Kemppi 25 User manual

PMT 25, 27, 32, 35, 42
30W, 42W, 52W
Operating manual • English
Käyttöohje • Suomi
Bruksanvisning • Svenska
Bruksanvisning • Norsk
Brugsanvisning • Dansk
Gebrauchsanweisung • Deutsch
Gebruiksaanwijzing • Nederlands
Manuel d’utilisation • Français
Инструкции по эксплуатации • По-русски
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EN
OPERATING MANUAL
English
PMT © Kemppi Oy / 1130

EN
CONTENTS
1. PREFACE.................................................................................................................3
1.1 General..........................................................................................................................3
1.2 Product Introduction ............................................................................................4
1.3 Operation Safety......................................................................................................4
2. CONNECTING THE GUN........................................................................5
3. USING THE PMT GUN WITH UNITS OTHER
THAN PROMIG AND FEED.................................................................6
3.1 Changing the connection ..................................................................................6
4. MOUNTING THE GUN REGULATOR RMT 10.................8
5. USING THE GUN REGULATOR RMT 10................................9
5.1 Regulating the wire feed speed and welding power .........................9
5.2 Selecting the selecto channel..........................................................................9
6. OPERATION OF THE THERMAL SHIELD..........................11
7. TWISTING THE NECK ...........................................................................11
8. USE AND MAINTENANCE................................................................12
9. OPERATION DISTURBANCES......................................................13
10. ORDERING NUMBERS.........................................................................14
11. TECHNICAL DATA.....................................................................................15
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1. PREFACE
1.1 GENERAL
Congratulations on having purchased this product. Used correctly,
Kemppi products can signicantly increase the productivity of your welding,
and provide years of economical service.
This operating manual contains important information on the use,
maintenance and safety of your Kemppi product. The technical specications
of the equipment can be found at the end of the manual.
Please read the manual carefully before using the equipment for the rst
time. For your own safety and that of your working environment, pay
particular attention to the safety instructions in the manual.
For more information on Kemppi products, contact Kemppi Oy, consult an
authorised Kemppi dealer, or visit the Kemppi web site at www.kemppi.com.
The specications presented in this manual are subject to change without
prior notice.
Important notes
Items in the manual that require particular attention in order to minimise
damage and personal harm are indicated with the ’NOTE!’ notation. Read
these sections carefully and follow their instructions.
Disclaimer
While every eort has been made to ensure that the information contained
in this guide is accurate and complete, no liability can be accepted for any
errors or omissions. Kemppi reserves the right to change the specication of
the product described at any time without prior notice. Do not copy, record,
reproduce or transmit the contents of this guide without prior permission
from Kemppi.
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1.2 PRODUCT INTRODUCTION
Kemppi PMT MIG/MAG guns for manual welding are designed for demanding
professional use. They are suitable to be used in all MIG units equipped with
a Euro adapter.
1.3 OPERATION SAFETY
Please study these Operation safety instructions and respect them when
installing, operating and servicing the machine.
Welding arc and spatters
The welding arc hurts unprotected eyes. Also be careful with reecting arc
ashes. The welding arc and spatter burn unprotected skin. Use safety gloves
and protective clothing.
Danger of re or explosion
Pay attention to re safety regulations. Remove ammable or explosive
materials from the welding location. Always reserve sucient re-ghting
equipment at the welding location. Be prepared for hazards in special
welding jobs, e.g. the danger of re or explosion when welding container
type work pieces.
NOTE! Fire can break out from sparks even several hours after welding has been
nished!
Mains voltage
Never take the welding machine inside a work piece (e.g. container or truck).
Do not place the welding machine on a wet surface. Always check cables
before operating the machine. Change damaged cables without delay.
Damaged cables may cause injury or start a re. Connection cable must not
be compressed or 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 damaged cables. Do not put
the MIG gun or welding cables on the 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
Make sure that there is sucient ventilation during welding. Take special
safety precautions when welding metals which contain lead, cadmium, zinc,
mercury or beryllium.
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2. CONNECTING THE GUN
In its delivery state, internal connections of PMT guns are made so that they
are suitable to be used only with Promig and Feed wire feeders.
Do not use the PMT gun in any other wire feeder than Promig and Feed
before you have changed internal connections of gun according to the
instructions in the following paragraph.
Do not use the PMT gun in units other than Promig and Feed before you are
certain that the RMT 10 gun control unit is not installed on the gun.
Set the snap connector carefully in its place so that control connectors will
not get damaged. Tighten the snap connector carefully in order to avoid
voltage loss. A loose connection will heat up the gun and the feeder unit.
Inspect the tightness of the connection daily.
Connect liquid hoses of the gun and interconnecting cable according to
operation instructions of the wire feeder. Fix liquid hoses in such a way that
ones having a red code are always connected to corresponding red counter
connectors and the blue ones respectively to blue counter connectors.
If the connections are crossed, cooling liquid will circulate in the wrong
direction in the gun. This might cause the gun handle and neck body to heat
up considerably more than usual.
When connecting the liquid and gas hoses, make sure there is no dirt, metal
powder or other waste in the connectors.
Waste may block the liquid circulation, damaging the gun and stopping or
breaking the pump.
Before you start welding, make sure that the wire liner is according to
recommendations (see colour code in the consumable parts sheet) and that
the contact tip corresponds to the wire diameter used.
Look out for wire coming out of the welding end of gun. Do not direct the
gun towards people or the work piece but make sure that the wire exits the
gun without obstruction.
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3. USING THE PMT GUN WITH UNITS OTHER
THAN PROMIG AND FEED
In the PMT guns, in addition to start operations, gun control and thermal
protection operations are also transmitted along the control lines of the snap
connector (PMT 30W, PMT 42W, PMT 52W). Hence the delivery state of the
guns is such that without any alternations to the internal connections, the
guns are suitable to be used only with Promig and Feed wire feed units.
The use of PMT guns in other MIG units without any alternations to the
connections may cause following erratic behaviour:
• Start is always switched on and wire is being fed continuously,
eventhough the trigger is not pulled.
• Start does not operate even if the trigger is pulled. If the RMT 10
gun control unit is installed, the use of the PMT gun in other units
than Promig or Feed may cause a malfunction as described above,
eventhough you have changed the internal couplings of the gun.
If the RMT 10 gun control unit is coupled at its place, using the PMT gun in
units other than Promig or Feed may cause malfunctions as described above,
eventhough you have changed the internal coupling of the gun.
3.1 CHANGING THE CONNECTION
Under the plastic cover of the snap connector head of the PMT gun there
is an electronics card, on which there is a shorting jumper for changing the
connection.
• Release the fastening screws (4 pcs.) of the plastic cover protector of the
snap connector head.
• Lift the cover approximately 50 mm. Do not bend the cooling liquid
hoses.
• Take the electronics card out of the plastic protector.
• Gently pull the insulating hose covering the card to the direction of the
snap connector so that the shorting jumper becomes accessible. Handle
the wires of card and their connections carefully.
• Ιn the delivery state, the shorting jumper is mounted to the connectors,
next to which, at the base of the card, there is a printed symbol text
“PRO”. Disconnect the shorting jumper and connect it to the another
connector pair with the symbol text “FU”.
• Pull the insulating hose back onto the card.
• Mount the card back in its original place. Make sure that clamper rings of
wires remain in their original position. Make sure the plastic cover does
not press against the card when it is reattached to the gun.
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• Press the cover of the plastic protection back in place. Make sure that
the cooling liquid hoses and their bending protections are placed inside
plastic protection without any sharp bends and make that they retain
the original shape of the hose.
• Tighten the screws of the cover.
• Mark the sticker on the cover to signify that the connection has been
changed into the position “FU”.
• The gun is now ready for use in devices other than Promig or Feed, e.g. in
FU wire feeders of Multisystems.
You can use the PMT gun with the FU connection also with the Promig and
Feed but control and thermal protection operations will not be available.
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4. MOUNTING THE GUN REGULATOR RMT 10
In the handle of the PMT gun there is a place for the gun regulator RMT 10
(6185475), which is available as an accessory. This regulator enables you to
ragulate the welding power of synergic MIG or pulsed MIG welding with the
Promig and Feed, or select preprogrammed welding parameters according to
your wishes.
In the delivery state there is a cover plate in place of the gun regulator.
RMT 10
• Release the fastening screw of the cover plate.
• Release the cover plate from the handle by pushing it out on its guides.
Under the rear end of the cover plate you will now see a connector to
which the gun regulator connects. Make sure the regulator RMT 10, its
connectors and the connectors of the gun are free of metal powder, dirt,
etc. Clean carefully if necessary.
• Push the gun regulator RMT 10 onto the guides, but not completely
to the end. Make sure that the connector on the handle side is in the
correct position and that the connectors are correctly connected to each
other. Push the regulator carefully to its place.
• Tighten the screw.
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PMT © Kemppi Oy / 1130