Kemppi Promig 100 User manual

1923460E
0601
Operation instructions • english
Gebrauchsanweisung • deutsch
Gebruiksaanwijzing • nederlands
Manuel d’utilisation • français
PROMIG
100

2 – Promig 100/0601 © KEMPPI OY
CONTENTS
1. PREFACE........................................................................................................................ 3
1.1. Introduction .......................................................................................................................3
1.2. Product introduction ..........................................................................................................3
1.2.1. Operation control and connectors................................................................................... 3
1.2.2. Accessories and cables ..................................................................................................4
1.3. Operation safety................................................................................................................7
2. INSTALLATION ............................................................................................................... 7
2.1. Assembly of the MIG system ............................................................................................7
2.2. Installation of MIG system.................................................................................................9
2.2.1. Equipment corresponding to wire diameter..................................................................... 9
2.2.2. Mounting of intermediate cable and wire liner................................................................. 9
2.2.3. Mounting of MIG welding gun ....................................................................................... 10
2.2.4. Operating switch positions of the Promig 501, 501L and 530 when
the Promig 100 subfeeder is used ................................................................................ 10
2.2.5. Mounting and locking of wire reel (Promig 501, 501L and 530).................................... 11
2.2.6. Automatic wire feed to intermediate cable and gun ...................................................... 11
2.2.7. Adjustment of pressure ................................................................................................. 11
2.2.8. Adjustment of tightness of reel brake (Promig 501, 501L and 530).............................. 12
2.2.9. Burn back time .............................................................................................................. 12
2.2.10. Ground cable................................................................................................................. 12
2.3. Shield gas .......................................................................................................................12
2.3.1. Installing gas bottle ....................................................................................................... 12
2.4. Main switch I/O ............................................................................................................... 13
2.5. Operation of cooling unit .................................................................................................13
3. CONTROL PANEL OPERATIONS................................................................................ 14
3.1. Welding method selecting switch....................................................................................14
3.2. The Promig 501, 501L and 530 has the MC control panel..............................................14
3.3. The Promig 501, 501L and 530 has the ML control panel ..............................................15
4. OPERATIONS OF REMOTE CONTROL UNITS ..........................................................16
5. DISPOSAL OF THE MACHINE..................................................................................... 16
6. SERVICE, OPERATION DISTURBANCES .................................................................. 17
7. ORDERING NUMBERS ................................................................................................ 17
8. TECHNICAL DATA........................................................................................................ 18
9. TERMS OF GUARANTEE............................................................................................. 19

Promig 100/0601 – 3
© KEMPPI OY
X1
X3
X4
X5
X2
b
H11
R1 R2
S1
S2 S3
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 specifications. Read this manual from front to
back before installing, operating or maintaining the equipment for the first time. For further
information on Kemppi products please contact us or your nearest Kemppi distributor.
The specifications 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
Promig 100 is a sub-feeder for demanding use, connectable to the Promig 501, 501L and 530
wire feeder, extending the reach of the air- and liquid-cooled Kemppi Pro gas-shielded arc
welding system up to 50 m.
Use of the Promig 100 demands the mounting of the Prosync 50 synchronizing set to the
Promig 501, 501L and 530 wire feeder.
These operation instructions handle the Promig 100 sub-feeder, assembly and installation of the
MIG system with accessories.
1.2.1. Operation control and connectors
X4 Connection for control cable
Remote control unit
X5 Connection of cable for MMA welding
b Locking of cooling liquid hoses
H 11 Warning lamp for thermal shield
R1 Wire feed speed control
R2 Welding voltage control
S1 Selection for welding method MMA/MIG
S2 Control mode selection
Local/Remote control
S3 Control mode selection
Gun/Remote control unit
X1 Central connector for intermediate cable
EURO
X2 Connection of welding gun EURO
X3 Connection for control cable

4 – Promig 100/0601 © KEMPPI OY
Promig 501, 501L, 530
Pro 3200
Pro 4200
Pro 5200
Promig 501, 501L, 530
Procool
10/30
Pro 3200
Pro 4200
Pro 5200
Pro Power source
Procool 10/30
Cooling liquid circulation unit
Promig 501, 501L and 530
Wire feed unit
RMT10, R10, R20
Remote control units, see page 16
1 Control cable
5 Cooling liquid hose R3/8 - Snap connector
8 Shielding gas hose Snap connector - 0
9a Welding current cable
12a Intermediate cable MIG air-cooled
12b Intermediate cable MIG liquid-cooled
16d Extension cable for remote control
1.2.2. Accessories and cabels
20 Earth cable
21 MMA welding cable
22a MIG gun air-cooled
22b MIG gun liquid-cooled

Promig 100/0601 – 5
© KEMPPI OY
Cables and hoses
Pro A B C
Combination Extension cable bundle Intermediate cable MIG welding gun
equipment
Pro 3200/4200
/5200+P40+
Promig 501+
Promig100
Pro 3200/4200
/5200+P30W+
Procool 10/30+
Promig 501+
Promig 100
Nominal length Order No. Air-cooled Liquid-cooled Nominal length Order No. Air-cooled Liquid-cooled Nominal lenght Order No.
1 5 8 9a m 12a 12b m 22a 22b m
PMT 32 – 3,0 6253213
PMT 32 – 4,5 6253214
PMT 35 – 3,0 6253513
PMT 35 – 4,5 6253514
PMT 42 – 3,0 6254213
1 – 1 1 10 6260313 PMT 42 – 4,5 6254214
MMT 32 – 3,0 6253213MMT
MMT 32 – 4,5 6253214MMT
1 – 1 1 15 6260315 X – 15 6260211 MMT 35 – 3,0 6253513MMT
1 – 1 1 20 6260317 X – 25 6260213 MMT 35 – 4,5 6253514MMT
1 – 1 1 25 6260319 MMT 42 – 3,0 6254213MMT
MMT 42 – 4,5 6254214MMT
– PMT 30W 3,0 6253043
1 2 1 1 10 6260314 – PMT 30W 4,5 6253044
1 2 1 1 15 6260316 – X 15 6260225 – PMT 42W 3,0 6254203
1 2 1 1 20 6260318 – X 25 6260227 – PMT 42W 4,5 6254204
1 2 1 1 25 6260320 – PMT 52W 3,0 6255203
– PMT 52W 4,5 6255204
– MMT 30W 3,0 6253043MMT
– MMT 30W 4,5 6253044MMT
– MMT 42W 3,0 6254203MMT
– MMT 42W 4,5 6254204MMT
– MMT 52W 3,0 6255203MMT
– MMT 52W 4,5 6255204MMT

6 – Promig 100/0601 © KEMPPI OY
ø 0,6...0,8 mm ø 1,0 mm 3134140
ø 0,9...1,6 mm ø 2,0 mm 3133700
ø 1,6...2,4 mm ø 4,0 mm 3134130
ø 0,8...1,6 mm ø 2,5 mm 3134290
ø 1,6...2,4 mm ø 3,0 mm 3134710
Fe
Mc
Fc
Ss
Al
ø 2,0 mm 3134120
ø 4,0 mm 3134110
ø 2,5 mm 3134300
ø 3,0 mm 3134720
ø 2,0 mm 4267220
ø 4,0 mm 4267030
ø 2,0 mm 4267220
ø 4,0 mm 4270180
ø 2,0 mm 4266970
ø 4,0 mm 4270180
ø 2,4 mm 4268210
ø 3,0 mm 4268560
Promig 511
Fe
Ss
Al
Fe
Fc
Mc
Fe
Fc
Mc
Ss
Al
ø 0,6/0,8 3133810 ø 1,0/1,2 3133210 ø 1,4-1,6/2,0 3133820 ø 2,4 3133880
Vetorattaan valintalevyn siirto, flyttning av distansbricka, flytting av avstandsskive for
matehjul, hvordan flytter man justerskiven, relocation of selection plate, Versetzen der
Wahlschalterplatte, verplaatsing van selectie plaat, remise en place de la rondelle de
sélection
Vetoratas, dr vhjul, trekktannhjul, dr vhjul, gearwheel, Aufz ehrad,
aandr jfrol, galet d'entra nement
ø 1,0/1,2 3133940 ø 1,4-1,6/2,0 3133990 ø 2,4 3134030
ø 1,2/1,2 (L) 3142210 ø 1,4/1,4 (L) 3142220 ø 2,0/2,0 (L) 3142230
ø 1,6/1,6 (L) 3141130
ø 1,6/1,6 (L) 3142200 ø 2,4 (L) 3142240
ø 1,2/1,2 (L) 3137380 ø 3,2 3134060
ø 1,2/1,2 (L) 3137390
ø 0,8/0,8 (L) 3143180 ø 1,0/1,0 (L) 3138650 ø 1,6/1,6 (L) 3141120 ø 3,2 3133910
ø 28 mm (0 - 8 m/min) 4265240, ø 40 mm (0 - 25 m/min) 4265250
Muovi, plast, plast, plastic, plastic, Kunststoff, plastic, plastique
ø 28 mm (0 - 8 m/min) 4287860, ø 40 mm (0 - 25 m/min) 4297270
Teräs, stål, stål, stål, steel, Stahl, staal, acier
Syöttöpyörän uran valinta, val av matarhjulspår, valg av matehjul spor, valg af spor i
trådhjul, selection of feed wheel groove, Auswahl der Transportrollennut, selectie van
de draaddiameter groef, sélection de la gorge du galet
4292030
pressure
adjustment
Wire guide tubes
Feed rolls
white red yellow
orange
red
orange yellow
orange brown grey
black
blue
black
yellow black
blue
Trapezoid
Plain
Knurled
(L) = Ball race
orange
white
blue
silver
yellow
orange
blue
silver
yellow
plastic
brass
plastic
plastic
plastic
plastic
yellow
yellow

Promig 100/0601 – 7
© KEMPPI OY
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 reflecting arc flash. Welding arc and
spatter burn unprotected skin. Use safety gloves and protective clothing.
Danger for fire or explosion
Pay attention to fire safety regulations. Remove flammable or explosive materials from welding
place. Always ensure that you have sufficent fire fighting equipment available where you are
welding. Be prepared for hazards in special welding jobs, eg. for the danger of fire or explosion
when welding containertype work pieces. Note! Fire can break out from sparks even several
hours after the welding work has been finished!
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 fire. 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 sufficient ventilation during welding. Take special safety precau-
tions when welding metals which contain lead, cadmium, zinc, mercury or beryllium.
2. INSTALLATION
2.1. ASSEMBLY OF THE MIG SYSTEM
1 Installation of power source
Read paragraph ”Installation” in operation instructions 1913170 for Pro power sources and
carry out the installation according to that.
2 Mounting of Pro power source to transport wagon
P40 6185261, air-cooled MIG system mounting
P30W 6185262, liquid-cooled MIG system mounting
3 Put the Promig 501, 501L and 530 onto the power source and lock it with bolts to handles
of power source, or mount to the wire feeder cables and roll carriage which extend the reach,
see page 7
4 Mount the control panel to the Promig 501, 501L and 530
MC 6263501
ML 6263502
MXE 6263503
5 Mount the synchronization set to the Promig 501, 501L and 530
Prosync 50 6263121
6 Connecting cables
Connect cables according to figures.
Air-cooled system. Liquid-cooled system.
You can change polarity of filler wire by interchanging the Promig welding current cable and
earth cable with welding cable connectors of Pro power source.

8 – Promig 100/0601 © KEMPPI OY
A001
JUMPER BLOCK
7 Max. wire feed speed
When the unit is delivered the max. wire feed speed is 18 m/min, which is enough for most
welding works. If you need a higher speed, you can increase the max. wire feed speed
to 25 m/min by replacing the gear wheel on motor shaft to a bigger one. The big gear
wheel D40 is delivered in accessory drawer of the Promig 501, 501L and 530 and in the
Promig 100 it is in plastic bag under cover.
When necessary speed is changed according to following:
1. Open cover of control box of the Promig 501, 501L and 530 and move
JUMPER BLOCK’s WFS jumper on control card A001 to point 25 m/min.
2. Change the gear wheel in both feeder units as follows:
- Open tightening lever (20). Remove lower feed rolls (21). Release screw (23) and
its washer. Remove gear wheel D28 (24) from motor shaft.
- Loosen screws (25) (3 pc) 1 twist. Mount the D40 gear wheel onto motor shaft.
Screw the screw (23) with its washer back.
- Put feed rolls (21) back to their axles, however don’t fasten yet fastening screws
of feed rolls (22).
- Lift the motor so that the tooth gap between gear wheel and both lower feed
rolls is approx. 0,2 mm.
- Tighten screws (25). Check gear teeth gaps, when necessary put the motor into a
better position. Screw on the mounting screws of feed rolls (22).
Too small gap between gear wheel and feed rolls will overload motor.
Too big gap for its part might cause too rapid wearing for teeth of feed rolls and
gearwheel.

Promig 100/0601 – 9
© KEMPPI OY
2.2. INSTALLATION OF MIG SYSTEM
2.2.1. Equipment corresponding to wire diameter
Promig wire feed rolls are available with plain groove, knurled groove and with U groove for
different purposes.
Feed rolls with plain groove: General feed roll for all kinds of wires.
Feed rolls with knurled groove: Special feed roll for cored wires and steel wires.
Feed rolls with U groove: Special roll for aluminium wires.
Promig wire feed rolls have two grooves for different filler wire diameters. Correct wire groove
is selected by moving selecting washer (28) from one side to another in feed roll.
Feed rolls and wire guide tubes of wire feed unit have colour codes in order to make identifica-
tion easier.
Feed rolls: white for 0,6... 0,8 mm fillerwires
red for 0,9 ... 1,32 mm fillerwires
yellow for 1,4... 2,0 mm fillerwires
Wire guide tubes: orange for 0,6... 1,6 mm fillerwires
blue for over 1,6 mm fillerwires
In delivery the Promig 100 is equipped with red feed rolls with plain groove and with orange
wire guide tubes for welding filler wires of 0,9...1,32 mm.
2.2.2. Mounting of intermediate cable and wire liner
The intermediate cable is connected with the EURO adaptor to the Promig 501, 501L and
530 wire feeder. Remote control and synchronizing connectors of the intermediate cable are
connected to the corresponding connectors in the feeder unit.
The tip of the intermediate cable on the sub-feeder side is pushed into the opening at the
rear of the Promig 100. The EURO adaptor is fastened carefully and the control/synchronizing
connector is pressed down on its place.
The cooling liquid hoses are placed into room reserved for them according to enclosed figure.
See in mounting of connectors that they really are fast, especially the EURO adaptors should be
tightened tightly enough that no voltage losses or sparking wouldn’t come up in connectors.
When you are fastening the intermediate cable to the sub-feeder, loosen the fastening screw 31
(see figure) of the wire guide tube in order to ensure the electric contact. A bad connection is
heated up in welding and connecting parts may even be destroyed.
Wire liner Length Symbol colour Order number
Steel spiral 15 m yellow 4188594
25 m yellow 4188596
Plastic 15 m black 4271020
25 m black 4271030
Wire liner of the intermediate cable is either of steel spiral or plastic. The plastic wire liner
is always used in welding of aluminium or stainless steel. The steel spiral is used in welding
of cored wire. In welding of solid steel wire you can use as wire liner both the steel spiral
and the plastic wire liner.

10 – Promig 100/0601 © KEMPPI OY
When delivered the intermediate cable is equipped with steel spiral wire liner.
The intermediate cable should be as straight as possible in mounting of the wire liner. Push the
wire liner into the intermediate cable from the Promig 501, 501L and 530 end, tighten the jacket
nut. The extra wire liner is cut off on the sub-feeder end; push the large pass of the wire liner into
the intermediate cable and cut off the wire liner at 40 mm length from the snap connector. Fasten
the tip of the wire liner with end connectors and jacket nut to the snap connector.
2.2.3. Mounting of MIG welding gun
In order to ensure trouble-free welding, check in operation instructions of gun used by you that
wire guide tube and contact tip of gun are according to manufacturer’s recommendation suitable
to be used for wire feed diameter and type in question.
Too tight a wire guide tube might cause for wire feed unit a bigger stress than normally as well
as disturbances in wire feed.
Screw snap connector of gun tight that there won’t come any voltage losses on connecting
surface. A loose connection will heat gun and wire feed unit.
When you are using liquid-cooled gun, mount liquid hoses according to figure.
Promig units have for overheating of liquid-cooled PMT gun and for overload of wire feed
motor a yellow pilot lamp for overload, which is operating as follows:
- Thermo shield of Kemppi PMT gun is operating: Equipment stops welding, yellow signal
lamp H11 is lighted and is illuminated in periods of 0,5 s until thermo shield has returned.
- Motor is overloaded: 2 different functions
1. Motor is overloaded to some extent: Signal lamp H11 is lighted and is illuminated
in periods of 0,25 s, equipment doesn’t stop welding. The lamp is not extinguished
until welding is started again after stop.
2. Motor is overloaded a lot: Equipment stops welding, signal lamp H11 is lighted and is
illuminated in periods of 0,25 s until welding is started again.
2.2.4. Operating switch positions of the Promig 501, 501L and 530
when the Promig 100 subfeeder is used
Welding mode switch (S21 or S31) is set on position MIG two-sequence procedure or MIG
four-sequence procedure according to necessarity.
Control mode selection switches (S22 or S32) are set on position for remote control.
With the above-mentioned selections the welding controls were transmitted to control panel of
the Promig 100, see the paragraph:”Control panel operations”.
SELECTO-/SYNERGIC-operations as well as the welding dynamics are adjusted on the Promig
501, 501L and 530 panel, also the digital displays for wire feed speed, current and voltage
are still operating on the panel, see the paragraph ”Control panels operations” in the operation
instructions for the Promig 501, 501L and 530.
NOTE! When the Promig 100 is switched on you can select the MMA characteristics on the
Promig 501, 501L and 530 panel only if the control mode selection switch is on position for
local control.