Kemppi ProCool 20 Technical manual

ProCool 20
1926410E
0712

2 – ProCool 10 / 0712 © kemPPi oy
CONTENTS
1. PREFACE....................................................................................................................... 3
1.1. INTRODUCTION......................................................................................................... 3
1.2. PRODUCT INTRODUCTION ...................................................................................... 3
1.3. OPERATION SAFETY................................................................................................. 3
2. INSTALLATION.............................................................................................................. 4
2.1. REMOVAL FROM PACKAGING.................................................................................. 4
2.2. LOCATING THE MACHINE......................................................................................... 4
2.3. SERIAL NUMBER ....................................................................................................... 4
2.4. INSTALLATION AND MAIN PARTS ............................................................................ 4
2.4.1. ASSEMBLING THE EQUIPMENT............................................................. 4
2.4.2. MAIN PARTS OF COOLING UNIT............................................................ 4
2.5. PREPARING FOR OPERATION ................................................................................. 5
3. OPERATION .................................................................................................................. 5
3.1. COOLING UNIT OPERATION..................................................................................... 5
3.2. COOLING UNIT PILOT LIGHTS ................................................................................. 5
3.3. STORAGE ................................................................................................................... 5
4. MAINTENANCE ............................................................................................................. 6
4.1. DAILY MAINTENANCE ............................................................................................... 6
4.2. EVERY SIXTH MONTHS ............................................................................................ 6
4.4. TROUBLE SHOOTING ............................................................................................... 6
5. TEChNICAL dATA ........................................................................................................ 7
6. TERMS OF GUARANTEE ............................................................................................. 7

ProCool 10 / 0712 – 3© 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
Procool is a cooling unit designed for Kemppi Pro -welding equipment and to be used for cooling
welding gun or torch. The operation of Procool is controlled by a microprocessor.
1.3. 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 reserve sufcient re-ghting equipment on welding place. 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 defect cables
without delay. Defect cables may cause an injury or set out a re. Connection cable must not be
compressed, 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 MIG-gun or welding cables on welding machine or
on other electric equipment. Do not press 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.

4 – ProCool 10 / 0712 © kemPPi oy
2. INSTALLATION
2.1. REMOvAL FROM PACkAGING
The equipment is packed in durable packages specially designed for them. Check the equipment
before taking it into use, to make sure that the equipment or a part of it have not got damaged
during the transportation. Also check that the delivery corresponds your order and that you have
received all the necessary instructions for installing and operating the equipment. The packaging
material can be recycled.
2.2. LOCATING ThE MAChINE
Place the machine on a horizontal, stable and clean ground. Protect the machine from heavy rain
and burning sunshine. Check that there is enough space for cooling air circulation in front of and
behind the machine.
2.3. SERIAL NUMbER
The serial number of the machine is marked on the machine CE-marking. Identicating
the serial number is the only proper means of maintaining and identifying parts for a specic
product. It is important to make correct reference to the serial number of the product when making
repairs or ordering spare parts.
2.4. INSTALLATION ANd MAIN PARTS
2.4.1. Assembling the equipment
The equipment is assembled in the following order:
1. Transport unit P40/P40L 6185264/6185264L
2. Cooling unit Procool 20 6262014NX
Assembly the transport unit according to the instructions in the package. Fasten the cooling unit
to the transport unit by using the screws and bolts delivered with the equipment.
2.4.2. Main parts of cooling unit
Front machine
A Housing
B Main switch and pilot lamp
C Test switch
D Overheat control lamp
E Water supply control lamp
F Filling hole
Back side
G Mains cable
H Control cable
I Cooling water output hose
J Cooling water input hose
A
D
B
E
G
HJ
I
C
F

ProCool 10 / 0712 – 5© kemPPi oy
2.5. PREPARING FOR OPERATION
Cooling liquid is injurious! Avoid also contact with skin or eyes. In case of injury,
seek for medical advice.
See also 2.4.2. Main parts of cooling unit.
1. Install the cooling unit control cable into the wire feed unit.
2. Connect the cooling water hoses with the wire feed unit, follow colour markings.
3. Fill the reservoir with a 20 - 40 % mixture of etanol and water, or with any other suitable
antifreeze agent. The capacity of the reservoir is 3 litres.
4. Install the mains cable plug to the earthed socket of power source.
3. OPERATION
3.1. COOLING UNIT OPERATION
See also 2.4.2. Main parts of cooling unit.
The operation of Procool is controlled by a microprocessor. The cooling unit pump starts
automatically when welding starts. The pump operates still for 5 minutes after welding has been
nished, to cool the water to the same temperature as in the machine surround. This reduces the
need of service. Proceed as follows:
1. Start power source and cooling unit.
2. Press the test switch until the red control light goes out.
3. The water is now circulating and you can start welding.
Check water level and input ow regulary, add liquid if needed.
3.2. COOLING UNIT PILOT LIGhTS
The control lamp is lighting always when the machine is connected to mains voltage and the main
switch is in position I.
Overheat signal lamp
The overheat signal lamp is lighting when temperature control of the machine has detected cooling
water overheat. The ventilator cools down the machine and when the lamp goes out welding can
be started again.
Water ow signal lamp
The red signal lamp is lighting when water ow is blocked.
3.3. STORAGE
The machine must be stored in a clean and dry room. Protect the machine from rain and keep it
away from direct sunshine in places where temperature exceeds +25 °C. Check that there is free
space in front of and behind the machine for air circulation.

6 – ProCool 10 / 0712 © kemPPi oy
4. MAINTENANCE
Watch out for mains voltage when handling electric cables!
In planning product maintenance machine utilization degree and circumstances should be considered.
Careful use and preventive maintenance help to avoid unnecessary production disturbances and
breaks.
4.1. dAILy MAINTENANCE
The following maintenance opeations should be carried out daily:
– Check water level and input ow, add liquid if needed.
– Check cables and connections. Tighten, if necessary and replace defect parts.
4.2. EvERy SIXTh MONThS
The following maintenance opeations should be carried out at least every sixth months:
– Clean off dust and dirt. Change the cooling liquid and wash up the pipes and water reservoir
with pure water.
– Check seals, cables and connections. Tighten, if necessary and replace defect parts.
4.3. TROUbLE ShOOTING
See also 3.2. Cooling unit pilot lights.
Main switch control lamp is not lighting.
There is no power in the machine.
– Check mains fuses, replace blown fuses.
– Check mains cable and plug, replace defect parts.
Overheat signal lamp is lighting.
The unit is overheated.
– Check water circulation.
– Check that there is enough free space behind the machine for cooling air circulation.
The water supply signal lamp is lighting.
– Remove blockages.
– Check water circulation, add liquid if needed.
For further information and assistance, contact your nearest Kemppi service workshop.

ProCool 10 / 0712 – 7© kemPPi oy
5. TEChNICAL dATA
Cooling unit ProCool 20
Connection voltage 1 ~, 50/60 Hz 220 V - 10 % ... 240 V+6%
Connection capacity 100 % ED 120 W
Mains cable 3 x 1.5 S - 0.8 m
Power factor 0,42
Control voltage 50 V DC
Cooling power 1,25 kW
Cooling liquid 20 % - 40 % etanol/water
Reservoir volume approx. 3 l
Overall dimension: length 610 mm
width 230 mm
height 290 mm
Weight 13 kg
Operating temperature range -20 … +40 oC
Storage temperature range -40 … +60 oC
Degree of protection IP 23 C
The products meet the conformity requirements of CE-marking.
6. TERMS OF GUARANTEE
Kemppi Oy provides a guarantee for products manufactured and sold by them if defects in
manufacture and materials occur. Guarantee repairs must be carried out only by an Authorised
Kemppi Service Agent. Packing, freight and insurance costs to be paid by orderer. The guarantee is

8 – ProCool 10 / 0712 © kemPPi oy
effected on the date of purchase. Verbal promises which do not comply with the terms of guarantee
are not binding on guarantor.
Limitations on guarantee
The following conditions are not covered under the terms of guarantee: defects due to natural wear
and tear, non-compliance with operating and maintenance instructions, connection to incorrect or
faulty supply voltage (including voltage surges outside equipment spec.), incorrect gas pressure,
overloading, transport or storage damage, re of damage due to natural causes i.e. lightning or
ooding.
This guarantee does not cover direct or indirect travelling costs, daily allowances or accommodation.
Note: Under the terms of guarantee, welding torches and their consumables, feeder drive rolls and
feeder guide tubes are not covered. Direct or indirect damage due to a defective product is not
covered under the guarantee. The guarantee is void if changes are made to the product without
approval of the manufacturer, or if repairs are carried out using non-approved spare parts.
The guarantee is also void if repairs are carried out by non-authorised agents.
Undertaking guarantee repairs
Guarantee defects must be informed to Kemppi or authorised Kemppi Service Agents within the
guarantee period. Before any guarantee work is undertaken, the customer must provide proof of
guarantee or proof of purchase, and serial number of the equipment in order to validate the guarantee.
The parts replaced under the terns of guarantee remain the property of Kemppi.
Following the guarantee repair, the guarantee of the machine or equipment, repaired or replaced,
will be continued to the end of the original guarantee period.