Installation; Accessories Corresponding To Wire Diameter; Mounting Of Mig Welding Gun; Mounting And Locking Of Wire Reel - Kemppi Kempoweld Wire 550 Operating Instructions Manual

5. INSTALLATION

5.1. ACCESSORIES CORRESPONDING TO WIRE DIAMETER

The wire feed rolls are available with plain groove, knurled groove and with trapezoidal groove for different
purposes. All rolls and accessories in tables fits both WIRE 400 and WIRE 550 wire feeders.
Feed rolls with plain groove:
1. Universal feed roll for welding of all kinds of
wires.
2. Special feed rolls for heavy duty use
Feed rolls with knurled groove:
Special feed roll for cored wires and steel wires.
Feed rolls with trapezoidal groove:
Special feed roll for aluminium wires.
The wire feed rolls have two grooves for different filler
wire diameters. Correct wire groove is selected by moving
selecting washer (28) from one side to another in feed
roll.
Feed rolls and wire guide tubes of wire feeder unit have
colour codes in order to make identification easier (see table on page 4).
In delivery the Kempoweld WIRE 400 is equipped with red feed rolls with plain groove and with orange wire
guide tubes for welding filler wires of 0.9-1.2 mm (0.035", 0.045" and 0.052"). Kempoweld WIRE 550 is equipped
with ball beared orange feed rolls with plain groove and with orange wire guide tubes for welding filler wire of
1.2 mm (0.052")

5.2. 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. Loose connection
will heat gun and wire feeder unit. When you are using liquid-cooled gun, mount water hoses according to
ASSEMBLY OF KEMPOWELD EQUIPMENT.

5.3. MOUNTING AND LOCKING OF WIRE REEL

LOCKED OPEN
Check that in filler wire reel 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.

5.4. ACCESSORY DRAWER

In the accessory drawer in the cover part of the power source there are in delivery Teflon guide tubes, needed for
welding of aluminium and stainless wires. In the drawer are there also screw and insulation bushings designed for
locking of rotation of the wire feeder unit, as well as big gear wheel D40.

5.5. AUTOMATIC WIRE FEED TO GUN

Automatic wire feed in wire feeder unit makes change of wire reel more rapid. In reel change the pressure of feed
rolls need not released and filler wire goes automatically to correct wire line.
8 – KEMPOWELD WIRE 400, 550 / 0530
– 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.
Feed rolls
colour filler 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)
orange 1.2 (0.052)
brown 1.4
yellow 1.4, 1.6 and 2.0 (1/16 and 5/64)
grey 2.0 (5/64)
black 2.4 (3/32)
Guide tubes
colour filler wire ø mm (inch)
orange 0.6-1.6 (0.024-1/16)
blue yli 1.6 (yli 1/16)
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