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The Kemppi WeldForce KPS3500, KPS4500, and KPS5500, along with their MVU variants (KPS3500 MVU, KPS4500 MVU, KPS5500 MVU), are robust multi-operator power sources engineered for demanding professional welding applications. These machines are versatile, supporting Manual Metal Arc (MMA) welding, Metal Inert Gas/Metal Active Gas (MIG/MAG) welding, pulsed MIG welding, and Direct Current (DC) Tungsten Inert Gas (TIG) welding.
The WeldForce power sources are designed to provide stable and reliable welding current for a variety of processes. They feature a main switch (S11) for power control, a signal lamp (H11) to indicate operation, and a warning lamp (H12) for thermal protection. Welding connections (X11, X12) are provided in parallel, along with an earth connection (X13). For enhanced control, the units include connections for control cables (X14, X15), also in parallel, allowing for the integration of remote control devices. The mains cable enters through an inlet (01) at the rear.
The KPS series can be used for MMA welding by connecting a Kemppi KWF200 or KWF300 wire feeder. Alternatively, for MMA welding without a wire feeder, an R10 or R20 remote control can be connected to the X14 or X15 terminals at the back of the power source for welding current adjustment, with the welding power cable connected to the (+) connector X11 or X12.
The KPS MVU models offer additional flexibility in mains supply, capable of connecting to both 230 V 3~ and 400 V 3~, with the power source automatically recognizing the mains voltage. This adaptability makes them suitable for a wider range of industrial environments.
Operation of the WeldForce machines is straightforward. When the main switch (S11) is turned to the "I" position, the green pilot lamp (H11) illuminates, indicating that the machine is on and ready for use.
Cooling is managed by internal fans. The KPS3500 has one fan, while the KPS4500 and KPS5500 models feature two simultaneously operating fans. The fan briefly starts when the main switch is turned on. During welding, the fan activates as the machine heats up and continues to run for 1 to 10 minutes after welding ceases to ensure proper cooling. In no-load conditions, the fan operates intermittently for about half an hour at a time.
The machines are equipped with thermal protection. If the machine overheats due to continuous loading beyond rated values or blocked cooling air circulation, the yellow pilot lamp (H12) will light up, indicating that the thermal protection thermostat has activated. The cooling fan will continue to run until the machine cools down, and once the H12 lamp turns off, the machine is automatically ready for welding again.
Remote control devices (R10, R20) offer convenient adjustment of welding parameters. The R10 device controls MMA/TIG welding current with a reference scale from 1 to 5. The R20 device, designed for MIG-MAG welding, provides controls for wire feed and voltage, with memory scales from 1 to 5, and can also be used to control MMA current. Extension cables (16d) are available for remote control devices, allowing for greater operational flexibility.
The WeldForce power sources are designed with electromagnetic compatibility (EMC) for industrial environments, classified as Class A equipment. This means they are not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system.
Regular maintenance is crucial for ensuring trouble-free operation and extending the lifespan of the WeldForce machines. The frequency of maintenance should be determined by the amount of use and the working environment.
Daily checks include inspecting the condition of welding and connection cables. Damaged cables must be replaced immediately to prevent injury or fire. Mains cables should always be safe and conform to local regulations, with any repairs or mounting of mains connection cables performed by an authorized electrician.
At least every six months, a more thorough inspection is recommended. This involves checking the machine's electric connectors, cleaning any oxidized parts, and tightening loosened connections. It is important to know the correct tension torques before attempting any repairs on joints. The inner parts of the machine should be cleaned of dust and dirt using a soft brush and vacuum cleaner, taking care not to use compressed air, which can pack dirt more tightly into cooling profiles. The ventilation net behind the front grate should also be cleaned. Pressure washing devices should not be used.
Before removing the cover plate for internal maintenance, it is essential to disconnect the machine's plug from the mains socket and wait approximately 2 minutes for the capacitors to discharge. Only authorized electricians should carry out repairs to the machines.
Kemppi Service Workshops offer regular maintenance services according to agreement. Key maintenance procedures include general cleaning of the machine, checking and maintaining welding tools, inspecting connectors, switches, and potentiometers, verifying electric connections, and checking the mains cable and plug.
The machines are protected against sudden, transient overvoltages in the primary circuits and are designed to withstand continuous 3 x 440 V voltage. If the mains supply experiences undervoltage (below approximately 300 V), the machine control will automatically stop operating. Loss of a phase in the mains supply can lead to noticeably poorer welding properties or prevent the machine from starting, often due to a blown mains supply fuse, a defective mains cable, or a bad connection at the terminal block or plug.
In the event of operational disturbances, users are advised to contact Kemppi works or a local Kemppi dealer. Before sending the machine for service, it is recommended to check the maintenance objects.
For environmental responsibility, the machines are designed for proper disposal. Electrical equipment should not be disposed of with normal waste. In accordance with European Directive 2002/96/EC on Waste Electrical and Electronic Equipment, end-of-life equipment must be collected separately and returned to an environmentally compatible recycling facility. Owners should seek information on approved collection systems from their local representative.
General| Brand | Kemppi |
|---|---|
| Model | WeldForce KPS 4500 |
| Category | Welding System |
| Language | English |
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