Kemppi Pulse 2800 MVU User Manual

KEMPACT™

PULSE 2800 MVU AUtoMotiVE

19101821

0709

Operation instructions • english

Bruksanvisning • norsk

2 – Kempact™ pulse 2800 mVu automotiVe / 0709 © Kemppi oy

CONTENTS

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

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

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

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

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

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

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. INSTALLATION OF WELDING GUN ........................................................................... 6

2.7. MOUNTING AND LOCKING OF WIRE REEL ............................................................. 6

2.8. AUTOMATIC WIRE FEED TO GUN ............................................................................ 6

2.9. ADJUSTMENT OF PRESSURE .................................................................................. 6

2.10. ADJUSTMENT OF TIGHTNESS OF SPOOL BRAKE ............................................... 7

2.11. SHIELDING GAS ....................................................................................................... 7

3. OPERATION .................................................................................................................. 8

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

3.2. TO SELECT POLARITY FOR WELDING .................................................................... 8

3.2.1. CHANGING THE POLARITY .................................................................... 8

3.3. PANEL ......................................................................................................................... 8

3.3.1. CHOOSING THE WELDING METHOD .................................................... 9

3.3.2. SELECTING 1-MIG/PULSE MIG SYNERGY CURVES ............................ 9

3.3.3. ADJUSTMENTS, DISPLAY AND WELD DATA ....................................... 10

3.3.4. TIMER ..................................................................................................... 10

3.3.5. ADJUSTMENT OF WELDING DYNAMICS............................................. 10

3.3.6. REMOTE CONTROL .............................................................................. 10

3.3.7. MIG EXTRA FUNCTIONS ....................................................................... 10

3.3.8. USE OF GAS TEST .................................................................................11

3.3.9. TESTING WIRE FEED .............................................................................11

3.3.10. SETUP ...................................................................................................11

3.3.11. ERROR CODES .................................................................................... 13

4. MAINTENANCE ........................................................................................................... 13

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

4.2. REGULAR MAINTENANCE ...................................................................................... 13

4.3. DISPOSAL OF THE MACHINE ................................................................................. 13

5. ORDERING INFORMATION ........................................................................................ 14

6. TECHNICAL DATA ...................................................................................................... 15

7. TERMS OF GUARANTEE ........................................................................................... 16

Kempact™ pulse 2800 mVu automotiVe / 0709 – 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 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

Kempact™ Pulse 2800 MVU Automotive is a compact puls MIG inverter specially suitable for car body repair. Good MIG brazing characteristics have been emphasized in designing of the

machine.

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. Make sure the necessary re extinguisher equipment is nearby. 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 involves working with a naked ame, 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. Ensure 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) makes it suitable for use in an industrial environment. Class A equipment is not intended for use in a residential location where the electrical power is provided by the public low-voltage supply system.

4 – Kempact™ pulse 2800 mVu automotiVe / 0709 © 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 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. CONNECTION TO THE MAINS SUPPLY

The Kempact™ Pulse 2800 MVU Automotive is delivered with a ve metre mains cable without a plug. Installation of the plug should be carried out only by a competent electrician. Power source recognizes the mains voltage automaticly. 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 of paint and rust. Use at least two 35 mm² cables. Thinner cross sectional

areas may cause the connectors to overheat.

2. 2.

2.6. 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.

Never use defected gun.

2.7. MOUNTING AND LOCKING OF WIRE REEL

– 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..

2.8. 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 off 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 off 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!

2.9. 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.

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.

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