Kemppi Kempomat 2500 User manual

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
1921960E

 COPYRIGHT KEMPPI OY
2 / Kempomat 2500, Kempomat 3200, Kempomat 4000 / 0340
Kempomat 2500, Kempomat 3200, Kempomat 4000 / 0340 / 3
 COPYRIGHT KEMPPI OY
CONTENTS
1. PREFACE ....................................................................................................3
1.1. Introduction ..........................................................................................3
1.2. Product introduction .............................................................................3
2. INSTALLATION OF THE POWER SOURCE...............................................3
2.1. Transport and lifting of the machine.....................................................3
2.2. Siting the machine ...............................................................................4
2.3. Connection to the mains supply...........................................................4
2.4. Mounting of the mains cable ................................................................4
2.5. Welding and return current cables .......................................................5
3. USE OF WIREFEEDER ..............................................................................6
3.1. Parts of wire feed mechanism..............................................................6
3.2. Installation of the wire feed system......................................................8
3.3. Installation of wire feed ........................................................................8
3.4. Mounting of MIG welding gun ..............................................................9
3.5. Mounting and locking of wire reel ........................................................9
3.6. Automatic wire feed to gun ................................................................10
3.7. Adjustment of tightness of wire reel brake .........................................10
3.8. shielding gas ...................................................................................... 11
4. OPERATION AND USE OF POWER SOURCE ........................................12
4.1. Kempomat panels ..............................................................................12
4.2. Wire feed panel.................................................................................. 13
4.3. Wire feeder unit..................................................................................13
4.4. Main switches and Pilot lamps...........................................................14
4.5. Adjustment for arc roughness I, II ...................................................... 15
4.6. Operation of cooling fan..................................................................... 15
5. CONTROL PANELS AND ADJUSTMENTS...............................................15
5.1. Wire feed speed potentiometer..........................................................15
5.2. Burn back time ...................................................................................15
5.3. KMW timer .........................................................................................16
6. ACCESSORIES.........................................................................................17
6.1. KMW sync.......................................................................................... 17
6.2. Installation and mounting ................................................................... 17
7. OPERATION DISTURBANCES.................................................................18
7.1. Cables................................................................................................19
7.2. Power source .....................................................................................19
8. REGULAR MAINTENANCE OF THE EQUIPMENT..................................19
9. ORDERING NUMBERS ............................................................................19
10. TECHNICAL DATA.....................................................................................20

 COPYRIGHT KEMPPI OY
2 / Kempomat 2500, Kempomat 3200, Kempomat 4000 / 0340
Kempomat 2500, Kempomat 3200, Kempomat 4000 / 0340 / 3
 COPYRIGHT 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 a small mount of seasonal mainte-
nance. This manual is arranged to give you a good understanding of the equipment and its
safe operation. It also contains maintenance information and technical specications. Read this
manual completely from front to back before installing, operating or maintaining the equipment
for the rst time. For further information on Kemppi products please contact us or your nearest
Kemppi distributor.
The specications and designs presented in this manual are subject to change without prior
notice.
In this document, where ever there exists a danger to life or injury the following symbol is
used:
Read the warnings carefully and follow the instructions. Please also study the Operation safety
instructions and respect them when installing, operating and servicing the machine.
1.2. PRODUCT INTRODUCTION
The power sources Kempomat 3200 and 4000 are compact MIG welding machines, designed
for heavy industrial use. Kempomat 2500 is compact MIG welding machine, designed for repair
shops and light and heavy industrial use.
Power source
Supply voltage of the Kempomat 3200 power source is 3~ 230 V / 400 V. Voltage of power
source is adjusted with turn type switches; together 16 steps. In Kempomat 4000 product range
there are different units for mains voltages 3~ 230 and 400 V and the welding voltage adjustment
is made in 32 steps. The Volt/Ampere metering unit MSD 1 (available as accessory) displays
voltage or welding current.
Wire feeder unit
The wire feeder unit is a 4-roll driven xed unit in the equipment, suitable for air-cooled guns.
Accessory unit KMW sync is needed for connection and use of push-pull guns Binzel and
Hulftegger. Accessory unit KMW timer controls continuous, spot and cycle-arc welding.
2. INSTALLATION OF THE POWER SOURCE
2.1. TRANSPORT AND LIFTING OF THE MACHINE
On the Kempomat power source bottom there are four xed lifting points for lifting devices,
hole diameter 47 mm.
On the power source´s front panel there are handles designed for moving the units on the oor.
Lift the entire machine only from lifting points in the bottom plate without gas
bottle
You may move the units from handles only by hands, it is forbidden to use any
mechanical devices!
Ensure that the unit is kept during lifting between lifting linens. When necessary use additional
binding round the lifting linens and the unit´s upper part. Use the protection between the lifting
device and the unit in order to eliminate impacts and shocks.

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4 / Kempomat 2500, Kempomat 3200, Kempomat 4000 / 0340
Kempomat 2500, Kempomat 3200, Kempomat 4000 / 0340 / 5
 COPYRIGHT KEMPPI OY
L1
L2
L3
60 °
max. 15 °
2.2. SITING THE MACHINE
Site the machine on a stationary, horizontal, dry and clean base from which there doesn´t come
any dust etc. into inlet air through the rear grate. Ensure the free circulation of the cooling air.
Degree of protection IP23C of the machine allows at its maximum the water jet coming in 60°
angle to hit machine´s outer covering. See to that the machine is positioned away from the line
of the particle spray, created by grinding tools etc.
- There must be free space in front of the machine as well as at the rear of the
machine to allow good circulation of the cooling air through the machine.
- Protect the machine against straight rain and in circumstances over 25 °C against
direct sunshine.
rain water
2.3. CONNECTION TO THE MAINS SUPPLY
Connection and change of the mains cable and the plug must be carried out only by a competent
electrician.
Remove for the mounting of the mains cable the left side plate, seen from the front of the
power source.
The Kempomat power source is equipped with 5 m supply cable without plug. The mains cable
is according to the marking H07RN-F of the norm CENELEC HD22. The mains cable must be
changed if it doesn´t meet local regulations.
2.4. MOUNTING OF THE MAINS CABLE
In cables of S type there is protective grounding conductor coloured green-yellow.
The cable is entered into the machine through the inlet ring on the rear wall of the machine
and locked with a cable clamp (05).
The phase conductors of the cable are coupled to connectors L1, L2 and L3. The earth protection
coloured green-yellow is coupled to connector marked with earth protection symbol . If
you are using 5-conductor cable, you must cut the zero conductor to the level of the cable´s
protective shield.
Sizes of mains cables and fuse ratings for the machine at 100% ED duty cycle are specied
in the table below:

 COPYRIGHT KEMPPI OY
4 / Kempomat 2500, Kempomat 3200, Kempomat 4000 / 0340
Kempomat 2500, Kempomat 3200, Kempomat 4000 / 0340 / 5
 COPYRIGHT KEMPPI OY
Kempomat 2500
Rated voltage 230 V 400 V
Fuses, delayed 16 A 10 A
Connection cable 4 x 2.5 S mm2 4 x 2.5 S mm2
Kempomat 3200 Kempomat 4000
Rated voltage 230 V 400 V 230 V 400 V
Fuses, delayed 20 A 16 A 25 A 16 A
Connection cable 4 x 2.5 S mm2 4 x 2.5 S mm2 4 x 6.0 S mm2 4 x 2.5 S mm2
Change of mains voltage / Kempomat 2500, 3200
Connection and change of the mains cable and the plug must be carried out only by a competent
electrician.
Connection 3~ 230 or 3~ 400 V of mains voltage
By delivery from the factory the Kempomat 3200 and 2500 machine has been connected for
mains voltage 3~ 400 V. In order to change the mains voltage in the Kempomat 2500/3200
machine, remove the side plate of the machine. Change the connections according to the
enclosed diagram. You nd the corresponding wiring diagram on the instruction label, which
is under terminal block.
Note! The Kempomat 4000 machine has the connection for only one mains voltage!
2.5. WELDING AND RETURN CURRENT CABLES
Use only copper cables with cross-sectional area of at least 50 mm2.
In enclosed table are shown typical loading capacities of rubber insulated copper cables, when
ambient temperature is 25 °C and conductor temperature is 85 °C.
Kempomat 2500
Cable cross-section Duty cycle ED Voltage loss / 10 m
Cu 100 % 60 % 30 % for 100 A
25 mm2 180 A 230 A 330 A 0.7 V
35 mm2 225 A 290 A 410 A 0.5 V
Kempomat 3200, 4000
Cable cross-section Duty cycle ED Voltage loss / 10 m
Cu 100 % 60 % 40 % for 100 A
50 mm2 285 A 370 A 450 A 0.35 V
70 mm2 355 A 460 A 560 A 0.25 V
Don´t overload welding cables over permissible values due to voltage losses and
heating.
Fasten the earthing press of the return current cable carefully, preferably direct
onto the piece to be welded.
The contact surface area of the press should always be as large and steady as pos-
sible. Clean the contact surface from paint and rust.

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 COPYRIGHT KEMPPI OY
Kempomat 3200, 4000
3. USE OF WIREFEEDER
3.1. PARTS OF WIRE FEED MECHANISM

 COPYRIGHT KEMPPI OY
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Kempomat 2500, Kempomat 3200, Kempomat 4000 / 0340 / 7
 COPYRIGHT KEMPPI OY
Kempomat 2500

 COPYRIGHT KEMPPI OY
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Kempomat 2500, Kempomat 3200, Kempomat 4000 / 0340 / 9
 COPYRIGHT KEMPPI OY
3.2. INSTALLATION OF THE WIRE FEED SYSTEM
Wire feeder unit:
1. Mount the return current cable to connector on the Kempomat´s front panel.
2. The MIG gun is mounted to the EURO connector of the wire feeder unit.
Use guide tubes and contact tips according to manufacturer´s operation instructions.
Accessories which are too tight or otherwise unsuitable for the wire type used by you,
will cause wire feed disturbances.
3. (Kempomat 3200 and 4000)
Max. wire feed speed
When the unit is delivered the max. wire feed speed is 18 m/min, which is enough for
the most welding works. If you need a higher speed, you can increase the max. wire feed
speed to 25 m/min by replacing the gear wheel on motor shaft to a bigger one. The big
gear wheel (D40) is delivered on order.
When necessary speed is changed according to following:
- Open tightening lever (20). Remove lower feed rolls (21). Release screw (23) and its
washer. Remove gear wheel D28 (24) from motor shaft.
- Loosen screws (25) (3 pc) 1 twist. Mount the D40 gear wheel onto motor shaft. Screw
the screw (23) with its washer back.
- Put feed rolls (21) back to their axles, however don´t fasten yet fastening screws of
the feed rolls (22).
- Lift the motor so that the tooth gap between gear wheel and both lower feed rolls is
approx. 0,2 mm.
- Tighten screws (25). Check gear teeth gaps, when necessary put the motor into a better
position. Screw on the mounting rolls of feed rolls (22).
Too small gap between gear wheel and feed rolls will overload motor.
Too big gap for its part might cause too rapid wearing for teeth of feed rolls and gear
wheel.
4. The shielding gas hose is mounted to the push-pull connector on the rear wall of the
unit. Mounting to the gas bottle and shielding gas ow regulation, see paragraph for
SHIELDING GAS.
KMW timer and KMW sync see paragraph for ACCESSORIES.
3.3. INSTALLATION OF WIRE FEED
Accessories according to wire feed
Wire feed rolls are available with plain groove, knurled groove and with U groove for different
purposes.
Kempomat 2500
Feed rolls
colour ller wire ø mm (inch)
white 0.6 and 0.8 (0.030)
red 0.9/1.0 and 1.2 (0.035, 0.045 and 0.052)
Guide tubes
colour ller wire ø mm (inch)
orange 0.6-1.6 (0.024-1/16)

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 COPYRIGHT KEMPPI OY
Kempomat 3200, 4000
feed rolls
colour ller wire ø mm (inch)
white 0.6 ja 0.8 (0.030)
red 0.9/1.0 and 1.2 (0.035, 0.045 and 0.052)
yellow 1.4, 1.6 and 2.0 (1/16 and 5/64)
guide tubes
colour ller wire ø mm (inch)
orange 0.6-1.6 (0.024-1/16)
Feed roll with plain groove:
Universal feed roll for welding of all kinds of wires
Feed rolls with knurled groove:
Special feed roll for cored wires and steel wires
Feed rolls with U groove:
Special feed roll for aluminium wires
Wire feed rolls have two grooves for different ller wire diameters. Correct wire groove is
selected by moving selecting washer from one side to another in feed roll.
Feed rolls and wire guide tubes have colour codes in order to make identication easier.
By delivery Kempomat is equipped with red feed rolls with plain groove and with orange wire
guide tubes for welding ller wires 0.9 - 1.2 mm (0.035”, 0.045” and 0.052”).
3.4. MOUNTING OF MIG WELDING GUN
In order to ensure trouble-free welding check in operation instructions of gun used by you that
wire guide tube and contact tip of gun are according to manufacturer´s recommendation suitable
to be used for wire feed diameter and type in question. Too tight a wire guide tube might cause
for wire feeder unit a bigger stress than normally as well as disturbances in wire feed.
Screw snap connector of gun tight that there won´t come any voltage losses on connecting
surface.
A loose connection will heat gun and wire feeder unit.
3.5. MOUNTING AND LOCKING OF WIRE REEL
- Release locking nails of wire reel hub by turning locking knob to the position OPEN.
- Mount the reel at its place. Note rotating direction of reel!
- Turn the locking knob to the position LOCKED.
Check in ller wire reel that there are no parts sticking out, which could e.g. chafe
against chassis or door of wire feeder unit. Dragging parts might expose chassis of
wire feeder unit under voltage.
LOCKED OPEN

 COPYRIGHT KEMPPI OY
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 COPYRIGHT KEMPPI OY
3.6. 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. Feed roll
groove is selected by moving the groove selecting washer.
- 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.
Don´t 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, Ss: 0.6...0.8 mm, Al, Fc: 0.8...1.0 mm).
Then it might be possible that you must open feed rolls and feed wire manually through feed
rolls.
Adjustment of pressure
Adjust the pressure of feed rolls with the control screw (20) so that the wire is fed into the
wire guide tube evenly and allows a little braking when coming out from the contact tip without
slipping at the feed rolls.
Excessive pressure causes attening of the ller wire and damage to the coating. It
also causes undue wear of the feed rolls as well as friction.
3.7. ADJUSTMENT OF TIGHTNESS OF WIRE REEL BRAKE
Brake force is adjusted through hole in locking device of reel hub by screwing the control
screw with screwdriver.
Adjust brake force as so big that the wire cannot spill from the reel when the rotation of the reel
stops. Need for brake force is increased with increase of the wire feed speed.
Since the brake loads for its part the motor, you shouldn´t keep it unnecessarily tight.
Make sure that the welding gun in your use is designed for max. welding current
needed by you! Never use a damaged welding gun!
Adjustment screw
groove selecting washer

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 COPYRIGHT KEMPPI OY
E
B
D
C
A
F
G
3.8. SHIELDING GAS
As MIG shielding gas is used carbon dioxide, mixed gases and argon. Shielding gas ow rate is
dened by welding current size. Typical rate of gas in welding of steel is 8-15 l / min.
Gas ow regulator
Gas ow regulator should be suitable for shielding gas used by you. The regulator being in
your use might be different from the one in picture, however, following general instructions are
valid for all pressure regulators.
Before mounting of ow regulator
1. Step aside and open the bottle valve (A) for a while to blow out possible impurities
from the bottle valve.
2. Turn the press regulation screw (B) of the regulator until no spring pressure can
be felt.
3. Close needle valve, if there is one in the regulator.
4. Install the regulator on bottle valve and tighten connecting nut (C) with a wrench.
5. Install hose spindle (D) and jacket nut (E) into gas hose and tighten with hose
clamp.
6. Connect the hose with the regulator and the other end with the power source.
Tighten the jacket nut.
7. Open bottle valve slowly. Gas bottle pressure meter (F) shows the bottle pressure.
Note! Do not use the whole contents of the bottle. The bottle should be lled when
the bottle pressure is 2 bar.
8. Open needle valve if there is one in the regulator.
9. Turn regulation screw (B) until hose pressure meter (G) shows the required ow (or
pressure). When regulating ow amount, the power source should be switched on
and gas test button on the panel pressed simultaniously.
Close bottle valve after having nished welding. If the machine will be out of use for a long
time, unscrew the pressure regulation screw.
Gas bottle
The gas bottle may explode if it falls!
Always fasten gas bottle tightly in vertical position, to wall stand or bottle cart, spe-
cially designed for it! For safety reasons always remove gas bottle from transport
stand of the machine before lifting or car transport of machine!
A Gas bottle valve
B Pressure regulation screw
C Connecting nut
D Hose spindle
E Jacket nut
F Gas bottle pressure meter
G Gas hose pressure meter

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 COPYRIGHT KEMPPI OY
4. OPERATION AND USE OF POWER SOURCE
4.1. KEMPOMAT PANELS
Wire feed panel
Push-pull gun connector and
switch (accessory)
Welding gun connector (EURO)
Mounting place for MSD 1 V/A
metering unit (accessory)
Signal lamp for Kempomat
4000 main switch
Signal lamp for overheating
(power source)
Kempomat 3200 main switch
Kempomat 4000 main switch and
voltage selecting range
Voltage selecting switch
(ne grading)
Voltage selecting switch (coarse grading)
I Return current dix-connector
(coarser arc)
II Return current dix-connector
(softer arc)
Control fuse (8 A delayed)
Shielding gas connector
Inlet of mains cable
Fan and inlet opening

 COPYRIGHT KEMPPI OY
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 COPYRIGHT KEMPPI OY
SS Fe
ø
Al
110
8
6
5
4
3
2
7
9
BURN-
BACK
WIRE INCH
Kempomat 2500
Kempomat 3200, 4000
4.2. WIRE FEED PANEL
KMW timer
continuous/hold
continuous/spot/cycle arc welding
spot or cycle time
4.3. WIRE FEEDER UNIT
Burn back time (according to f iller
material and wire feed)
Adjustment potentiometer for wire feed
KMW timer
continuous/hold
continuous/spot/cycle arc welding
spot or cycle time
Adjustment potentiometer for wire feed
Wire inch switch (wire feed into gun)

 COPYRIGHT KEMPPI OY
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 COPYRIGHT KEMPPI OY
Kempomat 2500
1 13,7 V
2 15,2 V
3 16,9 V
4 18,8 V
5 20,8 V
6 23,0 V
7 25,5 V
8 28,3 V
9 31,4 V
10 34,9 V
Kempomat 3200
1 / 4 1 / 4 - 4 / 4 15,2 -17,4 V
2 / 4 1 / 4 - 4 / 4 18,3 - 21,5 V
3 / 4 1 / 4 - 4 / 4 22,9 - 28,1 V
4 / 4 1 / 4 - 4 / 4 30,4 - 40,1 V
Kempomat 4000
15 - 28 V 1 / 4 1 / 4 - 4 / 4 15,9 -17,3 V
15 - 28 V 2 / 4 1 / 4 - 4 / 4 17,9 - 19,7 V
15 - 28 V 3 / 4 1 / 4 - 4 / 4 20,4 - 22,8 V
15 - 28 V 4 / 4 1 / 4 - 4 / 4 23,7 - 27,0 V
28 - 48 V 1 / 4 1 / 4 - 4 / 4 28,2 - 30,7 V
28 - 48 V 2 / 4 1 / 4 - 4 / 4 31,6 - 34,8 V
28 - 48 V 3 / 4 1 / 4 - 4 / 4 36,0 - 40,1 V
28 - 48 V 4 / 4 1 / 4 - 4 / 4 41,7 - 47,3 V
4.4. MAIN SWITCHES AND PILOT LAMPS
Main switch (Kempomat 2500 and 3200)
In zero position all control and welding current circuits of the equipment are dead (without
voltage). In position I the control circuits of the machine become live (get voltage). The primary
and welding circuits are dead, if the welding mode has not been started with the gun trigger.
Main switch (Kempomat 4000)
In zero position all control and welding current circuits of the equipment are dead (without
voltage). In positions 15 - 28 V and 28 - 48 V the control circuits and cooling fan of the
equipment get voltage. The primary and welding circuits are dead, if the welding mode has not
been started with the gun trigger.
Always switch on and switch off the machine from the main switch. Never use the mains plug
for switching on or switching off the units and equipment!
Adjustment of welding voltage
Table of adjustments, switch positions:
The welding voltage is adjusted with two 4-step turn switches . There is the switch for coarse
control, where voltage value of each step can be ne-adjusted with the switch .
voltage step open circuit voltage
coarse control ne control open circuit voltage
main switch coarse control ne control open circuit voltage

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 COPYRIGHT KEMPPI OY
Kempomat 4000
First select with the main swich the one of two ranges. The adjustment for range as with the
Kempomat 3200. The instructions for welding voltage selection are shown in table on door inte-
rior surface of the reel box for the unit.
Pilot lamps of the machine report about electric function:
The green pilot lamp indicating that the machine is ready for operation is always illuminated,
when the machine is connected to mains voltage and you have selected welding voltage range
from the main switch.
The yellow pilot lamp for thermal protection is illuminated, when thermal protection of the
welding circuit has released due to overheating. The protection releases if the power source is
continuously loaded over rated values or the cooling air circulation has been obstructed.
The cooling fan is cooling down the machine and after the pilot lamp has switched off, the
machine is again ready for welding from the gun trigger.
Control fuse
On the rear plate of the power source the fuse 8 A delayed is the short-circuit protection. Use the
fuse size and type according to markings. Damage caused by a wrong type fuse is not covered by
the guarantee. If the fuse is blowing again, send the unit to service.
4.5. ADJUSTMENT FOR ARC ROUGHNESS I , II
Arc roughness is adjusted by connecting the return current cable to the applicable one of the
two dix-connectors on the front plate.
The connector marked with symbol I gives a rougher arc, which is used for welding of thin
sheets and ferrous metals by 0.6 - 1.0 mm wires and especially with CO2 shielding gas. The
connector marked with symbol II is suitable for thicker wires and especially for aluminium and
stainless materials. The most suitable roughness is, however, most dependent on the welding
case. You will nd the best position by testing the different positions.
4.6. OPERATION OF COOLING FAN
The cooling fan on the rear plate of the Kempomat machine is started and stopped according to
use. The cooling fan is started after ca. 30 s after weld start and stopped after ca. 5 - 7 min after
weld end or release of the overheat protection.
Note! The fan is intaking air from rear plate side! Don´t switch off the unit with the main
switch before the cooling fan has automatically stopped. By open circuit the cooling fan
does not get started.
5. CONTROL PANELS AND ADJUSTMENTS
5.1. WIRE FEED SPEED POTENTIOMETER
The wire feed speed is adjusted steplessly with the potentiometer on the front panel, see the
paragraph Panels. The potentiometer has the memory scale for max. speeds of 18 m/min and
25 m/min. See the section Installation of wire feed equipment, paragraph 3. Max. wire feed
speed.
5.2. BURN BACK TIME
Different ller materials and shielding gases behave in different ways in the welding end, so that
you should switch off the welding current with a delay, which is suitable for wire feed stopping
according to the welding case.
If you try to end welding with an unsuitable burn back time, the wire will burn in the contact tip,
there will be too big “balloon” at the wire end, or the wire will stick at the ending point.

 COPYRIGHT KEMPPI OY
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 COPYRIGHT KEMPPI OY
SS Fe
ø
Al
110
8
6
5
4
3
2
7
9
BURN-
BACK
WIRE INCH
Factors inuencing on the delay:
The wire feed speed has a signicant inuence on required burn back time. By low wire feed
speeds always select the short burn back time.
- Melting of aluminium is much quicker than by steel-base materials, so that the burn
back time is clearly shorter.
- Steel and especially ller wires require longer time than the stainless materials.
- Thicker ller wires require longer time. Also by increase of wire feed speed the required
time should be longer. In the instruction label are given starting points for adjustment.
The ne-adjustment should be carried out according to each case in question.
- Memory scale for adjustment potentiometer
- The wire inch switch starts the wire feed motor and mechanism, but not the power
source.
The ller wire can be driven to the wire feeder unit, gun and interconnection cable also with
the welding gun´s switch, but then also the power source will get started and the wire becomes
live (gets voltage), and this can cause a danger situation by accidental contact to surrounding
objects.
5.3. KMW TIMER
The standard control includes the welding with the closed-open operation of the gun trigger, this is
called the 2-sequence procedure. The KMW timer also has the 4-sequence procedure, with which you
can release the trigger for the time of welding, as well as the wire feed timer, which helps you to control
the spot or cycle arc welding.
2 / 4-sequence procedure
2-sequence procedure The welding with the 2-sequence trigger procedure of the gun.
1. Switch pressed: welding starts
2. Switch open: welding stops
4-sequence procedure The welding with the 4-sequence trigger procedure of the gun.
1. Switch pressed: shielding gas is owing
2. Switch open: welding starts
3. Switch pressed: welding stops
4. Switch open: gas ow stops after the post gas time
Spot, cycle arc and continuous welding (is operating only in the 2-sequence procedure position)
Spot welding
1. Set the spot time with the potentiometer.
2. The gun switch pressed: welding starts
3. Welding ends automatically after the set time
Cycle arc welding - - -
1. Set the welding cycle time with the potentiometer. The pause time is constant ca. 0.3 s.
The pause time length can be adjusted from the control card trimmer as 0.2 - 1.0 s.
2. The gun switch pressed: welding is started and continued for so long as the switch is pressed.

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6. ACCESSORIES
Volt / Ampere metering unit MSD 1
For the mounting of the MSD 1 remove the cover plate on the front panel of the unit. The con-
nector of at cable fastened to the cover plate is connected to the corresponding connector of the
MSD 1. From the metering unit you can with lever switch select momentary display for either
voltage or current. By open circuit only voltage value is displayed, because there is no welding
current present.
The voltage value is the voltage between the unit´s welding connectors or terminal voltage.
The value of the open circuit voltage has not very much importance for the welding, so that
the display of the metering unit is adjusted according to the welding situation. The display of
the open circuit voltage differs 1 - 2 V from the true voltage. During welding the terminal
voltage is varying and the arc voltage differs from the terminal voltage due to cable etc. losses.
Accuracy of voltage true value in respect to real value is ±4.0 % ±0.2 V by welding values
according to the norm.
Accuracy of current true value in respect to real value is ±2.5 % ±2 A.
The metering unit doesn´t show wire feed values. The MSD 1 doesn´t need any calibration in the
Kempomat units. The switch positions: V = voltage display, A = current display.
6.1. KMW SYNC
The push-pull gun is most often used for feed of thin aluminium wires, when over 5 m reach
is required. You can connect the gun equipped with the EURO adaptor to the KMW sync unit.
The push-pull gun´s potentiometer is connected to amphenol connector, mounted onto front wall
of the Kempomat. You can connect to this connector also some other potentiometer, which has
suitable values for it. With the unit´s switch you can select the Kempomat operation or the
push-pull gun operation.
Concerning the right connections in the gun, contact your KEMPPI dealer.
6.2. INSTALLATION AND MOUNTING
In the accessories of the KMW timer are included electronics card, potentiometer knob, switch
protections, at cable and fastening screws.
1. Remove the side plate as well as frame and panel cover plate of the wire feed panel.
2. Remove protective knobs of the holes on the panel plate.
3. Mount the KMW timer electronics card in such a way that the switch levers and
potentiometer axle penetrate through the holes.
4. Mount the protective caps of the switches above the levers.
5. Fasten the card to back edge of the base with two screws. Don´t tighten unnecessarily
much. Mount the panel cover plate with its frame back at its place.
6. Turn the potentiometer axle into clockwise direction to extreme position. Mount the
potentiometer knob onto axle in such a way that the dial line shows the reading more
than 1.5 s. Check that the knob can be turned freely and that in the other extreme posi-
tion the dial line shows the value less than 0.1 s. Correct if necessary. Mount the knob
cap.
7. Connect one connector of the at cable to the KMW timer card connector.
8. Connect the other connector of the at cable to connector for KMW timer on the control
card A001.
9. Fasten the side plate back at its place.

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7. OPERATION DISTURBANCES
The amount of use and the working environment should be taken into consideration when plan-
ning the frequency of maintenance of the Kempomat. Careful use and preventive maintenance
will help to ensure trouble-free operation.
The following maintenance operations should be carried out at least every six months.
Wire feed:
- The wear of the grooves of the feed rolls. Excessive wear of grooves causes problems in
wire feed.
- The wear of the wire guide tubes of the wire feeder unit. Badly worn feed rolls and wire
guide tubes should be dis carded.
KMW sync control card
KMW sync
Mode selecting switch
Control connector for push-pull gun
(Binzel / Hulftegger)
MSD 1 V/A metering unit
- The wire guide tube should be set as near the feed rolls as possible, but not touching
them and the wire must follow a straight line from the end of the tube to the groove of
the feed roll.
- Reel brake adjustment.
- Electric connections
* Oxidized couplings must be cleaned
* Loose couplings must be tightened
Clean dust and dirt from the equipment.
When using compressed air, always protect your eyes with proper eye protection.
twice a year

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7.1. CABLES
Check the condition of welding and connection cables daily. Do not use faulty cables!
Make sure that the mains connection cables in use are safe and according to regulations!
The repair and mounting of mains connection cables should be carried out only by an authorized
electrician.
7.2. POWER SOURCE
NOTE! Disconnect the plug of the power source from the mains socket before removing the
cover plate.
Check at least every 6 months (twice a year):
- Electric connections of the unit - clean the oxidized parts and tighten the loosened ones.
NOTE! You must know correct tension torques before starting the repair of the joints.
- Clean the inner parts of the machine from dust and dirt e.g. with soft brush and vacuum
cleaner.
Do not use compressed air. Do not use pressure washing device!
- There is a risk that dirt is packed even more tightly into gaps of components!
Only authorized electrician shall carry out repairs to the machines.
8. REGULAR MAINTENANCE OF THE EQUIPMENT
Kemppi service repair shops make regular maintenance according to the agreement.
The major points in the maintenance procedure are listed as follows:
- Cleaning of the machine
- Checking and maintenance of the welding tools
- Checking of connectors, switches and potentiometers
- Checking of electric connections
- Metering units checking
- Checking of mains cable and plug
- Damaged parts or parts in bad connection are replaced by new ones
- Maintenance testing. Operation and performance values of the equipment are checked,
and adjusted when necessary by means of test equipment.
The amount of use and the working environment should be taken into consideration when plan-
ning the frequency of maintenance of the machine. Careful use and preventive maintenance will
help to ensure trouble-free operation.
9. ORDERING NUMBERS
Kempomat 2500 230 / 400 621425001
Kempomat 3200 230 / 400 V 621432001
Kempomat 4000 230 V 621440201
Kempomat 4000 400 V 621440401
KMW timer (Timer unit) 6219200
KMW sync (Synchronization unit) 6219100
MSD 1 (Volt / Ampere metering unit) 6185666
GH 20 (Gun holder) 6256020
Hub for wire reel 4289880
MT 25 3 m 6252023
MT 25 4,5 m 6252024
MT 32 3 m 6253023
MT 32 4,5 m 6253024
KMG 25 3 m 6252123
KMG 25 4,5 m 6252124
KMG 32 3 m 6253033
KMG 32 4,5 m 6253034
MMT 25 3 m 6252513MMT
MMT 25 4,5 m 6252514MMT

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MMT 27 3 m 6252713MMT
MMT 27 4,5 m 6252714MMT
MMT 32 3 m 6253213MMT
MMT 32 4,5 m 6253214MMT
MMT 35 3 m 6253513MMT
MMT 35 4,5 m 6253514MMT
MMT 42 3 m 6254213MMT
MMT 42 4,5 m 6254214MMT
KMP 300 6 m 6257306
KMP 300 8 m 6257310
Branch cable KMP/Kempomat 3151360
50 mm² 5 m 6184511
70 mm² 5 m 6184711