Kemppi PROMIG 200 ML User manual

Operation instructions • english 1923790E
0509
PROMIG
200 ML

PROMIG 200ML/0509 – 2 © 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 AND CONNECTIONS 5
2.5. LIFTING THE EQUIPMENT 5
2.6. FILLER WIRE MATERIALS AND EQUIPMENT 5
2.6.1. FILLER WIRES AND WIRE FEED 5
2.6.2. INSTALLING WIRE REEL 7
2.6.3. INSTALLING WELDING WIRE 7
2.7. SHIELDING GAS 8
2.7.1. INSTALLING GAS BOTTLE 8
3. OPERATION 9
3.1. WELDING PROCESSES 9
3.1.1. MIG/MAG -WELDING 9
3.1.2. SYNERGIC MIG/MAG -WELDING OR 1-MIG 9
3.1.3. SYNERGIC PULSED MIG-WELDING 9
3.2. SPECIAL FUNCTIONS 9
3.2.1. WELDING GUN TRIGGER 2-SEQUENCE FUNCTION 9
3.2.2. WELDING GUN TRIGGER 4-SEQUENCE FUNCTION 9
3.3. OPERATION FUNCTIONS 9
3.3.1. WIRE FEED UNIT AND FUNCTION PANEL 9
3.4. SELECTING AND ADJUSTING WELDING SETTINGS 12
3.4.1. MIG/MAG -WELDING 12
3.4.2. SYNERGIC MIG/MAG -WELDING (1-MIG) 12
3.4.3. SYNERGIC PULSED MIG -WELDING 12
3.4.4. MMA-WELDING 13
3.5. STORAGE 13
3.6. WELDING 13
3.6.1. CHOOSING WELDING POLARITY 13
3.6.2. EARTHING 13
3.6.3. WELDING OPERATION 13
4. MAINTENANCE 14
4.1. DAILY MAINTENANCE 14
4.2. REGULAR MAINTENANCE 14
4.2.1. EVERY SIXTH MONTHS 14
4.2.2. SERVICE CONTRACT 14
4.3. ORDERING NUMBERS 14
4.4. TROUBLE SHOOTING 15
4.4.1. ERROR CODES 15
5. TECHNICAL DATA 17
5.1. TECHNICAL DATA 17

PROMIG 200ML/0509 – 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 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 Ope-
ration safety instructions and respect them when installing, operating and servicing the
machine.
1.2. Product introduction
PROMIG 200 ML is a mobile wire feed unit designed for dock yards and heavy metal
industry. PROMIG wire feed units are used with PRO multi-function power sources.
Due to its operational properties and mechanical durability, PROMIG 200 is very sui-
table for flux-cored electrode welding with long intermediate cables. Operation of wire
feed unit is controlled and adjusted with microprocessor. The Tacho generator of wire
feed motor enables an accurate and even adjustment of wire feed speed.
PROMIG 200 is designed to be used with filler wire reels of max 200 mm (5 kg).
This equipment’s electromagnetic compatibility (EMC) is designed for use in an
industrial environment. Class A equipment is not intended for use in residential
location where the electrical power is provided by the public low-voltage supply
system.
1.3. Operation safety
Please study these Operation safety instructions and respect them when installing, ope-
rating 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 reserve sufficient fire-fighting equipment on welding place. Be
prepared for hazards in special welding jobs, eg. for the danger of fire or explosion
when welding container type work pieces. Note! Fire can break out from sparks even
several hours after the welding work has been finished!

PROMIG 200ML/0509 – 4 © KEMPPI OY
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 fire.
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 sufficient ventilation during welding. Take special safety precau-
tions when welding metals which contain lead, cadmium, zinc, mercury or beryllium.
2. INSTALLATION
2.1. Removal from packaging
The equipment is packed in a durable package specially designed for it. It is howe-
ver necessary to check the equipment before taking it in 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 circu-
lation in front of and behind the machine.
2.3. Serial number
The serial number of the machine is marked on the machine CE-marking. Identification
of the serial number is the only proper means of maintaining and identifying parts for
a specific 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
Fasten the units by using the screws and bolts delivered with the equipment. Install
welding gun and tighten carefully. Cable connections are presented in the following
chapters.

PROMIG 200ML/0509 – 5© KEMPPI OY
G
C
H
E
I
B
F
D
AJ
K
L
M
EDC AF B
Inside
A Selection of air/liquid cooling
B Wire reel locking
C Wire inch
D Gas test
E Tightening screw
F Feed roll
2.5. Lifting the equipment
For transferring the equipment or a part of it, use the machine handles. Machines can
be lifted with ropes. Fasten the ropes carefully round the machine. Note! Check that the
machine can not move vertically between the ropes.
2.6. Filler wire materials and equipment
2.6.1. Filler wires and wire feed
Choose contact tube, wire conduit and feed roll according to welding wire. Filler wires
and the corresponding wire feed equipment are presented in the following scheme. The
factory assembly includes feed rolls with plain groove and with orange wire guide tubes
for welding filler wires of 0.9-1.2 mm (0.035”, 0.045” and 0.052”).
Back side
Connections:
J Control cable to power source
K Shielding gas hose (snap connector)
L Welding current cable
M Connection for MMA
Front machine
A Welding voltage (MIG)
B Wire feed speed (MIG) / Wel-
ding current (MMA)
C Main switch
D Control mode
E Flowmeter / regulator for shiel-
ding gas
F Function panel
Connections:
G Control cable of remote control
H Control cable connector for sub-
feeder / motorized gun
I Welding gun cable
2.4.2. Main parts and connections

PROMIG 200ML/0509 – 6 © KEMPPI OY
Filler wires and wire feed mechanism
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
4 - roll wire feed mechanism
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
eng

PROMIG 200ML/0509 – 7© KEMPPI OY
2.6.2. Installing wire reel
1. Install wire reel so that the hole in the reel is aligned with the pin on the reel
holder. Use reel adaptor, if necessary.
2. Release the locking claws of wire reel locking by turning the latch 45 degrees.
3. Push the reel into its place. Note! Check the reel rotation direction.
4. Lock the reel by turning the locking latch.
Note! Check that the wire or wire reel does not touch the equipment body!
2.6.3. Installing welding wire
Do not direct welding gun to yourself or to persons around you!
Before installing welding wire, check that feed rolls, wire conduit and contact tip are
suitable for the wire.
1. Install feed rolls, check that the right groove is in the wire feed line. The
groove can be changed by changing the position of the adjusting plate.
2. Check that there are no sharp edges on wire end, round off if necessary. Sharp
edges may damage wire guide and wire conduit. Watch out that the wire does
not get loose!
3. Push the wire through wire guide tube into feed rolls. Do not release the
pressure of the feed rolls.
4. Use wire inch switch to make the wire roll into the gun. You can also feed the
wire to the gun by pressing the gun switch and pushing the wire slightly until
it automatically rolls through the feed rolls into the gun. Note! Check that the
wire runs in the grooves of the both feed roll pairs!
5. Adjust the pressure of wire feed rolls with adjusting screw. The press force to
the feed rolls is suitable when wire can be slightly restrained with fingers when
coming out of wire conduit, without feed rolls slipping. Note! If the pressure
is too high, filler wire flattens and its coating may fall off. Feed rolls wear out
more quickly and friction increases.
6. Adjust the wire reel braking force by turning the adjusting screw in the middle
of the locking latch with a screwdriver. Note! To avoid over-loading wire feed
motor, do not tighten too much.

PROMIG 200ML/0509 – 8 © KEMPPI OY
A
F
C
G
B
E
D
2.7. Shielding gas
Handle gas bottle with care. There is a risk of injury if gas bottle or bottle valve
gets damaged!
For welding stainless steels, mixed gases are normally used. Check that the gas bottle
valve is suitable for the gas. The flow rate is set according to the welding power used in
the job. A suitable flow rate is normally 8 - 10 l/min. If the gas flow is not suitable, the
welded joint will be sporous. Contact your local Kemppi-dealer for choosing gas and
equipment.
2.7.1. Installing gas bottle
Always fasten gas bottle properly in vertical position in a special holder on the
wall or on a carriage. Remember to close gas bottle valve after having finished
welding.
Parts of gas flow regulator
A Gas bottle valve
B Press regulation screw
C Connecting nut
D Hose spindle
E Jacket nut
F Gas bottle pressure meter
G Gas hose pressure meter
The following installation instructions are valid for most of the gas flow regulator types:
1. Step aside and open the bottle valve (A) for a while to blow out possible impu-
rities from the bottle valve.
2. Turn the press regulation screw (B) of the regulator until no spring pressure can
be felt.
3. Close needle valve, if there is one in the regulator.
4. Install the regulator on bottle valve and tighten connecting nut (C) with a
wrench.
5. Install hose spindle (D) and jacket nut (E) into gas hose and tighten with hose
clamp.
6. Connect the hose with the regulator and the other end with the wire feed unit.
See 2.5.2. Main parts of wire feed mechanism. Tighten the jacket nut.
7. Open bottle valve slowly. Gas bottle pressure meter (F) shows the bottle
pressure. Note! Do not use the whole contents of the bottle. The bottle should
be filled when the bottle pressure is 2 bar.
8. Open needle valve if there is one in the regulator.
9. Turn regulation screw (B) until hose pressure meter (G) shows the required
flow (or pressure). When regulating flow amount, the power source should be
in switched on and the gun switch pressed simultaniously.
Close bottle valve after having finished welding. If the machine will be out of use for a
long time, unscrew the pressure regulation screw.

PROMIG 200ML/0509 – 9© KEMPPI OY
3. OPERATION
Welding in places presenting an immediate fire or explosion hazard is forbidden!
3.1. Welding processes
3.1.1. MIG/MAG -welding
In MIG/MAG-welding the filler wire is feeded through welding gun wire conduit to the
welding joint. Welding current strenght and wire feed speed are chosen according to the
characteristics of the work piece to be welded. The values are selected and adjusted with
separate potentiometers.
3.1.2. Synergic MIG/MAG -welding or 1-MIG
In synergic MIG-welding the parameters are determined by the wire feed speed set-
ting. This means that in the synergic process, welding power can be adjusted using one
potentiometer only. In the beginning of the process, a synergic curve suitable for the
filler wire and gas must be chosen, to make the parameters adjustable from wire feed
potentiometer.
3.1.3. Synergic pulsed MIG-welding
In synergic pulsed MIG-welding the welding current is cut in pulses, so that the filler
material can be transferred to work piece controlled and without spatter. In the synergic
process, welding power can be adjusted using one potentiometer only. In the beginning
of the process, a synergic curve suitable for the filler wire and gas must be chosen, to
make the parameters adjustable from wire feed potentiometer. The pulse parameters of
power source change automatically when wire feed speed is changed.
3.2. Special functions
3.2.1. Welding gun trigger 2-sequence function
Gas flow and wire inch start, when the gun switch is pressed and stop when the switch
is released.
3.2.2. Welding gun trigger 4-sequence function
Gas flow starts, when the gun switch is pressed. When the switch is released, wire inch
starts and welding begins. When the gun switch is pressed again, wire inch stops and
when the switch is released, gas flow stops.
3.3. Operation functions
See also 2.4. Installation and main parts.
3.3.1. Wire feed unit and function panel
Before starting welding, welding settings suitable for the work piece are chosen in
function panel. See 3.1. Welding processes. When needed, the settings can be adjusted
on function panel. The main functions of the ML-panel are presented on the following
page.

PROMIG 200ML/0509 – 10 © KEMPPI OY
1
0
Main switch
When the switch is in position1 the unit is ready for welding. In
position 0 the machine gets no voltage and power source or wire
feed motor cannot not be started. In MIG/MAG welding the wire
drive switch is working.
Welding process selection switch
MMA welding with stepless welding current control
MIG two-sequence procedure (normal function)
MIG four-sequence procedure (hold switch)
MIG-process selection switch
Pulsed MIG
Synergic MIG (1-MIG)
Normal MIG
Control mode selection switch
Local control
Remote control
Wire feed speed and current control
MIG/MAG welding: local control of wire feed speed
MMA welding: welding current control.
ML-function panel