Kemppi WeldForce KPS 3500 MVU User manual

1931350E
0617
WeldForce
kps 3500
kps 4500
kps 5500
kps 3500 MVU
kps 4500 MVU
kps 5500 MVU

2 – Kemppi WeldForce KpS3500, KpS4500, KpS5500, KpS3500mVU, KpS4500mVU, KpS5500mVU / 0606 © Kemppi oy
CONTENTS
1. PREFACE....................................................................................................................... 3
1.1. INTRODUCTION......................................................................................................... 3
1.2. PRODUCT INTRODUCTION ...................................................................................... 3
1.2.1. OPERATION CONTROL AND CONNECTORS............................................. 3
1.3. ACCESSORIES........................................................................................................... 4
1.3.1. REMOTE CONTROL DEVICES..................................................................... 4
1.3.2. CABLES ......................................................................................................... 4
1.4. OPERATION SAFETY................................................................................................. 5
2. INSTALLATION.............................................................................................................. 6
2.1. SITING THE MACHINE............................................................................................... 6
2.2. CONNECTION TO THE MAINS SUPPLY ................................................................... 6
2.3. WELDING AND EARTH CABLES ............................................................................... 7
3. OPERATION CONTROL SWITCHES AND POTENTIOMETERS AND THEIR USE.... 7
3.1. MAIN SWITCH I/O....................................................................................................... 7
3.2. PILOT LAMPS ............................................................................................................. 7
3.3. OPERATION OF COOLING FAN ................................................................................ 8
4. MANUAL METAL ARC WELDING ................................................................................ 8
5. MAINTENANCE............................................................................................................. 8
5.1. CABLES ...................................................................................................................... 8
5.2. POWER SOURCE....................................................................................................... 8
5.3. REGULAR MAINTENANCE........................................................................................ 8
6. OPERATION DISTURBANCES..................................................................................... 9
6.1. OPERATION OF THE OVERLOAD PROTECTION.................................................... 9
6.2. CONTROL FUSES ...................................................................................................... 9
6.3. UNDER- AND OVERVOLTAGES IN THE MAINS SUPPLY ........................................ 9
6.4. LOSS OF A PHASE IN THE MAINS SUPPLY............................................................. 9
7. DISPOSAL OF THE MACHINE ................................................................................... 10
8. ORDERING NUMBERS............................................................................................... 10
9. TECHNICAL DATA .......................................................................................................11
10. TERMS OF GUARANTEE ......................................................................................... 12

Kemppi WeldForce KpS3500, KpS4500, KpS5500, KpS3500mVU, KpS4500mVU, 5500KpSmVU / 0606 – 3
© Kemppi oy
H12
H11
S11
KPS KPS MVU
H12
H11
S11 X12X11
01
F11
X13
X14
X15
X12
X11
01
F11
X13
X14
X15
1. PREFACE
1.1. INTRODUCTION
Congratulations on having purchased this product. Properly installed Kemppi products should
prove to be productive machines requiring maintenance at only regular intervals. 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 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, for danger to life or injury the following symbol is used:
Read the warning texts 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
Kemppi WeldForce KPS3500, 4500 ja 5500 are multi-operator power sources designed for
demanding professional use. They are suitable for MMA/MIG and pulsed MIG as well as for TIG
welding in DC.
1.2.1. Operation control and connectors
F11 Fuse for connection for control table 6,3 A delayed
H11 Signal lamp I/O
H12 Warning lamp for thermal protection
S11 Main switch I/O
X11, Welding connection parallel
X12
X13 Earth connection
X14, Connection for control cable parallel
X15
01 Inlet of mains cable

4 – Kemppi WeldForce KpS3500, KpS4500, KpS5500, KpS3500mVU, KpS4500mVU, KpS5500mVU / 0606 © Kemppi oy
1.3. ACCESSORIES
1.3.1. Remote control devices
R10
R20
MIG-MAG remote control device with controls for wire feed and voltage, memory scales 1 … 5.
You can use control device also for control of MMA current.
1.3.2. Cables
WeldForce KPS3500, WeldForce KPS4500, WeldForce KPS5500
WeldForce KPS3500 MVU, WeldForce KPS4500 MVU, WeldForce KPS5500 MVU
16d Extension cable for remote control
20 Earth cable
21 MMA welding cable
R10, Remote control devices
R20
Wire feed adjustment,
electrode current adjustment
Control of MMA/TIG welding
current, reference scale 1 … 5.
Voltage adjustment

Kemppi WeldForce KpS3500, KpS4500, KpS5500, KpS3500mVU, KpS4500mVU, 5500KpSmVU / 0606 – 5
© Kemppi oy
1.4. OPERATION SAFETY
Please study these Operation safety instructions and respect them when installing, operating and
servicing the machine.
Welding arc and spatters
Welding arc hurts unprotected eyes. Be careful also with reecting arc ash. Welding arc and
spatter burn unprotected skin. Use safety gloves and protective clothing.
Danger for re or explosion
Pay attention to re safety regulations. Remove ammable or explosive materials from welding
place. Always ensure that you have sufcient re ghting equipment available where you are
welding. Be prepared for hazards in special welding jobs, eg. for the danger of re or explosion
when welding container type work pieces. Note! Fire can break out from sparks even several hours
after the welding work has been nished!
Mains voltage
Never take welding machine inside a work piece (eg. container or truck). Do not place welding
machine on a wet surface. Always check cables before operating the machine. Change damaged
cables without delay. Damaged cables may cause an injury or set out a re. Connection cable must
not be crushed, it must not touch sharp edges or hot work pieces.
Welding power circuit
Isolate yourself by using proper protective clothing, do not wear wet clothing. Never work on a
wet surface or use defect cables. Do not put the MIG-gun or welding cables on welding machine
or on other electric equipment. Do not press the MIG-gun switch, if the gun is not directed towards
a work piece.
Welding fumes
Take care that there is sufcient ventilation during welding. Take special safety precautions when
welding metal, which contain 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.

6 – Kemppi WeldForce KpS3500, KpS4500, KpS5500, KpS3500mVU, KpS4500mVU, KpS5500mVU / 0606 © Kemppi oy
05
60º
max. 15º
2. INSTALLATION
2.1. SITING THE MACHINE
Site the machine on a stationary, horizontal, dry base in a position that does NOT allow
dust, dirt or metal particles to enter the machines cooling air ow.
2.2. CONNECTION TO THE MAINS SUPPLY
Kemppi WeldForce power sources are delivered equipped with 5 m mains cable without plug.
If local electricity regulations of operating country are stating otherwise, the mains cable should
be replaced in conformity with the local regulations.
Connection of the mains cable, mounting and change of the plug should only be carried out by a
competent electrician.
Remove the machine’s right side plate to enable the mounting of a mains cable.
KPS power sources can be connected to the mains supply of 400 V 3~ . KPS MVU power
sources can be connected to 230 V 3~ or 400 V 3~ . Power source automatic recognize the mains
voltage.
If changing the mains cable take into consideration the following:
The cable is entered into the machine through the inlet ring on the rear panel of the machine and
fastened 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.
If you are using 5-lead cable, you must connect neutral conductor with terminal N.
rain water
– Preferably site the machine somewhat higher above
the oor level.
– Ensure that the front as well as the rear of the
machine there is at least 20 cm free distance to
allow good circulation of the cooling air through
the machine.
– Protect the machine against heavy rain and in hot
circumstances against direct sunshine. Ensure the
free circulation of the cooling air.
Degree of protection of machine IP23 allows at
its maximum the water spray coming in 60º angle
to hit machine’s outer covering.
See to that the machine is positioned away from the line
of particle spray, created by grinding tools etc.

Kemppi WeldForce KpS3500, KpS4500, KpS5500, KpS3500mVU, KpS4500mVU, 5500KpSmVU / 0606 – 7
© Kemppi oy
Sizes of the mains cables and fuse ratings for the machine at 100 % duty cycle are specied in
the table below:
*) In cables of S type there is a protective grounding conductor coloured green-yellow.
2.3. WELDING AND EARTH CABLES
Recommended copper cables with cross-sectional area are as follows:
Kemppi WeldForce KPS3500 50 ... 70 mm²
Kemppi WeldForce KPS4500 70 ... 90 mm²
Kemppi WeldForce KPS5500 70 ... 90 mm²
In enclosed table are shown typical load capacities of rubber insulated copper cables, when ambient
temperature is 25 ºC and lead temperature is 85 ºC.
Do not overload welding cables due to voltage losses and heating.
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.
3. OPERATION CONTROL SWITCHES AND
POTENTIOMETERS AND THEIR USE
3.1. MAIN SWITCH I/O
When you turn the switch into I-position, pilot lamp H11 on the front face is illuminated and the
machine is ready for use.
Always turn the machine on and off with the mains switch, never use the mains plugs
as a switch.
3.2. PILOT LAMPS
The pilot lamps of the machine report the electric operation:
The green pilot lamp H11 when lit indicates that the machine is on and ready for use and it is
connected to the mains supply with the main switch in the I-position.
H12 indicates when lit that the thermal protection of the machine has been activated due to over
heating. The cooling fan will continue to run and cool the machine down and when the lamp is
off the machine is ready to weld.
Rated voltage Mains voltage range Fuses,
slow-blow
Connection
cable *) mm²
KPS3500 400 V 3~ 360 V… 440 V 25 A 4 x 6.0 S
KPS4500 400 V 3~ 360 V… 440 V 35 A 4 x 6.0 S
KPS5500 400 V 3~ 360 V… 440 V 35 A 4 x 6.0 S
KPS3500MVU 400 V 3~ 230 V 3~ 360 V… 440 V 200 V… 260 V 35 A 4 x 6.0 S
KPS4500MVU 400 V 3~ 230 V 3~ 360 V… 440 V 200 V… 260 V 50 A 4 x10 S
KPS5500MVU 400 V 3~ 230 V 3~ 360 V… 440 V 200 V… 260 V 60 A 4 x 16 S
Cable Duty cycle ED Voltage loss / 10 m
100 % 60 % 30 %
50 mm² 285 A 370 A 520 A 0,35 V / 100 A
70 mm² 355 A 460 A 650 A 0,25 V / 100 A
95 mm² 430 A 560 A 790 A 0,18 V / 100 A

8 – Kemppi WeldForce KpS3500, KpS4500, KpS5500, KpS3500mVU, KpS4500mVU, KpS5500mVU / 0606 © Kemppi oy
3.3. OPERATION OF COOLING FAN
In Kemppi WeldForce KPS3500 there is one and in Kemppi WeldForce KPS4500 and Kemppi
WeldForce KPS5500 there are two simultaneously operating fans.
– The fan is started for a moment when main switch is placed into position I.
– The fan will start during welding as the machine heats up and it will run for 1 to 10 minutes
after the welding has stopped.
– On no-load fan is started in intervals of approx. half an hour for minute’s time.
4. MANUAL METAL ARC WELDING
The Kemppi WeldForce power source can be used in electrode welding by connecting a Kemppi
WeldForce KWF200, KWF300 wire feeder to it. The power source can be made suitable for
electrode welding without a wire feeder by connecting an R10 or R20 remote control to the X14
or X15 terminal at the back of the power source for welding current adjustment, and the welding
power cable connected to the power source’s (+) connector X11 or X12.
5. MAINTENANCE
The amount of use and the working environment should be taken into consideration when planning
the frequency of maintenance of the machine. Careful use and preventive maintenance will help
to ensure trouble-free operation.
5.1. CABLES
Check the condition of welding and connection cables daily. Do not use damaged cables.
Make sure that the mains cables in use are safe and according to laid down regulations.
The repair and mounting of a mains connection cable should be carried out only by an authorised
electrician.
5.2. POWER SOURCE
Note! Disconnect the plug of the machine from the mains socket and wait approx.
2 minutes (capacitor charge) before removing the cover plate.
Check at least every half year:
– Electric connectors of the machine - clean the oxidised parts and tighten the loosened
ones.
– Note! You must know correction tension torques before starting the reparation of the
joints.
– Clean the inner parts of the machine from dust and dirt e.g. with a soft brush and vacuum
cleaner. Also clean the ventilation net behind the front grate.
– Do not use compressed air, there is a risk that dirt is packed even more tightly into gaps of
cooling proles.
– Do not use pressure washing device.
– Only authorised electrician shall carry out repairs to the machines.
5.3. REGULAR MAINTENANCE
Kemppi Service Workshops make regular maintenance according to 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
– Checking of mains cable and plug

Kemppi WeldForce KpS3500, KpS4500, KpS5500, KpS3500mVU, KpS4500mVU, 5500KpSmVU / 0606 – 9
© Kemppi oy
– Damaged parts or parts in bad connection are replaced by new ones
– Maintenance testing. Operation and performance values of the machine are checked, and
adjusted when necessary by means of test equipment.
6. OPERATION DISTURBANCES
In case of problems contact the Kemppi works in Lahti, Finland, or your local Kemppi dealer.
Check the maintenance objects before the machine is sent to the Service Workshop.
6.1. OPERATION OF THE OVERLOAD PROTECTION
Yellow pilot lamp H12 of thermal protection is lit when thermostat has operated due to overheating
of machine.
The thermostat of machine will operate, if machine is continuously loaded over rated values or
cooing air circulation is blocked.
Cooling fan cools down the machine and when the pilot lamp is not lit the machine is automatically
ready for welding.
6.2. CONTROL FUSES
Fuse F11, 6,3 A delayed, on the rear wall of machine is as protection for connection of auxiliary
devices X14-15.
Use same type and rating of fuse which is marked beside the fuse adapter. Damage
caused by a wrong type fuse is not covered by the guarantee.
6.3. UNDER- AND OVERVOLTAGES IN THE MAINS SUPPLY
Primary circuits of machine are protected against sudden, transient overvoltages.
Machine is designed to withstand 3 x 440 V voltage continuously (see technical data). See to
it that voltage is kept within admissible limits especially when mains supply is taken e.g. from
combustion engine generator.
If the mains has undervoltage (under approx. 300 V), machine control stops to operate
automatically.
6.4. LOSS OF A PHASE IN THE MAINS SUPPLY
Loss of a phase causes noticeable poorer welding properties than normally or the machine doesn’t
get started at all. Loss of a phase can be due to following:
– blowing of mains supply fuse
– defective mains cable
– bad connection of mains connection cable on terminal block or plug of machine

10 – Kemppi WeldForce KpS3500, KpS4500, KpS5500, KpS3500mVU, KpS4500mVU, KpS5500mVU / 0606 © Kemppi oy
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!
8. ORDERING NUMBERS
Kemppi WeldForce KPS 3500 6131350
Kemppi WeldForce KPS 4500 6131450
Kemppi WeldForce KPS 5500 6131550
Kemppi WeldForce KPS 3500MVU 613135003
Kemppi WeldForce KPS 4500MVU 613145003
Kemppi WeldForce KPS 5500MVU 613155003
Return current cable 5 m - 50 mm² 6184511
Return current cable 5 m - 70 mm² 6184711
Cable for MMA welding 5 m - 50 mm² 6184501
Cable for MMA welding 5 m - 70 mm² 6184701
R10 6185409
Remote controlled interconnecting cable 10 m 6185481
T400 6185267
P40 6185264
P40L 6185264L

Kemppi WeldForce KpS3500, KpS4500, KpS5500, KpS3500mVU, KpS4500mVU, 5500KpSmVU / 0606 – 11
© Kemppi oy
Kemppi WeldForce
KPS 3500/
KPS 3500MVU
Kemppi WeldForce
KPS4500/
KPS 4500MVU
Kemppi WeldForce
KPS5500/
KPS 3500MVU
Mains voltage KPS 3~50/60 Hz
400 V -15 %...+20 % 400 V -15 %...+20 % 400 V -15 %...+20 %
Mains voltage KPS MVU 3~50/60 Hz
400 V -15 %...+20 % 400 V -15 %...+20 % 400 V -15 %...+20 %
230 V -10 %...+10 % 230 V -10 %...+10 % 230 V -10 %...+10 %
Rated power
60 ED - 21,5 kVA 28 kVA
80 % ED 15 kVA 20 kVA 24,5 kVA
100 % ED 13,5 kVA 18,5 kVA 21 kVA
Connection cable/fuse delayed
KPS 4 x 6 S - 5 m / 25 A 4 x 6 S - 5 m /35 A 4 x 6 S - 5 m / 35 A
KPS MVU 4 x 6 S - 5 m / 35 A 4 x 10 S - 5 m /50 A 4 x 16 S - 5 m / 63 A
Max. loadability 40 ˚C
60 % ED - 450 A 550 A
80 % ED 350 A 420 A 500 A
100 % ED 320 A 380 A 440 A
Max. loadability 20 ˚C
100 % ED 320 A 400 A 450 A
Welding current and voltage range
MMA 10 A ... 320 A 10 A ... 420 A 10 A ... 520 A
MIG 12 V ... 37 V 12 V ... 39 V 12 V ... 42 V
Max. welding voltage 46 V / 300 A 46 V / 400 A 50 V / 500 A
Open circuit voltage approx. 65 V approx. 65 V approx. 65 V
Open circuit power < 75 W < 75 W < 75 W
Efciency at nominal values
approx. 85 % approx. 85 % approx. 85 %
Power factor at nominal values
approx. 0,93 approx. 0,93 approx. 0,93
Storage temperature range
-40 ... +60 ºC -40 ... +60 ºC -40 ... +60 ºC
Operating temperature range
-20 ... +40 ºC -20 ... +40 ºC -20 ... +40 ºC
Temperature class H (180 ºC) / B (130 ºC) H (180 ºC) / B (130 ºC) H (180 ºC) / B (130 ºC)
Degree of protection IP 23 C IP 23 C IP 23 C
External dimensions
length 690 mm 690 mm 690 mm
width 230 mm 230 mm 230 mm
height 520 mm, MVU 630 mm 520 mm, MVU 630 mm 520 mm, MVU 630 mm
Weight 37 kg/ MVU 45 kg 41 kg/MVU 49 kg 48 kg/MVU 56 kg
Voltage supply for auxiliary devices
50 V DC 50 V DC 50 V DC
X 14, X 15 fuse 6,3 A delayed fuse 6,3 A delayed fuse 6,3 A delayed
Voltage supply for cooling unit
1~, 400 V / 250 VA 1~, 400 V / 250 VA 1~, 400 V / 250 VA
9. TECHNICAL DATA

12 – Kemppi WeldForce KpS3500, KpS4500, KpS5500, KpS3500mVU, KpS4500mVU, KpS5500mVU / 0606 © Kemppi oy
10. 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: info[email protected]
KEMPPI WELDING
MACHINES AUSTRALIA PTY LTD
P.O. Box 404 (2/58 Lancaster Street)
Ingleburn NSW 2565, Australia
Tel. [phone]
Telefax [phone]
e-mail: info[email protected]
www.kemppi.com
Ver. 9