Kemppi Promig 300 User manual
1923540E
0537
Operation instructions • english
Gebrauchsanweisung • deutsch
Gebruiksaanwijzing • nederlands
Manuel d’utilisation • français
2 – PROMIG 200, PROMIG 300 / 0537 © KEMPPI OY
CONTENTS
1. INTRODUCTION ............................................................................................................. 3
1.1. To the reader .....................................................................................................................3
1.2. Product introduction .......................................................................................................... 3
1.2.1. Main functions ................................................................................................................. 3
1.2.2. Operation control and connectors ................................................................................... 4
1.2.3. Accessories and cables .................................................................................................. 5
1.2.4. Sub-feeder equipment ..................................................................................................... 6
1.2.5. Parts of fire feed mechanism .......................................................................................... 7
1.3. Operation safety ................................................................................................................ 8
2. INSTALLATION ............................................................................................................... 9
2.1. Assembly of MIG system
2.1.1. Installation of power source ............................................................................................ 9
2.1.2. Mounting of PRO power source to transport unit ............................................................ 9
2.1.3. Connecting cables ........................................................................................................... 9
2.1.4. Max. wire speed (Promig 300) ........................................................................................ 9
2.1.5. Mounting of Promig 200, 300 to boom .......................................................................... 10
2.2. Installation of MIG system ............................................................................................... 10
2.2.1. Accessories corresponding to wire diameter ................................................................ 10
2.2.2. Mounting of MIG welding gun ....................................................................................... 11
2.2.3. Mounting and locking of fire reel ................................................................................... 11
2.2.4. Automatic wire feed to gun ............................................................................................ 11
2.2.5. Adjustment of pressure ................................................................................................. 12
2.2.6. Adjustment of tightness of reel brake ............................................................................ 12
2.2.7. Burn back time .............................................................................................................. 12
2.2.8. Ground cable ................................................................................................................. 13
2.2.9. Shielding gas ................................................................................................................. 13
2.2.10. Installing gas bottle ....................................................................................................... 13
2.2.11. Main switch I/O of PRO power source .......................................................................... 14
2.2.12. Operation of cooling unit (PROCOOL 10, PROCOOL 30) ........................................... 14
3. OPERATIONAL FUNCTIONS ....................................................................................... 15
3.1. Main switch S14 .............................................................................................................15
3.2. Welding method selecting switch S15 ............................................................................. 15
3.3. Control mode selecting switch S16 ................................................................................ 15
3.4. Local controls ..................................................................................................................16
3.5. Regulation for shielding gas flow .................................................................................... 16
3.6. Signal lamp H12 indicating missing of shielding gas ...................................................... 16
3.7. Signal lamp H11 for errors .............................................................................................. 16
3.8. Wire inch switch S11 ....................................................................................................... 17
3.9. Gas purge switch S13 .....................................................................................................17
3.10. Selection of MIG gun’s cooling mode S12 ...................................................................... 17
4. OPERATIONS OF REMOTE CONTROL UNITS IN PROMIG 200 AND
300 WIRE FEED UNITS ................................................................................................ 18
5. SERVICE, OPERATION DISTURBANCES ................................................................. 18
6. ORDERING NUMBERS ................................................................................................ 19
7. TECHNICAL DATA ........................................................................................................ 20
8. DISPOSAL OF THE MACHINE ..................................................................................... 21
9. TERMS OF GUARANTEE ............................................................................................. 21
PROMIG 200, PROMIG 300 / 0537 – 3© KEMPPI OY
Promig 200 and Promig 300 are mobile wire feeders designed for dock yards and heavy metal
industry. PRO multi function power sources are used as power soures for Promig wire feeders.
Due to operational properties and mechanical durability of wire feeders, Promig 200 and 300
units are very suitable for flux-cored wire welding with long intermediate cables. Operations
of wire feed unit are controlled and adjusted with a microprocessor and a tacho generator of
wire feed speed. Promig 200 and 300 are based on same technical basic solutions, the units
are different from each other in the first place in respect of size or filler wire reel. Promig 200
is designed to be used with filler wire reel of max 200 mm (5kg), whereas Promig 300 is for
reels of max 300 mm (20 kg).
These operation instructions handle Promig 200 and Promig 300 wire feed units, assembly,
installation and operation functions of MIG-system.
This equipment’s electromagnetic compatibility (EMC) is designed for use in an indust-
rial 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.
1.2.1. Main functions
Main switch
Adjustment of welding voltage (MIG/MAG) and current (MMA)
Adjustment of wire feed speed
Selection of welding method MIG/MAG / MMA
Regulator/meter for shielding gas flow
Control of shielding gas
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
4 – PROMIG 200, PROMIG 300 / 0537 © KEMPPI OY
H13
S14
S15
H12
H11
11
X11
R11
R12
X12
S16
X13
a
X15
X16
H13
S14
S15
H12
H11
X11
X14
c
R11
11
R12
S16
X12
X13
a
X15
X16
b
S11 S13 S12
1.2.2. Operation control and connectors
H11 Error signal lamp
H12 Warning lamp for shielding gas guard
H13 Signal lamp for main switch
X11 Connection for control cable Remote control unit
X12 Connection of welding gun EURO
X13 Connection for control cable PRO power sources
X14 (PROSYNC 50 / Promig 300) Control cable
connector for sub-feeder / motorized gun, accessory
X15 Welding current connection PRO power source
W16 Connection for MMA
a Shielding gas connection (Snap connector)
b (Promig 300) Cooling liquid connection
c (Promig 300) Cooling liquid connections for gun
R11 Adjustment for wire feed speed (MIG) / welding current (MMA)
R12 Adjustment for welding voltage (MIG)
S11 Wire inch switch
S12 Selecting switch of air/liquid cooling
S13 Gas purge switch
S14 Main connector
S15 Selecting switch for welding mode
S16 Selecting switch for control mode (local/remote control)
11 Flowmeter/regulator for shielding gas
PROMIG 200, PROMIG 300 / 0537 – 5© KEMPPI OY
1.2.3. Accessories and cables
PRO Power source
Promig 200, 300 Wire feed unit
R20 Remote control unit
1 Control cable
8 Shielding gas hose
Snap connector - 0
9 Welding current cable
16d Extension cable for remote control
20 Earth cable
21 MMA welding cable
22a MIG gun air-cooled
PRO Power source
PROCOOL 10/30 Cooling liquid circulation unit
Promig 300 Wire feed unit
R20 Remote control unit
1 Control cable
5 Cooling liquid hose
R3/8 - Snap connector
8 Shielding gas hose
Snap connector - 0
9 Welding current cable
16d Extension cable for remote control
20 Earth cable
21 MMA welding cable
22b MIG gun liquid-cooled
6 – PROMIG 200, PROMIG 300 / 0537 © KEMPPI OY
1.2.4. Promig 300, Promig 100 sub-feeder equipment
PRO Power source
PROCOOL 10/30 Cooling liquid circulation unit
Promig 300 Wire feed unit
PROSYNC 50 Synchronization unit
Promig 100 Sub-feeder
R20 Remote control unit
1 Control cable
5 Cooling liquid hose R3/8 - Snap connector
8 Shielding gas hose Snap connector - 0
9 Welding current cable
12a (Promig 100)
MIG intermediate cable air-cooled
12b (Promig 100)
MIG intermediate cable liquid-cooled
16d Extension cable for remote control
20 Earth cable
21 MMA welding cable
22a MIG gun air-cooled
22b MIG gun liquid-cooled
22c Motorized gun air-cooled
22d Motorized gun liquid-cooled
PROMIG 200, PROMIG 300 / 0537 – 7© KEMPPI OY
1.2.5. Parts of wire feed mechanism
* included in delivery
** included in delivery, mounted
8 – PROMIG 200, PROMIG 300 / 0537 © 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 container type 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 precautions
when welding metals which contain lead, cadmium, zinc, mercury or beryllium.
PROMIG 200, PROMIG 300 / 0537 – 9© KEMPPI OY
Promig 300
JUMPER
BLOCK
2. INSTALLATION
2.1. ASSEMBLY OF MIG SYSTEM
Assemble the units in below-mentioned order and follow mounting and operation instructions
which are delivered in packages.
2.1.1. Installation of power source
Read paragraph: ”installation” in operation instructions 1913130E for PRO power sources and
carry out the installation according to that.
2.1.2. Mounting of PRO power source to transport unit
P40 6185264, air-cooled MIG system
P40L 6185264L
P30W 6185262, liquid-cooled MIG system
2.1.3. Connecting cables
Connect cables according to figures on pages 5-6.
Air-cooled system on page 5. Liquid-cooled system on page 5.
Promig 300 sub-feeders on page 6.
You can change polarity of filler wire by interchanging the Promig welding current cable and
earth cable with welding cable connectors from PRO power source.
2.1.4. Max. wire feed speed (Promig 300)
When the unit is delivered the max. wire feed speed is 18 m/min, which is enough for most
welding aplications. If you need a higher speed, you can increase the max. wire feed speed to
25 m/in min by replacing the gear wheel on motor shaft to a bigger one. The big gear wheel D40
is delivered only with the feed unit Promig 300.
10 – PROMIG 200, PROMIG 300 / 0537 © KEMPPI OY
When necessary speed is changed according to following:
- Open side plate and move jumper block’s 10th jumper on control card A001 to point
25 m/min.
- 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 gear 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).
NOTE! 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 gear wheel.
2.1.5. Mounting of Promig 200, 300 to boom
Wire unit must be mounted to boom in such a way that its chassis is galvanised
separated both from swing arm and boom.
For boom hanging you get with Promig 300 delivery plastic grip (is mounted onto rear plate of
the unit) as well as metallic suspension hook.
2.2. INSTALLATION OF MIG SYSTEM
2.2.1. Accessories 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: Universal feed roll for welding of all kinds of wires.
Feed rolls with knurled groove: Special feed roll for cored wires and steel wires.
Feed rolls with U groove: Special feed 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.
colour ....................... filler wire ø mm (inch)
white ......................... 0,6 and 0,8 (0,030)
red ............................ 0,9/1,0 and 1,2 (0,035, 0,045 and 0,052)
yellow ....................... 1,4, 1,6 and 2,0 (1/16 and 5/64)
black ......................... 2,4 (3/32)
colour ....................... filler wire ø mm (inch)
orange ...................... 0,6-1,6 (0,024-1/16)
blue ........................... over 1,6 (over 1/16)
PROMIG 200, PROMIG 300 / 0537 – 11© KEMPPI OY
28 28
Feed rolls and wire guide tubes of wire feed unit have colour codes in order to make identifica-
tion easier (see table on page 7).
In delivery Promig 200 and 300 are equipped with red feed rolls with orange wire guide tubes
for welding filler wires of 0,9-1,2 mm (0,035”, 0,045” and 0,052”).
2.2.3. Mounting and locking of wire reel
- Release locking tongues of wire reel hub by turning locking knob a quater of a turn.
- Mount the reel at its place.
Note rotating direction of reel!
- Lock the reel with locking knob, locking tongues of hub remain to outside position and will
lock the reel.
2.2.2. Mounting of MIG welding gun
In order to ensure trouble-free welding check the operation instructions of the gun used, that
the wire guide tube and contact tip are suitable for the wire diameter and type you are using.
Too tight a wire guide tube might cause for wire feed unit a bigger stress than normally as well
as disturbances in wire feed.
Ensure that the screw nut of the snap conector on the gun is done up tightly when fitted to
the Promig feeder so that there will not be any voltage losses through the snap connector. A
loose connection will heat gun and wire feed unit. When you are using liquid-cooled gun, mount
cooling liquid hoses according to fig. on pages 5, 6.
Error signal lamp H11 of Promig 200 and 300 units have operations for overheating of liquid-
cooled MIG gun and for overload of wire feed motor. By operation of the signal lamp its so-
called short flashes indicate the error code in question (also see operation of error signal lamp,
page 16):
8 short flashes Err 8: Liquid-cooled gun MIG is overheated.
9 short flashes Err 9: Overload of wire feed motor, which can come from blocked wire
liner of gun.
Blinking of H11 lamp which follows error codes Err 8 and Err 9 ends by following start, if
the fact which caused the error code has been eliminated, or if the gun has cooled down or the
motor is no more overheated.
Check that in filler wire reel there are no parts sticking out, which could e.g.
scrub against chassis or door of wire feed unit. Dragging parts might expose
chassis of wire feed unit under voltage.
2.2.4. Automatic wire feed to gun
When changing the wire reel the pressure of the feed rolls need not be released as the filler wire
will automatically feed into the correct wire line.
- Make sure that groove of feed roll match the diameter of welding wire used. Feed roll
groove is selected by moving the groove selecting washer (28).
LOCKED OPEN
12 – PROMIG 200, PROMIG 300 / 0537 © KEMPPI OY
41
- Release the wire end from reel and cut off the bent length.
Be careful that the wire does not unwind and spill from the reel!
Straighten about 20 cm of the wire and see that the end of it has no sharp edges
(file off if necessary). A sharp edge may damage the wire guide tube and contact
tip of the welding gun.
- Draw a bit of loose wire from reel. Feed wire through back liner to feed rolls.
Don’t release pressure of feed rolls!
- Press the wire drive switch S11 or the gun switch and feed a bit wire until wire goes through
feed rolls to gun.
See that wire is in grooves of both feed roll pairs!
- Press still the wire drive or the gun switch until wire has come through contact tip.
Automatic feed may sometimes fail with thin wires (Fe, Fc, Ss: 0,6 and 0,8 mm (0,030”)
(Al: 0,8 and 1,0 mm (0,030” and 0,035”). Then it might be possible that you must open feed
rolls and feed wire manually through feed rolls.
2.2.5. Adjustment of pressure
Adjust the pressure of feed rolls with the control screw (20) so that the wire is fed into the wire
guide tube evently and allows a little braking when coming out from the contact tip without
slipping at the feed rolls.
Excessive pressure causes flatening of the filler wire and damage to the coating.
It also causes undue wear of the feed rolls as well as friction.
2.2.6. Adjustment of tightness of reel brake
Brake force is adjusted through hole in locking device of reel hub by screwing the control screw
(41) with screwdriver.
Adjust the brake force to a point where the wire reel will not continue to overrun once the drive
motor has stopped. If this is too loose the wire will spill from the reel. If this is too tight the
brake puts excess load on the wire drive motor. The brake force may be different for high wire
feed speeds and the varied weights of the wire reels and filler materials.
2.2.7. Burn back time
Electronics of the unit controls stopping of welding automatically so that the wire end doesn’t
melt to fastened to the contact tip or the work piece. Automatics work regardless of the wire feed
speed. End automatics eliminate also forming so-called ”ball” at wire tip, disturbing next start.
PROMIG 200, PROMIG 300 / 0537 – 13© KEMPPI OY
A
CF
G
B
E
D
2.2.8. Ground cable
Fasten earth clamp of ground cable carefully, preferably direct to welding piece. Contact surface
of clamp always should be as large as possible.
Clean the fastening surface from paint and rust!
Use in your MIG equipment only 70 mm2 cable. Thinner cross-sectional area might cause
overheating of connectors and insulations.
Make sure that the welding gun in use is designed for max. welding current and loading capacity
needed by you!
Never use a damaged welding gun!
2.2.9. Shielding gas
Handle gas bottle with care. There is a risk for injury if gas bottle or bottle valve
is 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.
2.2.10. 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.
The following installing 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 impurities 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.
Tighten the jacket nut.
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
14 – PROMIG 200, PROMIG 300 / 0537 © KEMPPI OY
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.
2.2.11. Main switch I/O of PRO power source
When you turn the switch into I-position, pilot lamp on the front face is illuminated, and the
machine is ready for use. The equipment is returned to that welding method with which the wel-
ding was last carried out before the main switch was turned to zero position.
Always turn the machine on and off with the mains switch, never use the mains plug as a
switch!
2.2.12. Operation of cooling unit (PROCOOL 10, PROCOOL 30)
Operation of cooling unit is controlled in such a way that pump is started when welding is
started. After the welding has stopped the pump is rotating for approx. 5 min cooling the liquid
to ambient temperature. Purpose of this operation is to make maintenance intervals of pump
longer.
Read in operation instructions for the PROCOOL 10/30 unit the trouble situations of the liquid
circulation system and protection against gun etc. damage.
PROMIG 200, PROMIG 300 / 0537 – 15© KEMPPI OY
3. OPERATIONAL FUNCTIONS
3.1. MAIN SWITCH S14
Position I
Unit is ready for welding and this is indicated by green pilot lamp H13.
Position O
MIG/MAG welding: operations are arrested, power source and wire feed motor
don’t start and solenoid valve for gas is not opened though start switch of gun
is pressed down. Wire drive switch S11 for filler wire needed by reel change is
operating. MMA welding: Operations are arrested, welding circuit is dead.
3.2. WELDING METHOD SELECTING SWITCH S15
MMA
MMA welding with stepless welding current control
MIG two-sequence procedure (normal function)
MIG/MAG welding with two-sequence procedure of welding gun start switch
1. switch pressed: welding starts
2. switch released: welding stops
MIG four-sequence procedure (hold switch)
MIG/MAG welding with four-sequence procedure of welding gun start switch
1. switch pressed: shielding gas flow starts
2. switch released: welding starts
3. switch pressed: welding stops
4. switch released: shielding gas flow stops
Local control:
Control potentiometers R11 and R12 on panel are used.
Remote control:
Adjustments are carried out from remote control unit which is connected to remote
control connector X11 of wire feed unit. See operations of remote control units
R20 and R10 on page 18.
NOTE! If the remote control unit is not connected to the Promig unit and you have
selected remote control, controls operate with local control potentiometers like in
local control position.
3.3. CONTROL MODE SELECTING SWITCH S16
16 – PROMIG 200, PROMIG 300 / 0537 © KEMPPI OY
3.4. LOCAL CONTROLS
/I - potentiometer R11
MIG/MAG: Local control for wire feed speed 0…18 m/min or 0…
25 m/min (Promig 300)
MMA welding: Welding current control, 10 A … max current of power source
U - potentiometer R12
MIG/MAG: Local control for voltage of PRO power source, 10 V …
max. MIG voltage of power source
MMA welding: No operation
3.5. REGULATION FOR SHIELDING GAS FLOW
Shielding gas flow can be regulated with flow regulator 5…25 l/min. Display is calibrated for
Ar CO2 mixed gas (75% Ar, 25% CO2). By other gases the meter error remains within ±10%
limits compared with real flow.
The gas flow regulator shows within ± 10% limits right only when angle of
deflection is smaller than 15° in regard to vertical.
Regulate the meter always when the unit is in vertical position.
Gas flow is read in the centre of swimmer.
3.6. SIGNAL LAMP H12 INDICATING MISSING OF
SHIELDING GAS
The unit is equipped with shielding gas guard which by missing of shielding gas
prevents welding start and stops welding, if arrival of shielding gas is prevented
during welding.
Red signal lamp is illuminated:
Welding is prevented until shielding gas pressure is adequate.
Red signal lamp is not illuminated:
Welding is allowed.
3.7. SIGNAL LAMP H11 FOR ERRORS
By Promig 200 and 300 units check by each start, if there are error states in the
equipment, if error states are observed, the error state is shown by blinking of
signal lamp H11 for errors. E.g. one short flash means error code Err 1 and two
short flashes indicate error code Err 2 etc.
Error codes are:
1 short flash, Err 1: Promig has gone over to MMA welding, though you have already
selected MMA welding on power source panel.
2 short flashes, Err 2: You are pressing on start switch of gun, when data transmission
between Promig and PRO is broken (defect in control cable or in
connector), or you are pressing on gun switch, when MMA welding
has been selected on control panel of power source.
4 short flashes, Err 4: You are pressing on start switch of gun and selecting switch S12 for
cooling mode is in liquid position and you have forgotten to switch-on
the PROCOOL cooling unit or you have forgotten to connect it to
equipment.
PROMIG 200, PROMIG 300 / 0537 – 17© KEMPPI OY
5 short flashes, Err 5: PROCOOL cooling unit has stopped welding. Reason can be break of
supply voltage from PROCOOL, pressure of liquid circulation doesn’t
arise or temperature of cooling liquid has arisen too high.
6 short flashes, Err 6: Wire feed unit has stopped welding in liquid position of selecting S12
of liquid/air-cooled gun for Promig, because data communication to
cooling unit is broken (defect in intermediate cable or in connection).
7 short flashes, Err 7: Selecting switch S12 of liquid/air-cooled gun for Promig is in air
position, PROCOOL is switched-on and start switch is pressed down.
Purpose of operation is to prevent the liquid-cooled gun from being
destroyed, when the selecting switch S12 for liquid/air-cooling is in
wrong position.
8 short flashes, Err 8: Liquid-cooled MIG gun is overheated.
9 short flashes, Err 9: Overload of wire feed motor, which can be caused e.g. by blocked
wire guide of gun or by gun cable, which is too much curved.
10 short flashes, Err 10: Operation of thermal protection of PRO power source has stopped welding.
Air-cooling
This position is used when you are using an AIR cooled MIG gun. The equipment allows
welding when you have not connected a switched-on PROCOOL cooling unit to equipment (see
also operations of error signal lamp H11).
Liquid-cooling
This position is used when you are using a liquid cooled MIG gun. The equipment stops welding
if you have not connected a switched-on PROCOOL cooling unit to equipment, Err4. (see also
operations of error signal lamp H11).
Eliminate the Error codes as follows:
Error code Err 1 is eliminated, when Promig wire feed system is set into MIG state.
Blinking of error codes Err 2-4 ends automatically within 5 s, if the trigger is not pressed
down.
Eliminate the causer of error before next start.
Blinking of error codes Err 5-10 stops by next start, if the causer of error code has been
eliminated.
3.8. WIRE INCH SWITCH S11
Inside the wire reel compartment there is a switch with which you can feed filler wire without
starting power source and opening the gas valve. The operation is used e.g. by reel change.
3.9. GAS PURGE SWITCH S13
Inside the wire reel compartment there is a switch, which the gas valve can be opened without
starting power source or wire feed motor. The operation is used e.g. by gas flow regulation.
3.10. SELECTION OF MIG GUN’S COOLING MODE S12
In the wire reel compartment there is a switch which is set according to cooling mode of MIG
gun which is used.
18 – PROMIG 200, PROMIG 300 / 0537 © KEMPPI OY
R61
R63
R20
R10
R61
4. OPERATIONS OF REMOTE CONTROL UNITS
IN PROMIG 200 AND 300 WIRE FEED UNITS
................ R63 ....................................................... R61
MIG ......... Setting for wire feed: ............................. Setting for voltage:
................ I 1...18 m/min
................ II 1...25 m/min ....................................... 10 V...max. voltage of power source (35...46 V)
MMA ....... Setting for power:
................ 10 A...max. power of power source ....... NO OPERATION
................ R61
MIG ......... Setting for wire feed:
................ I 1...18 m/min
................ II 1...25 m/min
MMA ....... Setting for power:
................ 10 A...max. power of power source
5. SERVICE, OPERATION DISTURBANCES
The amount of use and the working environment should be taken into consideration when
planning the frequency of maintenance of Promig. Careful use and preventive maintenance will
help to ensure trouble-free operation.
The following maintenance operations should be carried out at least every six months:
Check:
- The wear of the grooves of the feed rolls. Excessive wear of grooves
causes problems in wire feed.
- The wear of the wire guide tubes of wire feed. Badly worn feed rolls
and wire guide tubes should be discarded.
- The wire guide tube in the gun should be set as near the feed rolls as
possible, but not touching them and the wire must follow a straight line
from the end of the feed roll.
- Reel brake adjustment
- Electric connections
* Oxidized couplings must be cleaned
* Loose couplings must be tightened
Clean dust and dirt from the equipment.
When using compressed air, always protect your eyes with proper
eye protection.
In case of problems contact the KEMPPI works in Lahti, Finland or your KEMPPI dealer.
twice a
year
PROMIG 200, PROMIG 300 / 0537 – 19© KEMPPI OY
6. ORDERING NUMBERS
Promig 200 6231520
Promig 300 6231530
Kemppi Pro Evolution 3200 6131320
Kemppi Pro Evolution 4200 6131420
Kemppi Pro Evolution 5200 6131520
P20L 6185264L
P40 6185264
Remote control unit R10 6185409
Remote control unit R20 6185419
Shielding gas hose 1,5 m 4269030
Extension cable for remote unit 10 m 6185481
Earth cable 5 m – 50 mm2 6184511
Earth cable 5 m – 70 mm2 6184711
MMA welding cable 5 m – 50 mm2 6184501
MMA welding cable 25 m – 70 mm2 6184701
Heating resistor (Promig 200) 4299240
W1 = 1+9
W1 / 20 m – 70 mm2 6260327
PROCOOL 10 6262012
PROCOOL 30 6262016
P30W 6185262
W3 = 1+9+5+5
W3 / 20 m – 70 mm2 6260337
PROSYNC 50 6231530
MIG-intermediate cable air-cooled 15 m 6260211
MIG-intermediate cable air-cooled 25 m 6260213
MIG-intermediate cable liquid-cooled 15 m 6260225
MIG-intermediate cable liquid-cooled 25 m 6260227
Earth cable 70 mm2, 5 m 6184711
Remote control RMT10 6185475
Gun holder GH20 6256020
Hub for wire reel 4289880
MIG guns
Air-cooled:
PMT 32 3 m 6253213
PMT 32 4,5 m 6253214
PMT 35 3 m 6253513
PMT 35 4,5 m 6253514
PMT 42 3 m 6254213
PMT 42 4,5 m 6254214
MMT 32 3 m 6253213MMT
MMT 32 4,5 m 6253214MMT
MMT 35 3 m 6253513MMT
MMT 35 4,5 m 6253514MMT
MMT 42 3 m 6254213MMT
MMT 42 4,5 m 6254214MMT
20 – PROMIG 200, PROMIG 300 / 0537 © KEMPPI OY
7. TECHNICAL DATA
Promig 200 Promig 300
Working voltage (safety volt.) 50 VDC 50 VDC
Rated power 100 W 100 W
Max. load
(nominal values) 60 % ED 460 A 460 A
100 % ED 355 A 355 A
Operation principle 4 roll feed 4 roll feed
Diameter of feed roll 32 mm 32 mm
Wire feed speed I 0...18 m/min 0...18 m/min
Wire feed speed II ¹) 0...25 m/min
Filler wires ø Fe, Ss 0,6...1,6 0,6...1,6
ø Cored wire 0,8...1,6 0,8...2,0
Wire reel max. weight 5 kg 20 kg
max. size ø 200 mm ø 300 mm
Torch connector Euro Euro
Operation temperature range 20...+40 °C -20...+40 °C
Storage temperature range -40...+60 °C -40...+60 °C
Degree of protection IP 23 IP 23
Dimensions with safety frame
length 500 mm 600 mm
width 230 mm 225 mm
height 315 mm 415 mm
Weight 13 kg 17 kg
The products meet conformity requirements for CE marking.
1) Changes of speed are carried out by changing rear wheel and jumper block
selection on circuit card A001.
Liquid-cooled:
PMT 30W 3 m 6253043
PMT 30W 4,5 m 6253044
PMT 42W 3 m 6254203
PMT 42W 4,5 m 6254204
PMT 52W 3 m 6255203
PMT 52W 4,5 m 6255204
MMT 30W 3 m 6253043MMT
MMT 30W 4,5 m 6253044MMT
MMT 42W 3 m 6254203MMT
MMT 42W 4,5 m 6254204MMT
MMT 52W 3 m 6255203MMT
MMT 52W 4,5 m 6255204MMT
This manual suits for next models
1
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