Kemppi Promig 100 Manuale utente

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

H11

R1 R2

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

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

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

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

yellow

Promig 100/0601 – 7

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

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.

Indice

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