Kemppi Pro Evolution 3200 User Manual

Kemppi pRO eVOLUTiON

3200, 4200, 5200

Kemppi pRO eVOLUTiON

3200 mVU, 4200 mVU, 5200 mVU

1913130E

0617

2 – Kemppi pro evolution 3200, 4200, 5200, 3200 mvu, 4200 mvu, 5200 mvu / 0617 © Kemppi oy

contents

1. preface ........................................................................................................................ 3

1.1. Introduction .......................................................................................................................3

1.2. Product introduction ..........................................................................................................

1.2.1. Operation control and connectors ................................................................................... 4

1.3. Accessories ....................................................................................................................... 5

1.3.1. Remote control devices ................................................................................................... 5

1.3.2. Control panels .................................................................................................................

1.3.3. Cables ............................................................................................................................. 6

1.4. Operation safety ................................................................................................................ 6

2. InstallatIon ............................................................................................................... 7

2.1. Siting the machine and mounting the control panels PL and PX ...................................... 7

2.2.1. Connection to the mains supply ...................................................................................... 7

2.2.2. Welding and earth cables ................................................................................................

3. operatIon control swItches and potentIometers and theIr use ..... 8

3.1. Main switch I/O ..................................................................................................................8

3.2. Pilot lamps .........................................................................................................................

3.3. Local or remote control of welding current ........................................................................

3.4. Operation of cooling fan ....................................................................................................

4. accessorIes ............................................................................................................... 9

4.1. PL and PX control panels’ operation in MMA welding ....................................................... 9

4.1.1. Control for MMA welding dynamics (PL, PX) .................................................................. 9

4.1.2. Control of ignition pulse current (PX) ............................................................................

4.1.3. Meter display (PL, PX) ..................................................................................................

4.1.4. Operation mede selection (PX) .....................................................................................

5. coolIng unIt supply .............................................................................................. 11

6. maIntenance ............................................................................................................

6.1. Cables ............................................................................................................................. 11

6.2. Power source ..................................................................................................................

6.3. Regular maintenance ......................................................................................................

7. operatIon dIsturbances .................................................................................... 12

7.1. Operation of the overload protection ............................................................................... 12

7.2. Control fuses ...................................................................................................................

7.3. Under- and overvoltages in the mains supply .................................................................

7.4. Loss of a phase in the mains supply ...............................................................................

7.5. Disposal of the machine ..................................................................................................

8. orderIng numbers ................................................................................................13

9. technIcal data .......................................................................................................

10. terms of guarantee .............................................................................................

Kemppi pro evolution 3200, 4200, 5200, 3200 mvu, 4200 mvu, 5200 mvu / 0617 – 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 specications. Read this manual from front to back before installing, operating or maintaining the equipment for the rst time. For further

information on Kemppi products please contact us or your nearest Kemppi distributor.

The specications 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

Kemppi Pro Evolution 3200, 4200 and 5200 are multi-operator power sources designed for demanding professional use. They are suitable for MMA/MIG and pulsed MIG as well as for TIG welding in DC. Kemppi Pro Evolution can be used as power source with a welding auto-

mate or robot.

Power control of Kemppi Pro Evolution power source has been realized with at approx. 20 kHz frequency IGBT transistors operating and control unit with microprosessor.

Kemppi Pro machines can be seen in operating instructions for each unit. Mounting intructions for control panels PX and PL are in their packages.

This manual handles installation and use of Kemppi Pro Evolution power sources.

This equipment’s electromagnetic compatibility (EMC) is designed for use in an industrial environment. Class A equipment is not intended for use in residential loca-

tion where the electrical power is provided by the public low-voltage supply system.

4 – Kemppi pro evolution 3200, 4200, 5200, 3200 mvu, 4200 mvu, 5200 mvu / 0617 © Kemppi oy

H12

S11

X14

F11

X16

F12

S11

H11

H12

F11

X14

X12

X13

X15

X11

X12

X13

X11

H11

X15

1.2.1. Operation control and connectors

F11 Fuse for connetion for control table 6,3 A delayed H11 Signal lamp I/O H12 Warning lamp for thermal protection S11 Main switch I/O X11, Welding connection parallel X12 X13 Earth connection X14, Connection for control cable parallel X15 01 Inlet of mains cable

02 Inspection cover for control panel PL, PX Accessories

X16 Socket outlet Fuse 230 V, 250 VA F12 Fuse for socket outlet 1,0 A delayed

pro evolutIon

pro evolutIon mvu

Kemppi pro evolution 3200, 4200, 5200, 3200 mvu, 4200 mvu, 5200 mvu / 0617 – 5© Kemppi oy

R61

R63

P21

P22 P23 R22

R21 S21

P31 P32 P33 H31

H32

S33 S34 S35 S36

S37

S31 S32

1.3. accessorIes

Control of MMA/TIG welding current (R61), reference scale 1 … 10.

R20 6185419

MIG-MAG remote control device with controls for wire feed (R63) and voltage (R61), memory scales 1 … 10.

You can use control device also for control of MMA current from potentiometer R63.

1.3.2. Control panels

PL panel 6185801

P21 Current meter set value / welding current P22 Voltage meter

open circuit / terminal voltage

P23 Display for adjustment value of MMA welding dynamics -9 … 0 …+9 R21 Adjustment of welding current R22 Adjustment of MMA welding dynamics S21 Selection for local / remote control

local / MIG/TIG / remote control

PX panel 6185802

H31 Signal lamp for voltage display H32 Signal lamp for display of adjustment status P31 Current meter / set value / welding current P32 Voltage meter / open circuit / terminal voltage P33 Display for adjustment value of MMA welding dynamics and start current -9 … 0 …+9 S31, Adjustment of welding current + / -

S32 S33 Selection for local / remote control local / MIG/TIG / remote control S34 Selection for characteristics Point to point welding / normal welding / carbon arc gouging

S35 Selection of property to be adjusted MMA welding dynamics / start current S36, Adjustment for MMA welding dynamics S37 and start current + / RECALL STD = resetting of factory set up (=0)

1.3.1. Remote control devices

R10 6185409

1.4. 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 reecting arc ash. Welding arc and

spatter burn unprotected skin. Use safety gloves and protective clothing.

Danger for re or explosion

Pay attention to re safety regulations. Remove ammable or explosive materials from welding place. Always ensure that you have sufcent re ghting equipment available where you are welding. Be prepared for hazards in special welding jobs, eg. for the danger of re or explosion when welding container type work pieces. Note! Fire can break out from sparks even several hours after the welding work has been nished!

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 re. 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 sufcient ventilation during welding. Take special safety precautions when welding metals which contain lead, cadmium, zinc, mercury or beryllium.

1.3.3. Cables

Pro Evolution 3200 Pro Evolution 4200 Pro Evolution 5200 Pro Evolution

3200 MVU

Pro Evolution

4200 MVU

Pro Evolution

5200 MVU

16d Extension cable for remote control 20 Earth cable

21 MMA welding cable R10, Remote control devices, see also page 5 R20

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