamics inuences the properties
of the welding arc and the amount of splatter. The recommended
basic setting is ‘0’. The values -> min (-1...-9) provide a softer arc for
diminishing the amount of spatter. The values -> max (1...9) provide a
coarser arc, suitable when increased arc stability is desired and when

using 100% CO² 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 specied 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 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 2520 / 0635 – 9 © Kemppi oy

4. MAINTENANCE

4.1. DAILY MAINTENANCE

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!

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. Also the operation of the welding machine

is tested.

5. ORDERING INFORMATION

Item Ordering number

Kempact MIG 2520 6218520

GH 30 Gun holder 6256030
Feed roll 0.6-0.8 V-groove 9483070
Feed roll 0.8-1.0 V-groove 9483071

Feed roll 1.0-1.2 U-groove 9483072

Feed roll 0.8-0.9 V-groove, knurled 9483073
Feed roll 1.0-1.2 V-groove, knurled 9483074

Feed roll 1.0-1.2 V-groove 9483075
MMT 25 3 m 6252513MMT
MMT 25 4,5 m 6252514MMT
MMT 27 3 m 6252713MMT
MMT 27 4,5 m 6252714MMT
Earth cable 35 mm² 5 m 6184311

Transport unit ST 7 6185290

Transport unit P250 6185268

Lift hook 4298180
Gas hose 6m W000566
Front quide tube orange 0.9-1.6 mm Ss W000431
Front quide tube white 0.6-0.8 mm Fe, Mc, Fc W000451
Front quide tube silver 0.8-1.6 mm Al W000449

The unit fulls the CE marking demands.

10 – Kempact mig 2520 / 0635 © Kemppi oy

6. TECHNICAL DATA

kempact Mig 2520

Mains connection 3~400V +/-15%, 50/60Hz

Connected load 40% ED 12 kVA 250A

60% ED 10 kVA 207A

100% ED 7,5 kVA 160A

Mains cable/fuse 4x1,5mm²-5m/16A delayed

Load capacity 40% ED 250A /26,5V

60% ED 207A /24V

100% ED 160A /22V

Adjustment range 10 - 30V

Wire feed speed 1 - 18 m/min

Idle voltage 40-50 V

Power ratio 0,64 (250A / 26V)

Efcency 0,87 (250A / 26V)

Wires with ller Fe, Ss Ø 0,6 ... 1,0 mm

Cored wire Ø 0,9 ... 1,2 mm

Al

Ø 0,9 ... 1,2 mm

Cusi Ø 0,8 ... 1,0 mm

Shielding gas CO², Ar, Ar & CO² mixed

gases

Wire reel diameter 200 mm (5 kg)

Thermal class H(180C) / B (130C)

Measurements L510 x W250 x H415

Weight 17,5 kg

Range of temperature for
use

-20C ... +40C

Storage temperature for use -40C ...+60 C

Degree of protection IP23C

7. DISPOSAL OF THE MACHINE

Do not dispose of electrical equipment together 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 returned to an

environmentally compatible recycling facility. As the owner of the equipment, you should

get information on approved collection systems from our local representative.

By applying this European Directive you will improve the environment and human
health!

Kempact mig 2520 / 0635 – 11 © Kemppi oy

8. TERMS OF GUARANTEE

Kemppi Oy provides a guarantee for products manufactured and sold by them if defects in

manufacture and materials occur. Guarantee repairs must be carried out only by an Authorised
Kemppi Service Agent. Packing, freight and insurance costs to be paid by orderer. The guarantee is
effected on the date of purchase. Verbal promises which do not comply with the terms of guarantee

are not binding on guarantor.

Limitations on guarantee

The following conditions are not covered under the terms of guarantee: defects due to natural wear
and tear, non-compliance with operating and maintenance instructions, connection to incorrect or
faulty supply voltage (including voltage surges outside equipment spec.), incorrect gas pressure,
overloading, transport or storage damage, re of damage due to natural causes i.e. lightning or
ooding.
This guarantee does not cover direct or indirect travelling costs, daily allowances or accommodation.
Note: Under the terms of guarantee, welding torches and their consumables, feeder drive rolls and
feeder guide tubes are not covered. Direct or indirect damage due to a defective product is not
covered under the guarantee. The guarantee is void if changes are made to the product without

approval of the manufacturer, or if repairs are carried out using non-approved spare parts.
The guarantee is also void if repairs are carried out by non-authorised agents.

Undertaking guarantee repairs

Guarantee defects must be informed to Kemppi or authorised Kemppi Service Agents within the
guarantee period. Before any guarantee work is undertaken, the customer must provide proof of

guarantee or proof of purchase, and serial number of the equipment in order to validate the guarantee.
The parts replaced under the terns of guarantee remain the property of Kemppi.

Following the guarantee repair, the guarantee of the machine or equipment, repaired or replaced,
will be continued to the end of the original guarantee period.

KEMPPI OY
PL 13
FIN – 15801 LAHTI
FINLAND
Tel [phone]
Telefax [phone]
www.kemppi.com

KEMPPIKONEET OY
PL 13
FIN – 15801 LAHTI
FINLAND
Tel [phone]
Telefax [phone]
e-mail: myynti.fi @kemppi.com

KEMPPI SVERIGE AB
Box 717
S – 194 27 UPPLANDS VÄSBY
SVERIGE
Tel [phone]
Telefax [phone] 94
e-mail: [e-mail]

KEMPPI NORGE A/S
Postboks 2151, Postterminalen
N – 3103 TØNSBERG
NORGE
Tel [phone]
Telefax 33 34 60 10
e-mail: [e-mail]

KEMPPI DANMARK A/S
Literbuen 11
DK – 2740 SKOVLUNDE
DANMARK
Tel [phone]
Telefax 44 941 536
e-mail:[e-mail]

KEMPPI BENELUX B.V.
Postbus 5603
NL – 4801 EA BREDA
NEDERLAND
Tel [phone]
Telefax [phone]
e-mail: [e-mail]

KEMPPI (UK) Ltd
Martti Kemppi Building
Fraser Road
Priory Business Park
BEDFORD, MK443WH
ENGLAND
Tel [phone]
Fax [phone]
e-mail: [e-mail]

KEMPPI FRANCE S.A.
65 Avenue de la Couronne des Prés
78681 EPONE CEDEX
FRANCE
Tel [phone]
Telefax (01) 30 90 04 45
e-mail: [e-mail]

KEMPPI GmbH
Otto – Hahn – Straße 14
D – 35510 BUTZBACH
DEUTSCHLAND
Tel [phone]
Telefax (06033) 72 528
e-mail:[e-mail]

KEMPPI SP. z o.o.
Ul. Piłsudskiego 2
05-091 ZA¸BKI
Poland
Tel [phone]
Telefax [phone]
e-mail: [e-mail]

KEMPPI WELDING
MACHINES AUSTRALIA PTY LTD
P.O. Box 404 (2/58 Lancaster Street)
Ingleburn NSW 2565, Australia
Tel. [phone]
Telefax [phone]
e-mail: [e-mail]

OOO KEMPPI
127018 Moscow, Polkovaya str. 1,
Building 6
e-mail: [e-mail]

ООО КЕМППИ
127018 Москва, ул. Полковая 1,
строение 6

Ver. 1 0

www.kemppi.com