Kemppi RA User Manual

Kempact

251R, 253R, 323R, 181A, 251A, 253A, 323A, 253RMV, 253AMV, 323RMV, 323AMV

Operating manual

Bruksanvisning

Gebrauchsanweisung

Manual de instrucciones

Käyttöohje

Manuel d’utilisation

Manuale d’uso

Gebruiksaanwijzing

Brugsanvisning

Instrukcja obsługi

Manual de utilização

Инструкции по эксплуатации

Bruksanvisning

操作手册

OPERATING MANUAL

English

CONTENTS

1. Introduction

1.1 General

1.2 About Kempact RA

1.2.1 Properties ....................................................................................................................3

1.2.2 About welding ............................................................................................................4

..................................................................................................................................3

.............................................................................................3

...........................................................................................................3

2. Preparations .............................................................................................4

2.1 Unpacking ............................................................................................................................4

2.2 Positioning and location of the machine .................................................................4

2.3 Distribution network ........................................................................................................5

2.4 Serial number ......................................................................................................................6

3. Machine introduction ............................................................................6

3.1 General view of the machine ........................................................................................6

3.2 Cable connections

............................................................................................................7

4. Before you start using the unit ...........................................................10

4.1 Installing ller wire ............................................................................................................10

4.2 Mounting and locking of ller wire spool ................................................................10

4.3 Setting the spool brake force ........................................................................................11

4.4 Loading the welding wire to feed mechanism ......................................................11

4.5 Welding gun ........................................................................................................................12

4.6 Setting the pressure of the feed rolls .........................................................................13

4.7 Wire guide tubes and feed rolls ...................................................................................14

4.8 Changing the feed rolls ...................................................................................................16

4.9 Reversing polarity .............................................................................................................17

4.9.1 Dusty work environments ..........................................................................................17

5. Using control panels ..............................................................................18

5.1 Regular control panel ......................................................................................................18

5.2 Adaptive control panel

....................................................................................................20

5.3 Parameter guides ..............................................................................................................24

6. MIG/MAG welding ..................................................................................24

6.1 HOT SPOT function ...........................................................................................................26

7. Maintenance ............................................................................................27

7.1 Daily maintenance

7.2 Troubleshooting

7.3 Storage

..................................................................................................................................29

7.4 Disposal of the machine

............................................................................................................27

................................................................................................................28

.................................................................................................29

8. Error codes ...............................................................................................29

9. Ordering codes........................................................................................30

10. Technical data ..........................................................................................31

1. INTRODUCTION

1.1 General

Congratulations on choosing Kempact RA welding equipment. Used correctly, Kemppi products can signicantly increase the productivity of your welding, and provide years of economical service.

This operating manual contains important information on the use, maintenance and safety of your Kemppi product. The technical specications of the equipment can be found at the end of the manual.

Please read the manual carefully before using the equipment for the rst time. For your own 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.

For Kemppi’s standard safety instructions and warranty terms and conditions, please visit our web site at www.kemppi.com.

The specications presented in this manual are subject to change without prior notice.

NOTE! Items in the manual that require particular attention in order to minimise damage and

personal harm are indicated with this symbol. Read these sections carefully and follow their instructions.

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.

1.2 About Kempact RA

Kempact RA MIG/MAG welding machines are designed for professional industrial use. Before use or doing any maintenance work on the machine, read the operating manual and keep it for further reference.

Welding and earth return cables are supplied in the delivery package, including gun, earth clamp and connections.

1.2.1 Properties

Kempact RA family sets new standards for the compact MIG/MAG equipment class and oers many innovative features, designed to make welding more accurate and productive.

All models are suitable for welding a wide range of ller wire materials, including Fe, FCAW, MCAW and MIG brazing. Kempact Adaptive models include a memory function for saving frequently used weld settings. They also feature automatic power regulation, adjusted through selection of plate thickness and weld prole.

All Kempact RA models feature a large and clear orange backlit LCD display for easy and fast reference of parameter settings. All models include stepless control of voltage and wire feed speed, spot and cycle arc timer, and 2T/4T gun switch selection, WireLine™ maintenance alert indicator, Brights™ cabinet lighting, GasMate™ chassis design and HOT SPOT carbon arc function.

1.2.2 About welding

In addition to the welding machine, welding outcome is inuenced by the work piece to be welded, welding technique and the welding environment. Therefore, recommendations in this manual must be followed.

During welding, an electric welding circuit is created between the ller wire and the welded piece. On delivery, the welding gun euro connector is connected to the positive pole. The terminals are located inside the wire feed case door and should not be changed unless you intend to run a ller wire that is directed to be used in reverse polarity, electrode negative.

When a ller wire is loaded to the machine and the gun trigger is pressed, the wire feed mechanism drives the ller wire through the wire liner to the contact tip mounted in the welding gun. The earth return socket on the back of the machine is set as the negative terminal, and when connected to the workpiece via the earth return lead, it completes the welding circuit.

When the ller wire touches the work piece, a short circuit occurs, forming the needed closed electrical circuit. A welding arc is formed and welding commences. Unrestricted current ow is possible only when the earth return clamp is properly attached to the workpiece and the xing point of the clamp to the workpiece is clean, and free from paint and rust.

2. PREPARATIONS

NOTE! Please read the separate safety instruction booklet provided before you commence welding.

Pay particular attention to the risks associated with re and explosion.

2.1 Unpacking

Make sure that you select appropriate wire feed rolls/groove type, welding gun contact tip and wire liner, and also ensure that the machine polarity is correctly set for the material ller type used. If using aluminium or stainless steel ller wire, we recommend you change the wire liner to a Kemppi plastic type, which is better suited for the material.

Before using the equipment, always make sure it was not damaged during transportation. Also check that you have received what you ordered and that there are instructions for it.

The packaging material of the products is suitable for recycling.

Environment

The machine is suitable for both indoor and outdoor use, but it should be protected from rain and sunshine. Store the machine in a dry and clean environment and protect it from sand and dust during use and storage. The recommended operating temperature range is –20…+40 °C. Place the machine in such a way that it does not come in contact with hot surfaces, sparks and spatters. Make sure the air ow into the machine is unrestricted.

2.2 Positioning and location of the machine

Place the machine on a rm, dry and level surface. Where possible, do not allow dust or other impurities to enter the machines cooling air ow.

Notes for positioning the machine

• The surface inclination should not exceed 15 degrees.

• Ensure the free circulation of the cooling air. There must be at least 20 cm of free space

around the machine for cooling air to circulate.

• Protect the machine against heavy rain and direct sunshine.

NOTE! The machine should not be operated in the rain as the protection class of the machine,

IP23S, allows for outside preserving and storage only.

NOTE! Never use a wet welding machine.

Kempact RA 181A, 251R, 251A, 253R, 253A, 253RMV, 253AMV, 323R, 323A, 323RMV, 323AMV

NOTE! When locating and siting the machine prior to and during operation, it is important to

ensure that the metal chassis of the machine does not come into contact with the welding circuit, and/or surfaces so connected.

NOTE! Never aim metallic grinding spray/sparks towards the equipment.

2.3 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 181A, 251R, 251A:

Equipment complying with IEC 61000-3-12

Kempact 253R, 253A:

This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc is greater than or equal to 2.7 MVA at the interface point between the user’s supply and the public supply network. 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 is connected only to a supply with a short-circuit power Ssc greater than or equal to 2.7 MVA.

Kempact 323R, 323A:

This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc is greater than or equal to 2.1 MVA at the interface point between the user’s supply and the public supply network. 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 is connected only to a supply with a short-circuit power Ssc greater than or equal to 2.1 MVA.

Kempact 253 MVU:

This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc is greater than or equal to 1.1 MVA at the interface point between the user’s supply and the public supply network. 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 is connected only to a supply with a short-circuit power Ssc greater than or equal to 1.1 MVA.

Kempact 323 MVU:

This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc is greater than or equal to 1.5 MVA at the interface point between the user’s supply and the public supply network. 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 is connected only to a supply with a short-circuit power Ssc greater than or equal to 1.5 MVA.

2.4 Serial number

The serial number of the unit is marked on the 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.

3. MACHINE INTRODUCTION

3.1 General view of the machine

1. Supply voltage cable

2. Main switch

3. Shielding gas hose connector

4. Welding gun and cable

5. Earth return clamp and cable

FE 32

Kempact RA 181A, 251R, 251A, 253R, 253A, 253RMV, 253AMV, 323R, 323A, 323RMV, 323AMV

3.2 Cable connections

Connection to the mains

Kempact RA models are available in either 1-phase 230 V, 3-phase 400 V, or multi-voltage units. Machines supplied with a mains power cable are not equipped with a plug, so you must select and t a suitable mains plug before you use the machine for the rst time.

Check that the mains cable complies with the local electrical regulations and replace the cable if necessary. See ’Technical data’.

NOTE! The mains cable or mains plug may be installed or replaced only by an electrical contractor

or installer authorised to perform such operations.

Welding gun

Kempact RA welding machines are supplied with Kemppi FE range welding guns as standard. These guns are designed for industrial applications and if used and maintained correctly will provide productive and reliable service.

NOTE! Make sure that you select appropriate feed rolls/groove size, welding gun contact tip and

gun liner. If using aluminium or stainless steel ller wire, we recommend you change the wire liner to a Kemppi DL-Chili liner.

Shielding gas

l/min

Shielding gas is used for replacing air around the welding arc. For steel wires, use CO₂ (carbon dioxide) or a mixture of Ar (argon) and CO₂ for shielding gas. Welding performance will be improved when using mixed gas products. For stainless steel ller wires, use a mixture of Ar and CO₂ (2 %), and for aluminium and CuSi ller wires, use pure argon. The required ow rate of the shielding gas is determined by the thickness of the welded sheet and the used welding power. Alternative gas mixtures are available. Contact your gas supplier for further advice.

The machine is delivered with a 1.5 m gas hose. Connect the gas hose to the machine’s male connector at the back of the machine. Connect the other end of the gas hose to the gas cylinder via a suitable and approved single stage regulator valve, where outlet ow rates can be adjusted.

NOTE! Never attempt to connect directly to a compressed gas cylinder. Always use an approved

and tested regulator and ow meter.

Connecting the gas hose to a typical welding regulator control valve

1. Connect the hose to the welding machine

2. Open the regulator valve of the gas cylinder

3. Measure the gas ow

4. Adjust the ow with the adjustment knob (12–18 lpm)

NOTE! Use a suitable shielding gas for the welding application. Always secure the gas cylinder in

an upright position with either a specially made wall rack or the Kempact RA GasMate chassis, securing the cylinder in place with the webbing and metal buckles provided. Always close the cylinder valve after welding.

Kempact RA 181A, 251R, 251A, 253R, 253A, 253RMV, 253AMV, 323R, 323A, 323RMV, 323AMV

Moving the machine and gas cylinder

The Kempact RA is designed to provide safe gas cylinder storage and movement in satisfactory workshop conditions. The oor surface should be sound, level and free from obstructions. These notes must be followed and an adequate risk assessment completed prior to use of the equipment. Cylinder size and weight vary and therefore aect the total weight and balance of equipment movement.

To move the machine and a small cylinder:

1. Load and secure the gas cylinder with straps provided.

2. Grip the machine handles and place one foot to the foot base plate, located in front of the air intake grill. Press your foot rmly downwards and pull back the machine at the same time, so lifting the machine and gas cylinder to a position for movement.

To move the machine and a large cylinder:

1. Load and secure the gas cylinder with straps provided.

2. With one hand, rmly grip the top of the cylinder and with the other hand grip one of the machine handles.

3. Place one foot to the foot base plate, located in front of the air intake grill. Press your foot rmly downwards and pull back the machine at the same time, so lifting the machine and gas cylinder to a position for movement.

Additional safety notes:

NOTE! In both cases listed above, you will quickly feel the fulcrum point, mechanical advantage

and the point of balance. You are now ready to move your machine and gas cylinder to a new location. However, caution should be observed at all times when moving heavy equipment and local safety conditions and laws must be respected.

NOTE! Be careful when lowering the cylinder to its resting position. Whilst maintaining a rm grip,

ensure that you keep your back straight and extend your arms. Maintain rm pressure to the foot base plate and slowly lower the machine and cylinder to its resting position. You will feel the weight increase as you move forwards over the point of balance. Ensure you keep a rm grip and your weight as far back as possible, as you lower the cylinder and machine chassis carefully to the oor.

NOTE! The chassis is designed to provide stability in the upright position, when loaded with or

without a gas cylinder. Reasonable eort is required to raise and lower the machine and cylinder to a position of movement. If you are light in weight or in any way unsure about moving the machine and cylinder, you should consider an alternative method or process. A local Health and Safety audit and risk assessment may be necessary before heavy or new equipment is taken into use, including the use for carrying or transporting compressed shielding gas cylinders.

NOTE! In all cases the chassis design is not recommended for lifting its weight clear of the

ground by the handles or any other means, with or without a gas cylinder loaded in place. When transporting the machine between sites, welding gas cylinders must be removed from the chassis, secured and transported by other means.

4. BEFORE YOU START USING THE UNIT

4.1 Installing ller wire

Kempact RA is designed for 300 mm wire spools and the following ller wire types:

• solid wires

• ux-cored wires

• self-shielded ux-cored wires

• stainless steel wires

• aluminium wires

• brazing wires

When choosing appropriate ller materials, remember that the wire must have approximately the same melting point as the base material to be welded. MIG brazing process is an exception to this rule.

NOTE! When changing the ller wire, always check that the feed rolls, their groove shape and size

and the wire liner inside the welding gun cable are suitable for the wire you are using. Also check that you are using the correct polarity for the ller wire.

4.2 Mounting and locking of ller wire spool

To mount the wire spool:

1. Turn the locking knob of the spool holder so that the locking clips are opened (1).

2. Check the rotating direction of the wire spool and push the spool into its place so that it rotates in the right direction (2).

3. Turn the locking knob of the spool holder to close the locking clips (3).

NOTE! Check that the ller wire spool is correctly mounted and locked into position. Ensure the

spool is not damaged or deformed in such a way that it can rub or cha against the internal surface of the wire feed unit chassis or door. This may result in increased drag, impacting on weld quality. This may also result in long term wire feed unit damage, rendering the unit unserviceable or unsafe to use.

Kempact RA 181A, 251R, 251A, 253R, 253A, 253RMV, 253AMV, 323R, 323A, 323RMV, 323AMV

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