Kemppi Pulse 3000 MVU User Manual
Kempact Pulse™
3000 MVU
Operating manual • English
Bruksanvisning • Norsk
EN
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OPERATING MANUAL
English
Kempact Pulse 3000 MVU / © Kemppi Oy / 1026
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CONTENTS
Kempact Pulse 3000 MVU / © Kemppi Oy / 1026
1. PREFACE ......................................................................................
1.1 General
1.2 Product introduction
1.3 General Safety Instructions
................................................................................................................................................................. 3
................................................................................................................................. 3
................................................................................................................... 3
2. BEFORE YOU START USING THE UNIT ......................................6
2.1 Unpacking ......................................................................................................................................................... 6
2.2 Placement of the unit ................................................................................................................................ 6
2.3 Serial number .................................................................................................................................................. 6
2.4 Connection to the mains supply ....................................................................................................... 6
2.5 Distribution network .................................................................................................................................6
2.6 Ground cable ................................................................................................................................................... 6
2.7 DuraTorque™ 400, 4 wheel wire feed mechanism ...............................................................7
2.8 Installation of welding gun ................................................................................................................... 8
2.9 Mounting and locking of wire reel .................................................................................................. 8
2.10 Automatic wire feed to gun ..................................................................................................................8
2.11 Adjustment of pressure ...........................................................................................................................8
2.12 Adjustment of tightness of spool brake ......................................................................................9
2.13 Shielding gas ................................................................................................................................................... 9
3. OPERATION ...............................................................................10
3.1 Main switch and signal lights ........................................................................................................... 10
3.2 To select polarity for welding ........................................................................................................... 10
3.2.1 Changing the polarity ......................................................................................................................10
3.3 Panel
...................................................................................................................................................................11
3.3.1 Choosing start switch function .................................................................................................... 11
3.3.2 Choosing the welding method .................................................................................................... 11
3.3.3 Selecting 1-mig/pulse mig synergy curves ..............................................................................12
3.3.4 Adjustments, display and weld data ..........................................................................................13
3.3.5 Timer ...................................................................................................................................................... 14
3.3.6 Adjustment of welding dynamics ............................................................................................... 14
3.3.7 Remote control ..................................................................................................................................14
3.3.8 MIG extra functions .......................................................................................................................... 14
3.3.9 Use of gas test .....................................................................................................................................15
3.3.10 Testing wire feed ...............................................................................................................................15
3.3.11 Memory channels, MEMORY .........................................................................................................15
3.3.12 SETUP .....................................................................................................................................................16
3.3.13 Error codes ...........................................................................................................................................17
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4. MAINTENANCE .........................................................................18
4.1 Daily maintenance .................................................................................................................................... 18
4.2 Regular maintenance ............................................................................................................................. 18
4.3 Disposal of the machine .......................................................................................................................18
5. ORDERING NUMBERS ..............................................................19
6. TECHNICAL DATA .....................................................................20
7. WARRANTY POLICY ..................................................................21
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1. PREFACE
1.1 GENERAL
Congratulations on your choice of the Kempact Pulse™ series power source. Reliable
and durable, Kemppi products are aordable 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 specications 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 specications 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.
1.2 PRODUCT INTRODUCTION
The Kempact Pulse 3000 MVU is a compact MIG inverter suitable for repair and installation
use, and for light and medium industrial use.
Kempact Pulse 3000 MVU / © Kemppi Oy / 1026
1.3 GENERAL SAFETY INSTRUCTIONS
Kemppi welding equipments conform to international safety standards. Safety is an important
issue in equipment design and manufacturing. Therefore, Kemppi welding solutions are
unparalleled in safety. There are, however, always certain hazards involved in using welding
equipment. Therefore, to ensure your personal safety and the safety of your working
environment, carefully read the safety instructions below and respect them.
Use of personal protective equipment
• The arc and its reecting radiation damage unprotected eyes. Shield your eyes and
face appropriately before you start welding or observe welding. As the welding current
increases, the welding face screen lens darkness should also increase.
• Arc radiation and spatters burn unprotected skin. Always wear protective gloves,
clothing and footwear when welding.
• Always wear hearing protection if the ambient noise level exceeds the allowable limit
(e.g., 85 dB).
General operating safety
• Exercise caution when handling parts heated during welding. For example, the tip of
the welding torch or gun, and the end of the welding rod and the work piece. The
temperature of items burn unprotected skin.
• Never wear any welding device on the shoulder during welding and never suspend it by
the carrying strap during welding.
• Do not expose the machine to high temperatures, as this may cause damage.
• Keep intermediate and earth return cables as close to each other as possible throughout
their length. Straighten any loops in the cables as this limits inductive eects on welding
performance. This also minimizes your exposure to harmful magnetic elds, which may,
for example, interfere with a pacemaker.
• Do not wrap the welding cables around your body.
• In environments classied as dangerous, only use S-marked welding equipments with
a safe idle voltage level. These work environments include, for example, humid, hot or
small spaces, where the user may be directly exposed to the surrounding conductive
materials.
• Do not use arc welding equipment for pipe thawing.
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Kempact Pulse 3000 MVU / © Kemppi Oy / 1026
Spatter and re safety
• Welding is always classied as hot work, so pay particular attention to the re safety
regulations during welding and after it.
• Remember that re can break out from sparks, even several hours after the welding work
is completed.
• Protect the environment from welding spatter. Remove combustible materials, such as
ammable liquid from the welding vicinity, and supply the welding site with adequate
re ghting equipment.
• In special welding jobs, be prepared for hazards such as re or explosion when welding
inside enclosed work spaces, such as tanks and vessels. Ensure you have authority to
work.
• Never direct the sparks or cutting spray of a grinder toward the welding machine or
ammable materials.
• Beware of hot objects or spatter falling on the machine when working above. Welding in
ammable or explosive sites is absolutely forbidden.
General electric safety
• Only connect the welding machine to an earthed electric network. Note the
recommended mains fuse size.
• Do not take the welding machine inside a container, vehicle or similar work piece unless
authorized to do so.
• Do not place the welding machine on a wet surface and do not work on a wet surface.
• Do not allow the mains cable to be directly exposed to water.
• Ensure cables or welding torches are not squashed by heavy objects and that they are
not exposed to sharp edges or a hot work piece.
• Make sure that faulty and damaged welding torches are changed immediately as they
may cause electrocution or re.
• Remember that the cable, plugs and other electric devices may be installed or replaced
only by an electrical contractor or engineer authorized to perform such operations.
• Turn o the welding machine when it is not in use.
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Welding power circuit
• Insulate yourself from the welding circuit by using dry and undamaged protective
clothing.
• Never touch the work piece and welding rod, welding wire, welding electrode or contact
tip at the same time.
• Do not put the welding torch or ground cable on the welding machine or other electric
equipment.
Welding fumes
• Ensure proper ventilation and avoid inhaling the fumes.
• Ensure a sucient supply of fresh air, particularly in closed spaces. You can also ensure
an adequate supply of clean breathing air by using a ltered fresh-air mask.
• Take extra precautions when working on metals or surface-treated materials containing,
for example, lead, cadmium, zinc, mercury or beryllium.
Transportation, lifting and suspension
• Pay attention to correct working position when lifting a heavy device – risk of injury to
the back.
• Never pull or lift the machine by the welding torch or other cables. Always use the lifting
points or handles designed for that purpose.
• Only use a transport unit designed for the equipment. Try to transport the machine in an
upright position, if possible.
• Never lift a gas cylinder and the welding machine at the same time. There are separate
provisions for gas cylinder transportation.
• Never use a welding machine when suspended unless the suspension device has been
designed and approved for that particular purpose.
• Do not exceed the maximum allowable load of suspension beams or the transportation
trolley of welding equipment. It is recommended that the wire coil be removed during
lifting or transportation.
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Environment
• Welding equipment is not recommended for use in rain or snow – see manual. Protect
the equipment against rain and strong sunlight. Always store the machine in a dry and
clean space.
• Protect the machine from sand and dust during use and in storage. The recommended
operating temperature range is -20 to +40 °C. The machine’s operation eciency
decreases and it becomes more prone to damage if used in temperatures in excess of
40 °C.
• Place the machine so that it is not exposed to hot surfaces, sparks or spatter.
• Make sure the airow to and from the machine is unrestricted.
• EMC classication of this product is class A in accordance with electromagnetic
compatibility standards CISPR 11 and IEC 60974-10, and therefore the product is
designed to be used in an industrial environment only.
WARNING: This class A equipment is not intended for use in residential locations where
the electrical power is provided by a public low-voltage supply system. In those locations
it may be dicult to ensure the electromagnetic compatibility due to conducted and
radiated disturbances.
• Arc welding equipments cause electromagnetic disturbance. To minimize the harmful
eects, strictly use the equipment according to the operating manual and other
recommendations.
Gas bottles and pneumatic devices
• Adhere to the instructions for handling pneumatic devices and gas bottles.
• Make sure that gas bottles are used and stored in properly ventilated spaces.
• A leaking gas bottle may replace the breathable air, causing suocation.
• Before use, make sure that the gas bottle contains gas suitable for the intended welding
purpose.
• Always x the gas bottle securely in an upright position, against a bottle wall rack or
purpose-made bottle cart.
• Never move a gas bottle when the regulator or ow adjuster is in place. Replace the
valve cover during transportation. Close the bottle valve after use.
Kempact Pulse 3000 MVU / © Kemppi Oy / 1026
Circuit diagram and spare part lists
If the circuit diagram and the spare parts list are not included in delivery package, please
inquire for them at your local Kemppi service representative. For more information, please visit
www.kemppi.com.
Disclaimer
While every eort 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 specication 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.
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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.
Kempact Pulse 3000 MVU / © Kemppi Oy / 1026
2.4 CONNECTION TO THE MAINS SUPPLY
The Kempact Pulse 3000 MVU is delivered with a ve metre mains cable without a plug.
Installation of the plug should be carried out only by a competent electrician. Kempact Pulse
MVU can be connected to mains supply of 230 V 3~ or 400 V 3~ power source. Power source
recognizes the mains voltage automaticly. For fuse and cable sizes, see the technical data in
the end of this document.
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2.5 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.
Connection to 400 V supply:
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.
2.6 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.
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