Kemppi PROMIG 200 ML Bedienungsanleitung

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

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

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

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

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

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.

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

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