10 – KEMPOWELD 4200, 4200W, 5500W / 0531
© KEMPPI OY
2.5.6. Operation of cooling fan
The cooling fan on the rear plate of the Kempoweld equipment is started and stopped according to use. The cool-
ing fan is controlled by the gun trigger and control circuits. The cooling fan is started after ca. 15 s after weld start
and stopped after ca. 10 min after weld end or release of the overheat protection.
Do not 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.
2.5.7. Accessory drawer
In the accessory drawer of the power source are included the parts, needed in welding of aluminium and stainless
materials and the parts for changing also the max. wire feed speed. In the drawer are also the screw and the insula-
tion bushings needed for locking of rotation of the wire feeder.
2.5.8. Adjustment for wire feed
The wire feed is adjusted from the potentiometer on the control panel of the wire feeder unit. The adjustment has
been described in the operation instructions of the wire feeder unit.
2.6. VOLT / AMPERE METERING UNIT MSD-1
Included in the delivery of Kempoweld 5500W. Accessory for Kempoweld
4200 and 4200W.
For the mounting of the MSD-1 remove the cover plate on the front panel
of the unit. The connector of flat cable fastened to the cover plate is con-
nected 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 2-3 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 does not show wire feed values.
The MSD-1 does not need any calibration in the Kempoweld power source.
The switch positions: V = voltage display, A = current display.
2.7. COOLING UNIT
The Kempoweld 4200W and 5500W units have an inbuilt cooling unit inside the power source.
2.7.1. Installation of cooling
The cooling unit is connected to the gun by means of water hoses, which are mounted to the wire feeder unit. The
interconnection cable contains also the water hoses, which are mounted to the gun through the wire feeder unit
without any extension parts. See operation instruction for Kempoweld WIRE feeders.
Before connection check that in the hoses are no dirt, metal powder, rubber waste etc. The connectors for hoses
and cooling unit are marked with red or blue identification rings or spots. Blue is colour for water supplied from
cooling unit to gun and red is colour for water returning back from gun to cooling unit.
The cooling unit´s tank is filled with 40 % antifreeze according to British Standard BS3151. If the circumstances
do not require frost resistance, you can use a more dilute mixture, or some other mixture, of which you have good
experriences.
Tank volume is ca. 3 litres, volume of gun and interconnection cable is 0.3-1.5 litres. Filling of hoses takes 5 s-3
min time. Check the return flow to the tank. Before filling check that tank, cooling water, pouring tank etc. are
clean, and that there is no metal powder, waste etc.
If the water does not start circulating, see paragraph Operation disturbances: “The water does not
circulate... etc.
Do not let any waste and dirt into the water circulation! Check filling volume before starting to
weld!
Use the cooling liquid according to recommendations, or the one you know as good beforehand. Watch
over liquid material´s quality and possible sediments in hoses of the gun.
Do not swallow cooling liquid. If somebody has swallowed the liquid, take him immediately to medical
care. Avoid contact with skin and eyes, wash the liquid from your skin with clean water.
