Kemppi Kempact 251R Operating Manual
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Kemppi Kempact 251R Operating Manual

Kempact welding machine
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Kempact
251R, 253R, 323R, 181A, 251A, 253A, 323A
Operating manual
Käyttöohje
Bruksanvisning
Bruksanvisning
Brugsanvisning
Gebrauchsanweisung
Gebruiksaanwijzing
Manuel d'utilisation
Manual de instrucciones
Instrukcja obsługi
Инструкции по эксплуатации
操作手册
Manual de utilização
Manuale d'uso
EN
FI
SV
NO
DA
DE
NL
FR
ES
PL
RU
ZH
PT
IT

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  • Page 1 Kempact 251R, 253R, 323R, 181A, 251A, 253A, 323A Operating manual Käyttöohje Bruksanvisning Bruksanvisning Brugsanvisning Gebrauchsanweisung Gebruiksaanwijzing Manuel d’utilisation Manual de instrucciones Instrukcja obsługi Инструкции по эксплуатации 操作手册 Manual de utilização Manuale d’uso...
  • Page 3 OPERATING MANUAL English...

  • Page 4: Table Of Contents

    ................Kempact 251R, 253R, 323R, 181A, 251A, 253A, 323A...

  • Page 5: Introduction

    This operating manual contains important information on the use, maintenance and safety of your Kemppi product. The technical specifications of the equipment can be found at the end of the manual. Please read the manual carefully before using the equipment for the first time. For your own safety and that of your working environment, pay particular attention to the safety instructions in the manual.

  • Page 6: 1.2.2 About Welding

    If using aluminium or stainless steel filler 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.

  • Page 7: 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...

  • Page 8: Serial Number

    MACHINE INTRODUCTION General view of the machine Supply voltage cable Main switch Shielding gas hose connector Welding gun and cable Earth return clamp and cable Kempact 251R, 253R, 323R, 181A, 251A, 253A, 323A...

  • Page 9: Cable Connections

    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.
  • Page 10 Kempact RA GasMate chassis, securing the cylinder in place with the webbing and metal buckles provided. Always close the cylinder valve after welding. Kempact 251R, 253R, 323R, 181A, 251A, 253A, 323A...
  • Page 11 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. © Kemppi Oy / 1135...

  • Page 12: Before You Start Using The Unit

    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 251R, 253R, 323R, 181A, 251A, 253A, 323A...

  • Page 13: Setting The Spool Brake Force

    Euro connector block, exposing about 150 mm of filler wire from the front of the machine. Close the top feed roll(s) lever(s) over the filler wire and close the pressure arm(s). © Kemppi Oy / 1135...

  • Page 14: Welding Gun

    This is particularly important for soft filler wires such as aluminium. It will also improve feed quality and increase the service life of your gun liner. Kempact 251R, 253R, 323R, 181A, 251A, 253A, 323A...

  • Page 15: Setting The Pressure Of The Feed Rolls

    Too much wire feed roll pressure may flatten the filler wire, damage its coating, increase NOTE! friction and result in the filler wire sticking in the welding gun liner or contact tip. Also excessive pressure will result in increased wear to wire drive roll bearings, reducing their life. © Kemppi Oy / 1135...

  • Page 16: Wire Guide Tubes And Feed Rolls

    ø 2.5/33mm, W006369, plastic W000956, plastic Fe, MC, FC ø 0.6–0.8mm ø 1.5/75mm, ø 2.0/33mm, ø 2.0mm, W006421, steel W001435, steel W005784, brass ø 1.0–1.6mm ø 2.0/75mm, W006422, steel W006410, ø 2.5/125mm, steel Kempact 251R, 253R, 323R, 181A, 251A, 253A, 323A...
  • Page 17 For aluminium and stainless steel filler wires, always use Kemppi DL Teflon gun liners. These liners are especially developed by Kemppi and significantly reduce friction losses, so improving welding performance and quality.

  • Page 18: Changing The Feed Rolls

    However, it may be necessary to select alternative feed rolls to suit different filler wire sizes used. So you may occasionally need to replace the feed rolls. Kemppi feed rolls and gun liners are colour-coded in order to make identification easy.

  • Page 19: Reversing Polarity

    Filter maintenance Once fitted, the filter should be removed, checked and cleaned with dry compressed air weekly. Every six months, wash the filter in a solution of warm soapy water. Allow to dry thoroughly before replacing. © Kemppi Oy / 1135...

  • Page 20: Using Control Panels

    This control knob increases and reduces the speed of filler wire delivery to the welding arc. The scale is regulated in meters per minute. There is also a graphical display bar indicating the proportion of motor speed selected. Kempact 251R, 253R, 323R, 181A, 251A, 253A, 323A...
  • Page 21 The large illuminated parameter display is designed to provide excellent visibility of welding values and machine settings in a variety of welding situations. The display is protected by a polycarbonate lens fitted into the control panel housing. © Kemppi Oy / 1135...

  • Page 22: Adaptive Control Panel

    12. Selection for filler wire diameter (adaptive mode) 13. Selection for shielding gas or post gas function (adaptive mode) 14. Selection of crater fill function (adaptive mode) 15. Selection for memory function 16. Material thickness and weld shape display Kempact 251R, 253R, 323R, 181A, 251A, 253A, 323A...
  • Page 23 • In 4T mode the gun trigger is pressed and gas starts to flow. When the trigger is released, the arc ignites. Welding continues unti the trigger is pulled and released for a second time. This mode is useful for long welding durations. © Kemppi Oy / 1135...
  • Page 24 11. Materials selection includes FE, BRAZING, FCAW, MCAW. When selecting a suitable filler material, POWER regulation is achieved through POWER selection knob 2. A long press (5 secs) of button 11 also switches the display from m/min to amperes. Kempact 251R, 253R, 323R, 181A, 251A, 253A, 323A...
  • Page 25 MEMORY button for 5 seconds. To recall the welding settings for future use, simple short press the MEMORY buttons. To record new weld settings to a channel, repeat the long press sequence. © Kemppi Oy / 1135...

  • Page 26: Parameter Guides

    • Ensure that the correct wire liner and contact tip size is fitted to the welding gun. • Ensure that the correct shielding gas type is connected and the flow rate adjusted before welding starts. Kempact 251R, 253R, 323R, 181A, 251A, 253A, 323A...
  • Page 27 As with all craft skills – practice will make perfect! For more information, visit the Welding ABC section in www.kemppi.com. © Kemppi Oy / 1135...

  • Page 28: Hot Spot Function

    FE welding gun parts ready to continue welding. HOT SPOT function is only possible in 2T gun trigger mode. If 4T selection is made, the NOTE! function will automatically revert to 2T operation. Kempact 251R, 253R, 323R, 181A, 251A, 253A, 323A...

  • Page 29: Maintenance

    Daily maintenance • Remove welding spatters from the welding gun’s tip and check the condition of the parts. Change damaged parts to new ones immediately. Only use original Kemppi spare parts. • Change damaged insulation parts to new ones immediately.

  • Page 30: Gun Spare Parts

    3.5 m W006453 0.9–1.2 mm 3.5 m W006457 0.8–1.0 mm Al/Ss 3.5 m W006459 1.0–1.6 mm Al/Ss 3.5 m 4188576 0.6–0.8 mm W006454 0.9–1.2 mm W006458 0.8–1.0 mm Al/Ss W006460 1.0–1.6 mm Al/Ss Kempact 251R, 253R, 323R, 181A, 251A, 253A, 323A...
  • Page 31 ø 0.6–0.8 mm 3.5 m W006453 0.9–1.2 mm 3.5 m W006457 0.8–1.0 mm Al/Ss 3.5 m W006459 1.0–1.6 mm Al/Ss 3.5 m 4188576 0.6–0.8 mm W006454 0.9–1.2 mm W006458 0.8–1.0 mm Al/Ss W006460 1.0–1.6 mm Al/Ss © Kemppi Oy / 1135...
  • Page 32 1.4–1.6 mm 3.5 m W006457 0.8–1.0 mm Al/Ss 3.5 m W006459 1.0–1.6 mm Al/Ss 3.5 m 4188576 0.6–0.8 mm W006454 0.9–1.2 mm W006456 1.4–1.6 mm W006458 0.8–1.0 mm Al/Ss W006460 1.0–1.6 mm Al/Ss Kempact 251R, 253R, 323R, 181A, 251A, 253A, 323A...
  • Page 33 3.5 m W006455 1.4–1.6 mm 3.5 m W006457 0.8–1.0 mm Al/Ss 3.5 m W006459 1.0–1.6 mm Al/Ss 3.5 m 4188576 0.6–0.8 mm W006454 0.9–1.2 mm W006456 1.4–1.6 mm W006458 0.8–1.0 mm Al/Ss W006460 1.0–1.6 mm Al/Ss © Kemppi Oy / 1135...
  • Page 34 1.4–1.6 mm 3.5 m W006457 0.8–1.0 mm Al/Ss 3.5 m W006459 1.0–1.6 mm Al/Ss 3.5 m 4188576 0.6–0.8 mm W006454 0.9–1.2 mm W006456 1.4–1.6 mm W006458 0.8–1.0 mm Al/Ss W006460 1.0–1.6 mm Al/Ss Kempact 251R, 253R, 323R, 181A, 251A, 253A, 323A...

  • Page 35: Troubleshooting

    • Check that operator maintains correct technique/arc length/travel speed/gun angle Many of these checks may be carried out by the operator. However certain checks relating to NOTE! mains power must be completed by an authorised trained electrician. © Kemppi Oy / 1135...

  • Page 36: Storage

    The owner of the equipment is obliged to deliver a decommissioned unit to a regional collection centre, per the instructions of local authorities or a Kemppi representative. By applying this European Directive you will improve the environment and human health.

  • Page 37: Ordering Codes

    ORDERING CODES Kempact 251R, 253R, 323R, 181A, 251A, 253A, 323A 253RMV, 323RMV, 253AMV, 323AMV Kempact 251R, FE25 3.5m P2203 Kempact 323RMV, FE 27, 3.5m P2216 Kempact 251R, FE25 5m P2204 Kempact 323RMV, FE 27, 5m P2215 Kempact 253R, FE27 3.5m P2207 Kempact 323RMV, FE 32, 3.5m...

  • Page 38: Technical Data

    IP23S Operating –20…+40 °C –20…+40 °C temperature range Storage temperature –40…+60 °C –40…+60 °C range Standards IEC 60974-1 IEC 60974-1 IEC 60974-5 IEC 60974-5 IEC 60974-10 IEC 60974-10 IEC 61000-3-12 IEC 61000-3-12 Kempact 251R, 253R, 323R, 181A, 251A, 253A, 323A...
  • Page 39 F (155 °C) EMC class Degree of protection IP23S IP23S Operating –20…+40 °C –20…+40 °C temperature range Storage –40…+60 °C –40…+60 °C temperature range Standards IEC 60974-1 IEC 60974-1 IEC 60974-5 IEC 60974-5 IEC 60974-10 IEC 60974-10 © Kemppi Oy / 1135...
  • Page 40 623 x 579 x 1070 mm L x W x H 623 x 579 x 1070 mm dimensions Weight Not including gun 44 kg Not including gun 44 kg and cables and cables Kempact 251R, 253R, 323R, 181A, 251A, 253A, 323A...
  • Page 41 F (155 °C) EMC class Degree of IP23S IP23S protection Operating –20…+40 °C –20…+40 °C temperature range Storage –40…+60 °C –40…+60 °C temperature range Standards IEC 60974-1 IEC 60974-1 IEC 60974-5 IEC 60974-5 IEC 60974-10 IEC 60974-10 © Kemppi Oy / 1135...
  • Page 42 78681 EPONE CEDEX myynti.fi@kemppi.com info.ru@kemppi.com FRANCE Tel +33 1 30 90 04 40 KEMPPI SVERIGE AB KEMPPI, TRADING (BEIJING) COMPANY, Telefax +33 1 30 90 04 45 LIMITED Box 717 sales.fr@kemppi.com Room 420, 3 Zone, Building B, S-194 27 UPPLANDS VÄSBY No.12 Hongda North Street,...

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Kempact 253rKempact 253aKempact 323aKempact 323rKempact 181aKempact 251a ... Show all

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