KEMPPI MIG 2530 Kempact GMAW Welding Machine Instruction Manual
- June 3, 2024
- KEMPPI
Table of Contents
MIG 2530 Kempact GMAW Welding Machine
Instruction Manual
PREFACE
1.1 General
Congratulations on choosing Kempact series welding equipment. Used correctly,
Kemppi products can significantly 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 specifications of the
equipment can be found at the end of the manual.
Please read the operating manual and the safety instructions booklet 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.
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 specifications 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 effort 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 specification 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 Product introduction
The Kempact MIG 2530 is compact MIG inverter suitable for repair and
installation use, and for light and medium industrial use. The power source
and the wire feeding mechanism are contained in the device. The power
regulation of the power source is implemented with IGBT transistors operating
at a frequency of approximately 30 kHz.
Disclaimer
While every effort 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 specification 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.
BEFORE YOU START USING THE UNIT
2.1 Unpacking
The equipment is packed in durable packages, designed specially for it.
Nevertheless, before using the equipment, always make sure it was not damaged
during transport. Also check that you have received what you ordered and that
there are instructions for it. NOTE! The packaging material of the
products is suitable for recycling.
2.2 Placement of the unit
Place the unit on a horizontal, solid, and clean surface. Shield it from heavy
rain and scorching sun. Make sure that cooling air circulates freely.
2.3 Serial number
The serial number of the unit is marked on the rating plate of the unit. 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.
2.4 Connection to the mains supply
The Kempact 2530 is equipped with a five metre mains cable without a plug.
Installation of the plug should be carried out only by a competent
electrician. For fuse and cable sizes, see the technical data in the end of
this document.
2.5 Distribution network
All regular electrical devices without special circuits generate harmonic
currents into distribution network. High rates of harmonic current may cause
losses and disturbance to some equipment.
WARNING: This equipment does not comply with IEC 61000-3-12. If it is
connected to a public low voltage system, it is the responsibility of the
installer or user of the equipment to ensure, by consultation with the
distribution network operator if necessary, that the equipment may be
connected.
2.6 Ground cable
Fasten the earth clamp of the return current cable carefully, preferably
direct onto the piece to be welded. The contact surface of the earth clamp
should always be as large as possible. Clean the fastening surface from paint
and rust. Use at least 35 mm² cables. Thinner cross-sectional areas cause
overheating of connectors.
2.7 Wire feeding mechanism components
- Clamp screw
- Clamping lever
- Feed rolls
- Gun connector (Euro)
- Wire guides
DuraTorque™ 400, 4 wheel wire feed mechanism
Wire feed rolls
| ∅ MM| Colour| Drawing| Pressing
---|---|---|---|---
Fe, Ss, Al, V-groove| 0.6| pale grey| W001045| W001046
0.8/0.9| white| W001047| W001048
1.0| red| W000675| W000676
1.| orange| W000960| W000961
1.| braun| W001049| W001050
2.| yellow| W001051| W001052
2.0| grey| W001053| W001054
2.| black| W001055| W001056
Fe, Fc, Mc, knurled| 1.0| red| W001057| W001058
1.| orange| W001059| W001060
1.4/1.6| yellow| W001061| W001062
2.0| grey| W001063| W001064
2.| black| W001065| W001066
Fe, Fc, Mc, Ss, Al, U-groove| 1.0| red| W001067| W001068
1.| orange| W001069| W001070
2.| yellow| W001071| W001072
2.8 Installation of welding gun
Make sure the gun wire conduit and the flow nozzle match the manufacturer’s
recommendations for the type and diameter of wire you use. Too small a conduit
may overload the wire feed device and disturb the wire feeding. Tighten the
gun quick connectto eliminate voltage losses. A loose joint will make the gun
and the wire feeder warm.
NOTE! Do not use a damaged gun.
2.9 Mounting and locking of wire reel
- Release locking nails of wire reel hub by turning locking knob a quarter round.
- Mount the reel at its place. Note rotating direction of reel!
- Lock the reel with locking knob, locking nails of hub remain to outside position and will lock the reel.
2.10 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 filler wire goes
automatically to correct wire line.
- Make sure that groove of feed roll matches the diameter of welding wire used.
- 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 (file 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. Do not 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, Fc, Ss: 0.6…0.8 mm, Al:
0.8…1.0 mm). In that case you might have to open feed rolls and feed wire
manually through feed rolls.
NOTE! Check that the wire or wire reel does not touch the equipment body,
there is a danger of short circuit
2.11 Adjustment of pressure
Adjust the pressure of feed rolls with the control screw 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.
NOTE! Excessive pressure causes flattening of the filler wire and damage
to the coating. It also causes undue wear of the feed rolls as well as
friction.
2.12 Adjustment of tightness of reel brake
Brake force is
adjusted through hole in locking device of reel hub by screwing the control
screw (A) with screwdriver.
Adjust brake force as so big that the wire is not allowed to become too loose
on the reel so that it would spill from the reel when the rotation of the reel
stops. Need for brake force is increased with increase of wire feed speed.
Since the brake loads for its part the motor, you shouldn’t keep it
unnecessarily tight.
2.13 Shielding gas
The MIG shielding gas consists of carbon dioxide, mixed gases and argon.
Shielding gas flow rate is determined by the amount of welding current. The
typical flow rate of gas in the welding of steel is 8–15 l / min.
The following installation instructions are valid for most gas flow
regulator types:
Parts of gas flow regulator
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
-
Step aside and open the bottle valve (A) for a while to blow out possible impurities.
-
Turn the press regulation screw (B) of the regulator until no spring pressure can be felt.
-
Close the needle valve if there is one in the regulator.
-
Install the regulator on bottle valve and tighten the connecting nut (C) with a wrench.
-
Install the hose spindle (D) and jacket nut (E) into the gas hose and tighten with a hose clamp
-
Connect the hose with the regulator and the other end with the wire feed unit.
Tighten jacket nut. -
Open the bottle valve slowly. The gas bottle pressure meter (F) shows bottle pressure.
NOTE! Do not use the whole contents of the bottle. Bottle should be filled when bottle pressure is 2 bar. -
Open the needle valve if there is one in the regulator.
-
Turn the regulation screw (B) until the hose pressure meter (G) shows the required flow (or pressure). When regulating the flow amount, the power source should be switched on and the gun switch pressed simultanously.
NOTE! Close the bottle valve after welding is finished. If the machine will not be in use for a long time, unscrew the pressure regulation screw. Always fasten the gas ottle tightly in vertical position, to a wall stand or bottle cart, specially designed for it. For safety reasons, always remove the gas bottle from the transport stand of the machine before lifting of transport of the machine by car!
OPERATION
3.1 Main switch and signal lights
With the switch in the ‘I’ position, the primary and control circuits of the
machine become live and the ‘ON’ signal light on the panel lights up. The
welding circuit receives voltage when the gun switch is operated or when the
wire feed test switch is pressed.
Always use the main switch to turn the machine on and off with the main
switch; do not use the power plug for this purpose.
3.2 To select polarity for welding
Solid wire is usually welded in + pole and cored wire in – pole gun. Check for
the recommended polarity on the package or consult the supplier of the
product. The welding of very thin plates (0.5 to 0.7 mm) – polarity might also
work best for solid wire.
3.2.1 Changing the polarity 1. – pole
2. + pole
NOTE! Only a service shop authorised by Kemppi may change the polarity.
3.3 Panel
Adjusting voltage and wire feed speed
The welding voltage can be adjusted from 10 to 30 V, and the wire feed speed from 1 to 18 m/min. Adjust the values appropriately by using the table of guideline values on the door of the wire compartment and by testing.
- ON signal light
- Thermostat signal light
- Selecting welding procedure (2T/4T)
- MIG welding dynamics adjustment
- Wire feed adjustment
- Welding voltage adjustment
3.4 Selecting the welding procedure (2T/4T)
2T: MIG welding with double action of the start switch of the gun:
- Switch closed – welding starts.
- Switch open – welding ends.
4T: MIG welding with quadruple action of the start switch of the gun:
- Switch closed – flow of shielding gas starts.
- Switch open – welding starts.
- Switch closed – welding ends.
- Switch open – flow of shielding gas ends.
3.5 Adjusting welding dynamics The adjustment of MIG welding dynamics
influences the properties of the welding arc and the amount of splatter. The
recommended basic setting is ‘0’. The values -> min (-1…-9) provide a softer
arc for diminishing the amount of spatter. The values -> max (1…9) provide a
coarser arc, suitable when increased arc stability is desired and when using
100% CO₂ shielding gas for welding steel.
3.6 Thermostat
The temperature control of the machine prevents the power source from over-
heating.This means that the machine can not become damaged if loading exceeds
the specified load factor during welding. When the signal lamp indicating
overheating is lit, the welding circuit can not be activated. The lamp will
turn off after a pause of about three minutes, and welding can be started
again in the usual way by pressing gun switch.
3.7 Wire feed switch The wire feed switch will start the wire feed motor
without opening the gas valve. The power source will start up, but without
providing welding power.
MAINTENANCE
4.1 Daily maintenance
NOTE! Be careful of mains voltage when handling electric cables!
Clean the wire channel of the electrode and check the contact tip regularly.
Always check the condition of the mains and welding cable before operation and
replace defective cables.
NOTE! Only a competent electrician is allowed to remove or install the
mains cable!
4.2 Regular maintenance
KEMPPI -service workshops sign special service contracts with customers for
regular maintenance. All parts are cleaned, checked and if necessary,
repaired. Also the operation of the welding machine is tested.
4.3 Disposal of the machine
Do not dispose of electrical equipment 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 taken to an appropriate environmentally responsible recycling
facility.
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.
ORDERING NUMBERS
| Kempact MIG 2530 | 6.22E+08 | |
|---|---|---|
| GH 30 Gun holder | 6256030 | |
| Earth cable 35 mm² | 5 m | 6184311 |
| Transport unit ST 7 | 6185290 | |
| Transport unit P250 | 6185268 | |
| Lift hook | 4298180 | |
| Wire spool pole | 4289880 | |
| 5 kg spool adapter | 4251270 | |
| Gas hose | 6 m | W000566 |
TECHNICAL DATA
Kempact MIG 2530
Connection voltage| 3~, 50/60Hz| 380 – 440V ±10%
Rated power at max. current| 40% ED| 250 A / 12 kVA
Supply current| I1max| 17 A
| I1eff| 11:00 AM
Connection cable| H07RN-F| 4G1.5 (5 m)
Fuse (delayed)| | 16 A
Output 40 °C| 40% ED| 250 A /26.5 V
| 60% ED| 207 A / 24 V
| 100% ED| 160 A / 22 V
Welding range| | 10 – 30 V
Open circuit voltage| | 30 – 45 V
Power factor at max. current| | 0.64
Efficiency at max. current| | 87%
Wire feed speed| | 1 – 18 m/min
Filler wires| Fe, Ss| ø 0.6 – 1.0 mm
| Cored wire| ø 0.9 – 1.2 mm
| Al| ø 0.9 – 1.2 mm
| Cusi| ø 0.8 – 1.0 mm
Shielding gas| | CO₂, Ar, Ar & CO₂ mixed gases
Wire spool (max. ø)| | 300 mm (15 kg)
Thermal class| | H(180 °C) / B (130 °C)
External dimensions| LxWxH| 580x280x440
Weight| | 20 kg
Operating temperature range| | -20 °C … +40 °C
Storage temperature range| | -40 °C … +60 °C
EMC class| | A
Degree of protection| | IP23S
Standards
IEC/EN 60974-1
IEC/EN 60974-5
IEC/EN 60974-10
For connection options of all gun and torch models and corresponding remote controls, refer to Kemppi Userdoc at https://kemp.cc/connectivity.