Kemppi PROCOOL 10 Operating instructions
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TROUBLESHOOTING FOR PRO COOLING UNIT
GENERAL MAINTENANCE OF PROCOOL 10
The amount of use and the working enviroment should be taken into consideration when
planning the frequency of maintenance. Careful use and preventive maintenance will
help to ensure trouble-free operation.
CHECK DAILY!
-amount of cooling liquid (NOTE! If cooling liquid has boiled, it must be
replaced, because then the solution has lost its metal coats protective effect.)
- check with test switch that liquid is also returned to reservoir.
-gaskets of welding/liquid cables. DON´T USE LEAKING WELDING CABLES OR
HOSES.
- condition of connection cables.
The number of systems in operation and the importance of minimize not running time
will determine to what extend consumable- and spare parts will be stocked.
TROUBLESHOOTING CHART
TROUBLE CAUSE REMEDY
Indicator lamp H002 is
swicthed on. Pump does not
work, motor does not rotate.
Faulty pumpr, motor does not
rotate or PROCOOL is out of
liquid.
Liquid leakage in cooling
system.
See check point picture.
Repair the pump/pumpmotor
or add cooling liquid.
Repair/change leaking liquid
hose.
Follow the the check point
instructions.
Indicator lamp H001 is swit-
ched on. Liquid circulation
continues.
Cooling liquid is overheated. Wait until cooling liquid and
PTC is cooled.
MIG/TIG unit stops welding,
liquid circulation continues.
Control cable broke during
welding.
Bad connection in control
cables.
Check that control cables are
properly tightened.
Check all wires with
multimeter that they are not
cut. See picture of connector
and cable.
MIG/TIG welding can not be
started.
Control cable broke when
welding is not going on.
Bad connection in control
cables.
Check that control cables are
properly tightened.
Check all wires with
multimeter that they are not
cut. See picture of connector
and cable.
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TROUBLESHOOTING FOR PRO COOLING UNIT
TROUBLESHOOTING CHART
TROUBLE CAUSE REMEDY
Welding is interrupted. Supply voltage 220 V is dis-
connected during welding.
Check supply voltage cable
and tighten wires from con-
nection terminal
Check supply voltage 220V
from connector X1/1 - X1/3
on PCB A001.
MIG/TIG welding can not be
started.
Supply voltage 220 V is dis-
connected when welding is
not going on.
Check supply voltage cable
and tighten wires from con-
nection terminal
Check supply voltage 220V
from connector X1/1 - X1/3
on PCB A001.
Signal lamp H2 is flashing
when there is normal pause
in liquid circulation.
Pressure guard is broke or
there is pressure in system.
See check point picture,
check point 3.
Check funktion of the
pressure guard from
connector X2/1 - X2/2 on
PCB A001 with multimeter
that S003 is not broken;
enough pressuer 0V and low
pressure 5V.
PRCOOL don´t work at all. Burned fuse F1 on PCB
A001.
Check/change fuse F1
(630 mA).
CONTROL CONNECTOR AND CABLE
PCB A001 CONNECTOR X3 CONTROL CABLE X003
1. Data, serial A. GND
2. +50 VDC B. Data, serial
3. GND C. +50 VDC
1 2 3
A
B
C
D
E
F
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TROUBLESHOOTING FOR PRO COOLING UNIT
WATER CIRCULATION PARTS (see check point picture)
1. Return hose for liquid
2. Ajustment screw
3. Pressure guard
4. Liquid surface level
CHECK POINT PICTURE
NOTE !
If signal lamp for pressure illuminates, liquid circulation operates from test switch
S2. Is there any leakage, check disturbance as follows:
1. Press switch S2.
2. Check through filling opening of reservoir that liquid returned to reservoir and the
height of the liquid surface is right, check point 4., (about 60 mm). If any liquid dosen´t
come from the return hose of liquid, check point 1., take contact with nearest KEMPPI
authorised service repair shop.
3. Continue pressing on switch S2 and adjust the ADJUSTMEN SCREW for pressure,
check point 2., insuch way that the signal lamp H2 is only just switched off.
4. Release switch S2 and wait for approx.10 s and check that signal lamp H2 is not
flashing.
5. Still check by welding for approx. 20 s that there aren´t any more disturbances.
1.
2.
3.
4.
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TROUBLESHOOTING FOR PRO COOLING UNIT
JUMPERS
X8 With this jumper two alternative usage methods can be sellected:
1. AUTOMATIC START/STOP. Short circuit block between X8/2 -
X8/3.
Start and stop is determined by the MIG/TIG unit.
2. CONTINUOUS LIQUID CIRCULATION (MANUAL
START/STOP). Short circuit block between X8/1 - X8/2. Liquid
circulation starts immediately
after S001 is switched on. Liquid circulation is stopped only if an error
is detected or S001 is switched off.
X9 A short circuit block between X9/1 - X9/2 decreases the operation time
after welding to 15s. NOTE ONLY FOR TEST USE!
X10 Not in use.
JUMPERS AND CONNECTORS ON CONTROL CARD A001
X10
X9
X8
T1
D2
K2
K1
X7
X2
X11
X3
X
6
X5
X1
F1 PROCOOL 10 A001
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