Kemppi Pro 3200 EVOLUTION User manual

1913130E
Pro 3200 EVOLUTION
Pro 4200 EVOLUTION
Pro 5200 EVOLUTION
Operation instructions  english
Gebrauchsanweisung  deutsch
Gebruiksaanwijzing  nederlands
Manuel dutilisation  français

2 – Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 © COPYRIGHT KEMPPI OY
CONTENTS
1. PREFACE ........................................................................................................................ 3
1.1. Introduction .......................................................................................................................3
1.2. Product introduction ..........................................................................................................3
1.2.1. Operation control and connectors ................................................................................... 4
1.3. Accessories.......................................................................................................................5
1.3.1. Remote control devices................................................................................................... 5
1.3.2. Control panels ................................................................................................................. 5
1.3.3. Cables ............................................................................................................................. 6
1.4. Operation safety................................................................................................................6
2. INSTALLATION ...............................................................................................................7
2.1. Siting the machine and mounting the control panels PL and PX ......................................7
2.2.1. Connection to the mains supply ...................................................................................... 7
2.2.2. Welding and earth cables................................................................................................ 8
3. OPERATION CONTROL SWITCHES AND POTENTIOMETERS AND THEIR USE......8
3.1. Main switch I/O..................................................................................................................8
3.2. Pilot lamps.........................................................................................................................9
3.3. Local or remote control of welding current ........................................................................9
3.4. Operation of cooling fan ....................................................................................................9
4. ACCESSORIES............................................................................................................... 9
4.1. PL and PX control panels’ operation in MMA welding.......................................................9
4.1.1. Control for MMA welding dynamics (PL, PX) .................................................................. 9
4.1.2. Control of ignition pulse current (PX) ............................................................................ 10
4.1.3. Meter display (PL, PX) .................................................................................................. 10
4.1.4. Operation mede selection (PX) ..................................................................................... 10
5. COOLING UNIT SUPPLY.............................................................................................. 11
6. MAINTENANCE ............................................................................................................ 11
6.1. Cables.............................................................................................................................11
6.2. Power source ..................................................................................................................12
6.3. Regular maintenance......................................................................................................12
7. OPERATION DISTURBANCES .................................................................................... 12
7.1. Operation of the overload protection...............................................................................12
7.2. Control fuses...................................................................................................................12
7.3. Under- and overvoltages in the mains supply .................................................................13
7.4. Loss of a phase in the mains supply ...............................................................................13
8. ORDERING NUMBERS ................................................................................................ 13
9. TECHNICAL DATA AND TERMS OF GUARANTEE .................................................... 14
9.1. Technical data .................................................................................................................14
9.2. Terms of guarantee .........................................................................................................15

Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 – 3
© COPYRIGHT KEMPPI OY
1. PREFACE
1.1. INTRODUCTION
Congratulations on having purchased this product. Properly installed Kemppi products should
prove to be productive machines requiring maintenance at only regular intervals. This manual
is arranged to give you a good understanding of the equipment and its safe operation. It also
contains maintenance information and technical specications. Read this manual from front to
back before installing, operating or maintaining the equipment for the rst time. For further
information on Kemppi products please contact us or your nearest Kemppi distributor.
The specications and designs presented in this manual are subject to change without prior
notice.
In this document, for danger to life or injury the following symbol is used:
Read the warning texts carefully and follow the instructions. Please also study the Operation
safety instructions and respect them when installing, operating and servicing the machine.
1.2. PRODUCT INTRODUCTION
Pro 3200-, 4200- and 5200 Evolution are multi-operator power sources designed for demanding
professional use. They are suitable for MMA/MIG and pulsed MIG as well as for TIG welding
in DC. Pro can be used as power source with a welding automate or robot.
Power control of Pro power source has been realized with at approx. 20 kHz frequency IGBT
transistors operating and control unit with microprosessor.
Kemppi pro machines can be seen in the table below which shows the different device assemb-
lies being suitable for various welding methods as well as operating instruction has been
described in manual for each unit. Mounting intructions for control panels PX and PL are in
their packages.
This manual handles installation and use of Pro power sources.

4 – Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 © COPYRIGHT KEMPPI OY
H12
H11
S11
02
X14
X15
X11 X12 X13
01
F11
X16
F12
1.2.1. Operation control and connectors
F11 Fuse for connetion for control table 6,3 A slow-blow
H11 Signal lamp I/O
H12 Warning lamp for thermal protection
S11 Main switch I/O
X11, Welding connection parallel
X12
X13 Earth connection
X14, Connection for control cable parallel
X15
01 Inlet of mains cable
02 Inspection cover for control panel PL, PX Accessories
Socket outlet Fuse 230 V, 250 VA
F12 Fuse for socket outlet 1,0 A slow-blow

Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 – 5
© COPYRIGHT KEMPPI OY
R61
R61
R63
P21 P22 P23 R22
R21 S21
P31 P32 P33 H31 H32
S33 S34 S35 S36
S37
S31
S32
1.3. ACCESSORIES
Control of MMA/TIG welding current (R61), reference scale 1 … 10.
R20 6185419
MIG-MAG remote control device with controls for wire feed (R63) and voltage (R61), memory
scales 1 … 10.
You can use control device also for control of MMA current from potentiometer R63.
1.3.2. Control panels
PL panel 6185801
P21 Current meter
set value / welding current
P22 Voltage meter
open circuit / terminal voltage
P23 Display for adjustment value of MMA
welding dynamics -9 … 0 …+9
R21 Adjustment of welding current
R22 Adjustment of MMA welding dynamics
S21 Selection for local / remote control
local / MIG/TIG / remote control
PX panel 6185802
H31 Signal lamp for voltage display
H32 Signal lamp for display of adjustment status
P31 Current meter / set value / welding current
P32 Voltage meter / open circuit / terminal voltage
P33 Display for adjustment value of MMA
welding dynamics and start current -9 … 0 …+9
S31, Adjustment of welding current + / -
S32
S33 Selection for local / remote control
local / MIG/TIG / remote control
S34 Selection for characteristics
Point to point welding / normal welding /
carbon arc gouging
S35 Selection of property to be adjusted
MMA welding dynamics / start current
S36, Adjustment for MMA welding dynamics
S37 and start current + / -
RECALL STD = resetting of factory set up (=0)
1.3.1. Remote control devices
R10 6185409

6 – Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 © COPYRIGHT KEMPPI OY
1.4. OPERATION SAFETY
Please study these Operation safety instructions and respect them when installing, operating and
servicing the machine.
Welding arc and spatters
Welding arc hurts unprotected eyes. Be careful also with reecting arc ash. Welding arc and
spatter burn unprotected skin. Use safety gloves and protective clothing.
Danger for re or explosion
Pay attention to re safety regulations. Remove ammable or explosive materials from welding
place. Always ensure that you have sufcent re ghting equipment available where you are
welding. Be prepared for hazards in special welding jobs, eg. for the danger of re or explosion
when welding container type work pieces. Note! Fire can break out from sparks even several
hours after the welding work has been nished!
Mains voltage
Never take welding machine inside a work piece (eg. container or truck). Do not place welding
machine on a wet surface. Always check cables before operating the machine. Change damaged
cables without delay. Damaged cables may cause an injury or set out a re. Connection cable
must not be crushed, it must not touch sharp edges or hot work pieces.
Welding power circuit
Isolate yourself by using proper protective clothing, do not wear wet clothing. Never work on
a wet surface or use defect cables. Do not put the MIG-gun or welding cables on welding
machine or on other electric equipment. Do not press the MIG-gun switch, if the gun is not
directed towards a work piece.
Welding fumes
Take care that there is sufcient ventilation during welding. Take special safety precautions
when welding metals which contain lead, cadmium, zinc, mercury or beryllium.
1.3.3. Cables
Pro 3200 Evolution
Pro 4200 Evolution
Pro 5200 Evolution
16d Extension cable for remote control
20 Earth cable
21 MMA welding cable
R10, Remote control devices, see also pages 5
R20

Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 – 7
© COPYRIGHT KEMPPI OY
max. 150
600
2. INSTALLATION
2.1. SITING THE MACHINE
Site the machine on a stationary, horizontal, dry base in a position that does NOT
allow dust, dirt or metal particles to enter the machines cooling air ow.
- Preferably site the machine somewhat higher above the
oor level.
- Ensure that the front as well as the rear of the machine
there is at least 20 cm free distance to allow good
circulation of the cooling air through the machine.
- Protect the machine against heavy rain and in hot
circumstances against direct sunshine. Ensure the free
circulation of the cooling air.
Degree of protection of machine IP23
allows at its maximum the water spray coming
in 60º angle to hit machine’s outer covering.
2.2. MOUNTING THE CONTROL PANELS PL AND PX
Mounting of panel should only be carried out by competent electrician.
Attention! Disconnect plug of machine from mains socket and wait for approx. 2 min
before removing cover plate.
- On the front face of machine there is a cover plate where the control panel is mounted.
Without a panel the machine is controlled either from remote control unit or Promig
or Protig unit.
- Mount PL or PX panel according to mounting instructions delivered with them.
2.2.1. Connection to the mains supply
Pro power sources are delivered equipped with 5 m mains cable without plug.
If local electricity regulations of operating country are stating otherwise, the mains cable should be
replaced in conformity with the local regulations.
Connection of the mains cable, mounting and change of the plug should only be carried out by a
competent electrician.
Remove the machine’s right side plate to enable the mounting of a mains cable.
See to that the machine is positioned away from the line of
particle spray, created by grinding tools etc.
rain water

8 – Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 © COPYRIGHT KEMPPI OY
05
If changing the mains cable take into consideration the following:
The cable is entered into the machine through the inlet ring on the rear panel of the machine and
fastened with a cable clamp (05). The phase conductors of the cable are coupled to connectors
L1, L2 and L3. The earth protection coloured green-yellow is coupled to connector
If you are using 5-lead cable, you must connect neutral conductor with
terminal N.
Sizes of the mains cables and fuse ratings for the machine at 100% duty cycle
are specied in the table below:
.............................................Pro 3200...................Pro 4200................. Pro 5200
Rated voltage ........................................................ 400 V 3~ .................................
Mains voltage range .......................................... 360 V… 440 V.............................
Fuses, slow-blow .................25 A..........................25 A ........................ 35 A
Connection cable *) mm2.....4 x 2,5 S ...................4 x 6,0 S ................. 4 x 6,0 S
*) In cables of S type there is a protective grounding conductor coloured green-yellow.
2.2.2. Welding and earth cables
Recommended copper cables with cross-sectional area are as follows:
Pro 3200................50 ... 70 mm2
Pro 4200................70 ... 90 mm2
Pro 5200................70 ... 90 mm2
In enclosed table are shown typical load capacities of rubber insulated copper
cables, when ambient temperature is 25 ºC and lead temperature is 85 ºC.
CABLE...............DUTY CYCLE ED ............................ VOLTAGE LOSS / 10m
...........................100%.........60% ........... 30%
50 mm2..............285 A.........370 A ......... 520 A.......... 0,35 V / 100 A
70 mm2..............355 A.........460 A ......... 650 A.......... 0,25 V / 100 A
95 mm2..............430 A.........560 A ......... 790 A.......... 0,18 V / 100 A
Don’t overload welding cables due to voltage losses and heating.
Fasten the earth clamp of the return current cable carefully, preferably direct onto the piece to be
welded. The contact surface of the earth clamp should always be as large as possible.
Clean the fastening surface from paint and rust.
3. OPERATION CONTROL SWITCHES AND
POTENTIOMETERS AND THEIR USE
3.1. MAIN SWITCH I/O
When you turn the switch into I-position, pilot lamp H11 on the front face is illuminated and
the machine is ready for use.
Always turn the machine on and off with the mains switch, never use the
mains plugs as a switch.

Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 – 9
© COPYRIGHT KEMPPI OY
0 =
9
-9
0
t
I2
3.2. PILOT LAMPS
The pilot lamps of the machine report the electric operation:
The green pilot lamp H11 when illuminated indicates that the machine is on and ready for
use and it is connected to the mains supply with the main switch in the I-position.
H12 indicates when illuminated that the thermal protection of the machine has been
activated due to over heating. the cooloing fan will continue to run and cool the machine
downn and when the lamp is off the machine ia ready to weld.
3.3. LOCAL OR REMOTE CONTROL OF WELDING CURRENT
You can control welding current either from local controls of PX or PL control panel, or from
remote control unit which is connected to remote control connector X14 or X15, or from Promig
or Protig unit.
Selector switch of control panel has to be in a position corresponding to control mode: local
control / MIG/TIG / remote control unit.
Suitable remote control units R10 and R20, see page 5.
At MIG and TIG welding, current control is made according to operation instruction of
controlling MIG or TIG unit.
3.4. OPERATION OF COOLING FAN
In Pro 3200 there are one and in Pro 4200 and 5200 two simultaneously operating fans.
- The fan is started for a moment when main switch is placed into postion I.
- The fan will start during welding as the machine heats up and it will run for 1 to 10 minutes
after the welding has stopped.
- On no-load fan is started in intervals of approx. half an hour for minute’s time.
Soft arc. Object to reduce amount of spatter in welding at the upper end of recommen-
ded currents for electrode.
Factory setup (PX). Normal setting for all electrode types.
Rough arc. Object e.g. cellulose covered electrodes and thin stainless electrode in
welding at the lower end of the recommended curents for electrode.
Roughening
Factory set up
Softening
4. ACCESSORIES
4.1. PL AND PX CONTROL PANELS’ OPERATION IN
MMA WELDING
4.1.1. Control for MMA welding dynamics (PL, PX)
With control for electrode dynamics you can inuence arc behaviour in different kinds of
operation situations.
When arc is roughened, blowing is increasing and at the same time also spatter.

10 – Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 © COPYRIGHT KEMPPI OY
9
-9
0
I2
t
U2
max.
I2
4.1.2. Control of ignition pulse current (PX)
Display 0 corresponds to factory set up of ignition pulse. Number of ignition pulses depends on
electrode type and diameter which are used. Ignition pulse changes with set value of welding
current in such a way that at low values ignition pulse is low and short and at high values it
is higher and longer.
Low, short ignition pulse. Object e.g. small stainless electrodes.
4.1.3. Meter display (PL, PX)
Voltage meter shows machine’s terminal voltage which is voltage between connectors X11/X12
and X13.
Accurancy of current true value in respect to real value is ±2,5 %, ±2 A.
Accurancy of voltage true value in respect to real value is ±2,5 %, ±0,2 V.
Depending on welding cable legth and copper cross section, real arc voltage and meter display
might differ main volts from each other. Error will incease when current is growing. See table in
paragraph ”Welding and earth cables”, page 8.
In current measurement the same error won’t appear.
4.1.4. Operation mede selection (PX)
Normal MMA welding
In normal MMA welding there are constant current characteristics in the machine. The machine
is trying to keep welding current value regardless of arc length changes.
0 = factory set up
Factory set up. Object e.g. basic electrodes.
High, long ignition pulse. Object e.g. high efciency electrodes.
U2=20V+0,04xI2
norm line
statically constant current