1. Introduction
The Kemppi Kempact RA series is engineered for modern welding workshops, offering a blend of stylish design, high-quality construction, and functional user benefits. This machine ensures productive, accurate, and efficient welding tasks. Based on Kemppi's latest power source program, the Kempact RA provides optimal welding performance, excellent energy efficiency, and cost-effectiveness. This manual provides essential information for the safe and effective operation and maintenance of your Kempact 323A welding machine.
2. Safety Information
Always prioritize safety when operating welding equipment. Failure to follow safety guidelines can result in serious injury or death. Read and understand all instructions before use.
- Electric Shock: Welding current can cause fatal electric shock. Do not touch live electrical parts. Wear dry, insulating gloves and protective clothing.
- Fumes and Gases: Welding produces fumes and gases that can be hazardous to health. Work in a well-ventilated area. Use local exhaust ventilation or a respirator if ventilation is poor.
- Arc Rays: Arc rays can burn eyes and skin. Wear a welding helmet with an appropriate shade filter. Protect other personnel in the area with non-flammable screens.
- Fire and Explosion: Welding can cause fire or explosion. Keep flammable materials away from the welding area. Have a fire extinguisher readily available.
- Hot Parts: Welded parts and equipment can be hot. Allow them to cool before handling or wear appropriate heat-resistant gloves.
- Maintenance: Only qualified personnel should perform maintenance and repairs. Disconnect power before servicing.
3. Package Contents
Verify that all items listed below are included in your package:
- Kemppi Kempact 323A Power Source
- DuraTorque 4-Roll Wire Feeder (0.8-1.2 mm selectable)
- Kemppi GX 303 G Torch (5 m)
- Earth Cable
- Spool Adapter
- Ar/CO2 Pressure Reducer (200 bar)
- WH20 Jackson Welding Helmet
- Binzel Pistol Spray
- Welding Wire (0.8, 1.0, or 1.2 mm - specify after order)
- GL-121 MIG/MAG Welder's Gloves (Size 9, 10, or 11 - specify after order)
4. Setup
Follow these steps for the initial setup of your Kemppi Kempact 323A welding machine.
- Placement: Position the welding machine on a stable, level surface. Ensure adequate ventilation around the unit. The GasMate housing design allows for easy loading of gas cylinders at ground level.
- Power Connection: Connect the power cable to a suitable 400V power supply. Ensure the power supply meets the machine's requirements (e.g., 380-400V, 11A effective current).
- Gas Cylinder Connection: Connect the Ar/CO2 gas cylinder to the pressure reducer, then connect the pressure reducer to the gas inlet on the welding machine. Ensure all connections are secure and leak-free.
- Wire Feeder Setup:
- Open the side panel of the machine to access the wire feeder compartment. The Brights housing illumination will assist visibility.
- Install the welding wire spool onto the spool adapter.
- Thread the welding wire through the DuraTorque 4-roll wire feeder mechanism. Ensure the wire is correctly seated in the grooves of the feed rollers.
- Adjust the wire tension according to the wire diameter and material.
Figure 4.1: The side panel opened to reveal the wire feeder compartment, designed for easy access and wire spool installation. 
Figure 4.2: A detailed view of the DuraTorque 4-roll wire feeder, highlighting the precision mechanism for consistent wire delivery. 
Figure 4.3: The wire feeder compartment illuminated by the Brights housing lighting, improving visibility during setup and maintenance. - Torch and Earth Cable Connection: Connect the Kemppi GX 303 G torch to the appropriate connector on the front panel. Connect the earth cable clamp to the workpiece.
- Personal Protective Equipment (PPE): Always wear the provided WH20 Jackson welding helmet, GL-121 MIG/MAG welder's gloves, and other appropriate protective clothing before operating the machine.
5. Operating Instructions
The Kempact 323A features an intuitive control panel for precise welding parameter adjustments.
- Power On: Turn on the main power switch. The large, clear LCD display will illuminate.
- Parameter Selection (Adaptive Panel):
- Use the control knobs to navigate and adjust welding parameters. The adaptive panel simplifies setup by automatically adjusting certain parameters based on your primary selections.
- Material: Select the type of material being welded.
- Wire Ø (Diameter): Set the diameter of the welding wire being used.
- Gas: Select the shielding gas type (e.g., Ar/CO2 mix or CO2).
- Crater Fill: Adjust the crater fill function for optimal end-of-weld performance.
- Spot / Cycle: Utilize the Arc-Timer for precise spot and interval welding.
- 2T/4T: Select between 2-stroke (2T) and 4-stroke (4T) torch trigger functions.
- Mode: Choose the welding mode (e.g., HotSpot for enhanced arc starting).
Figure 5.2: A close-up of the LCD display, showing various welding parameters such as material thickness, wire feed speed, and voltage, along with selected functions like 2T/4T and gas type. - Memory Functions: The machine includes memory slots (1-4) to save and recall frequently used welding settings, enhancing productivity.
- Welding: Once parameters are set, begin welding. The machine provides excellent welding performance with mixed or CO2 shielding gas, and precise, clean arc ignition.
6. Maintenance
Regular maintenance ensures the longevity and optimal performance of your Kemppi Kempact 323A.
- General Cleaning: Keep the machine clean and free from dust and debris. Use a soft, dry cloth for external surfaces.
- Wire Feeder Maintenance: Regularly inspect and clean the wire feeder mechanism. The WireLine maintenance indicator will alert you to necessary service. Ensure the feed rollers are free of wire shavings and debris.
- Torch Maintenance: Clean the torch nozzle and contact tip regularly. Replace worn-out contact tips and gas nozzles to maintain arc stability and weld quality. Use Binzel Pistol Spray as needed.
- Cooling System: Ensure the cooling air inlets and outlets are unobstructed. Periodically clean the internal components with compressed air, ensuring power is disconnected.
- Cable Inspection: Check all cables (power, earth, torch) for damage, cuts, or frayed insulation. Replace damaged cables immediately.
- Storage: When not in use, store the machine in a dry, clean environment. Utilize the integrated spare parts storage compartments for consumables.
7. Troubleshooting
This section provides solutions to common issues you might encounter.
| Problem | Possible Cause | Solution |
|---|---|---|
| No power to the machine. | Power cable disconnected, circuit breaker tripped, faulty power switch. | Check power cable connection. Reset circuit breaker. Contact service if switch is faulty. |
| No arc ignition. | Poor earth connection, incorrect wire feed speed, clogged contact tip, no shielding gas. | Ensure earth clamp is securely attached to clean metal. Adjust wire feed speed. Clean/replace contact tip. Check gas cylinder and flow. |
| Inconsistent wire feed. | Incorrect wire tension, worn feed rollers, bent liner, wrong contact tip size. | Adjust wire tension. Inspect/replace feed rollers. Check torch liner for kinks. Ensure contact tip matches wire diameter. |
| Porous weld. | Insufficient shielding gas, gas leak, contaminated workpiece, incorrect gas type. | Increase gas flow. Check gas lines for leaks. Clean workpiece thoroughly. Verify correct gas selection. |
8. Specifications
Technical specifications for the Kemppi Kempact 323A welding machine.
| Feature | Detail |
|---|---|
| Model | Kempact 323A |
| Input Voltage | 3~ 50-60 Hz, 380-400V |
| Effective Input Current (I1eff) | 9A |
| Max Input Current (I1max) | 18A |
| Open Circuit Voltage (U0) | 44V |
| Output Current (I2) | 320A |
| Duty Cycle (X) | 35% at 320A (260V) |
| Power Factor (λ) | 0.90 |
| Protection Class | IP23S |
| Standards | IEC 60974-1, IEC 60974-5, IEC 60974-10 |
| Max Gas Pressure (pmax) | 0.5 MPa |
| Serial Number (Example) | 2600584 |
9. Warranty and Support
Kemppi offers a 3+ year warranty on the Kempact RA series, ensuring peace of mind and long-term reliability for your investment.
- Warranty Coverage: Refer to your purchase documentation for specific terms and conditions of the Kemppi 3+ year warranty. This warranty covers defects in materials and workmanship under normal use.
- Technical Support: For technical assistance, troubleshooting beyond this manual, or warranty claims, please contact your authorized Kemppi dealer or visit the official Kemppi website for support contact information.
- Online Resources: Additional resources, including updated manuals and FAQs, may be available on the Kemppi website.
For more information, visit: www.kemppi.com
