Kemppi Promig 540R User Manual

   
1923740E
0425
2 – Promig 540R, Promig 120R/0425
© KEMPPI OY
CONTENTS
1. PREFACE........................................................................................................................ 3
1.1. Introduction .......................................................................................................................3
1.2. Product introduction ..........................................................................................................3
1.3. Operation safety................................................................................................................ 4
2. INSTALLATION ...............................................................................................................5
2.1. Operation control and connectors ..................................................................................... 5
2.1.1. Promig 540R control unit................................................................................................. 5
2.1.2. Promig 120R wire feeder ................................................................................................ 6
2.2. Units, accessories, cables................................................................................................. 7
2.3. Parts of wire feed mechanism........................................................................................... 8
2.4. Assembly of MIG system ..................................................................................................9
3. INSTALLATION OF MIG SYSTEM ...............................................................................10
3.1. Accessories corresponding to wire diameter ..................................................................10
3.2. Mounting of MIG gun....................................................................................................... 11
3.3. Automatic wire feed to gun.............................................................................................. 11
3.4. Adjustment of pressure ................................................................................................... 11
3.5. Burn back time ................................................................................................................12
3.6. Ground cable................................................................................................................... 12
3.7. Shield gas .......................................................................................................................12
3.7.1. Installing gas bottle ....................................................................................................... 12
3.8. Main switch I / O.............................................................................................................. 13
3.9. Operation of cooling unit (PROCOOL 10, PROCOOL 30).............................................. 13
4. MXE CONTROL PANEL................................................................................................14
5. OTHER USER FUNCTIONS .........................................................................................15
6. JUMPERS...................................................................................................................... 15
7. ERROR CODES OF PANELS....................................................................................... 17
8. SERVICE AND OPERATION DISTURBANES ............................................................. 17
9. ORDERING NUMBERS ................................................................................................18
10. TECHNICAL DATA........................................................................................................ 19
Promig 540R, Promig 120R/0423 – 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.
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
Promig 540R is a welding system designed for robotic and automated welding. It consists of Promig 540R with inbuilt robot interface and a robot arm mounted feed unit Promig 120R. These two units are connected with an intermediate cable assembly.
Manual control is possible using interchangeable control panel:
MXE: Synergic MIG/MAG and Pulsed MIG in the most demanding welding environment. MMA welding is also possible.
Welding operation is controlled by microprocessor. The wire feed motor includes an amplied tachometer feedback system to ensure accurate wire feed speed. The interface stage handles eldbus signal covering all automated requirements.
4 – Promig 540R, Promig 120R/0425
© 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 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 reserve sufcient re-ghting equipment on welding place. Be prepared for hazards in special welding jobs, e.g. 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 defect cables without delay. Defect cables may cause an injury or set out a re. 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’s 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.
Promig 540R, Promig 120R/0423 – 5
© KEMPPI OY
2. INSTALLATION
2.1 OPERATION CONTROL AND CONNECTORS
2.1.1. Promig 540R control unit
MXE control panel
Wire inch
Gas purge
Motor overcurrent indicator
Place for user connector
Holes for gas snap connectors
Welding current output connector (+)
Control cable connector (to 120R or voltage controlled wire feeder SWF)
Control cable connector (to 2nd 120R)
Robot controller eldbus
Control cable connector (Probus)
Voltage monitoring connector (–)
Fixed welding cable to Pro power source
Fixed control cable to Pro power source
Lock switch of panel
Signal throughput connector
Analog signal to robot
6 – Promig 540R, Promig 120R/0425
© KEMPPI OY
2.1.2. Promig 120R wire feeder
Gas purge
Wire inch
Euro connector for robot gun
Snap connector for air blast
Connector for motorised gun
Snap connectors for
cooling liquid
Control cable connector
Snap connector for gas
Wire liner inlet
Welding current cable connector
Promig 540R, Promig 120R/0423 – 7
© KEMPPI OY
A
B
C
D
E
F
G
H
I
J
K
L
2.2. UNITS, ACCESSORIES, CABLES
A Air hose
B Intermediate cable
assembly
C Air blast
D Shielding gas hose
E Cooling liquid hoses
F Control cable
G Control cable
H Welding current cable
I Voltage monitor cable
J Branch connector
K Earth cable
L Robot control
8 – Promig 540R, Promig 120R/0425
© KEMPPI OY
2.3 PARTS OF WIRE FEED MECHANISM
Promig 540R, Promig 120R/0423 – 9
© KEMPPI OY
2.4. ASSEMBLY OF MIG SYSTEM
Assemble the units according to the mounting instructions delivered with the unit.
1. Installation of power source
Read paragraph “INSTALLATION” in operation instructions for PRO power sources and install accordingly.
2. Mounting of PRO power source to transport wagon
P 20 see air-cooled MIG system
P 30W see liquid-cooled MIG system
P 40 see air-cooled MIG system
3. Put PROMIG onto the power source and lock it with bolts to handles of powersource.
4. Installation of the eldbus card
MXE 6263504, installation instruction 4279220
Open side plate and install eldbus card by mounting above the interface card with two M3 nut.
See mounting instructions.
5. Connecting cables
Connect cables according to paragraph ”UNITS, ACCESSORIES, CABLES”.
6. Max. wire feed speed
By delivery, the max. wire feed speed is 18 m/min, which is enough for most welding applications. If you need a higher speed, you can increase the wire feed speed to 25 m/min by replacing the gear wheel on motor shaft. The high ratio wheel (*D40*) is delivered with the feed unit.
Changing the maximum wire feed speed:
– Open side plate and remove JUMPER 3 on control card A001. This alters the tacho
feedback ratio to 0 - 25 m/min
Fieldbus card
M3 nut
Interface card
10 – Promig 540R, Promig 120R/0425
© KEMPPI OY
20
21 23 2 4 2 1
22 25 22
25
– 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 pcs) by one twist. Mount D40 gear wheel onto motor shaft. Screw the
screw (23) with its washer back.
– Put feed rolls (21) back on their shafts.
– Lift motor so that tooth gap between gear wheel and both lower feed rolls is approx. 0,2 mm.
– Tighten screws (25). Check gear teeth gaps, if necessary put the motor into a better position.
Screw on mounting screws of feed rolls (22).
Too small a clearance between drive wheel and feed rolls will overload the motor. Too large a clearance causes rapid wearing of feed rolls’ drive wheel.
3. INSTALLATION OF MIG SYSTEM
3.1. ACCESSORIES CORRESPONDING TO WIRE DIAMETER
PROMIG wire feed rolls are available with plain groove, knurled groove and with U groove.
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. Correct wire groove is selected by moving selecting washer from over to underneath the feed rolls. Move also drive wheel with the black plastic washer.
Feed rolls and wire guide tubes of wire feed unit have colour codes to make identication easier.
Promig 540R, Promig 120R/0423 – 11
© KEMPPI OY
3.2. MOUNTING OF MIG GUN
To ensure trouble-free welding, check in welding gun operating instructions that wire liner and contact tip are correct for wire feed diameter and wire type. Too tight a wire liner might cause disturbances in wire feed, and motor overload (this is also a symptom of liner blockage).
Ensure that the welding gun connector is tight.
When you are using liquid-cooled gun, mount water hoses according to the diagram.
Error signal lamp of PROMIG 540R indicates overloading of wire feed motor. Operation of signal lamp is as follows (also see error codes):
Wire feed motor is slightly overloaded e.g. due to a blocked gun. At a predetermined load the error signal lamp starts to blink.
If the load is too great the system will shut down (wire feed) and the display panel will indicate Err 9.
Error code 9, followed by blinking signal lamp is cleared by next start if error condition is no longer present or motor is not overheated any more.
3.3. AUTOMATIC WIRE FEED TO GUN
Automatic wire feed in PROMIG wire feed units makes changing of wire reel more rapid. When changing the reel, feed rolls need not be released as the wire will pass directly through.
Groove selecting washer
– Make sure that groove of feed roll matches the diameter of welding wire used. Feed roll
groove is selected by moving the groove selecting washer from top to bottom or vice versa.
– Straighten the wire at a length of about 20 cm and see that its end has no sharp edges (le
off if necessary). A sharp edge may damage the wire guide tube and contact tip of welding gun.
Automatic feed may sometimes fail with thin wires (Fe, Fc, Ss: 0,6...0,8 mm, Al: 0,8...1,0 mm). Then you might have to open feed rolls and feed wire manually through feed rolls.
– Feed wire through wire cone until it touches the feed rolls. Do not release pressure of feed
rolls!
– Press wire inch switch and feed wire until wire goes through both sets of rolls.
– Keep inch switch pressed until wire has come through contact tip.
3.4. ADJUSTMENT OF PRESSURE
Adjust feed roll pressure with the control screw (20) so that some resistance may be applied to the wire without slipping at the feed rolls.
Excessive pressure causes attening of ller wire and damage to the coating. It also causes undue wear of feed rolls as well as friction.
12 – Promig 540R, Promig 120R/0425
© KEMPPI OY
A
C
G
B
E
D
F
3.5. BURN BACK TIME
The system includes an electronic burn back control which is pre-set.
3.6. GROUND CABLE
Use at least 70 mm2 cables. Thinner cross-sectional areas cause overheating of connectors and poor Pulsed MIG performance.
Never use a damaged welding gun!
3.7. SHIELD 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 ow rate is set according to the welding power used in the job. A suitable ow rate is normally 8 - 15 l/min. If the gas ow is not suitable, the welded joint will be sporous. Contact your local Kemppi dealer for choosing gas and equipment.
3.7.1. 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 nished welding.
Parts of gas ow 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
Following installing instructions are valid for most gas ow regulator types:
1. Step aside and open bottle valve (A) for a while to blow out possible impurities.
2. Turn press regulation screw (B) of regulator until no spring pressure can be felt.
3. Close needle valve if there is one in the regulator.
4. Install 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 hose with regulator and the other end with wire feed unit. Tighten jacket nut.
7. Open bottle valve slowly. Gas bottle pressure meter (F) shows bottle pressure. Note! Do not use the whole contents of the bottle. Bottle should be lled when bottle pressure is 2 bar.
Promig 540R, Promig 120R/0423 – 13
© KEMPPI OY
8. Open needle valve if there is one in the regulator.
9. Turn regulation screw (B) until hose pressure meter (G) shows the required ow (or pressure). When regulating ow amount, power source should be switched on and gun switch pressed simultaniously.
Close bottle valve after having nished welding. If the machine will be out of use for a long time, unscrew pressure regulation screw.
3.8. MAIN SWITCH I/O
When you turn the main switch of PRO power source into position I, pilot lamp next to it is lit and the equipment is ready for welding. The equipment reverts to the welding method used before the main switch was turned to position zero.
Always start and switch off the machine with the main switch, never use the mains plug as a switch.
3.9. OPERATION OF COOLING UNIT (PROCOOL 10, PROCOOL 30)
Operation of cooling unit is controlled so that pump is turned on when welding is started. After welding stop pump is rotating for approx. 5 min, thus cooling the liquid to ambient temperature.
Read in operation instructions for cooling unit the trouble situations in liquid circulation system and protection against damage of gun etc.
14 – Promig 540R, Promig 120R/0425
© KEMPPI OY
4. MXE CONTROL PANEL
Operations of MXE control panel are described in manual delivered with MXE.
Exceptions to the operations of MXE in robot use:
- 4T start switch function is not active
- gun remote control is not active
- there are 63 active memory channels
Other functions related to robot use:
MXE panel can be used in normal local control by setting MEMORY OFF and LOCAL. Key switch on machine front is turned to position MANUAL. All adjustments are set with the panel. In this case start and stop of machine can be controlled with robot.
By setting MXE panel to REMOTE mode, wire feed speed/voltage or power/ne control can be regulated with robot via analog lines.
Memory channels can be programmed as described in the operating manual of MXE panel.
When retrieving memory channels, you can choose with robot whether to use wire feed speed/ voltage or power/ne control values retrieved from memory, or whether these values are controlled with robot via analog lines (see technical manual).
When controlling memory channels with robot, memory functions are to be set to MEMORY ON mode. Key switch is turned to position AUTO.
Note! On memory channel 0 (= no memory channel selected) machine always retrieves memory channel which was used last.
Promig 540R, Promig 120R/0423 – 15
© KEMPPI OY
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
5. OTHER USER FUNCTIONS
Selection between gas-cooled and water-cooled gun is made using the switch inside the control unit.
Wire inch switch function is in the front of control unit and feeder unit.
– displays main motor current on welding current window and gun motor current on voltage
display window
– inch speed is set by local control setting (panel)
Gas purge switch is in the front of control unit and feeder unit.
– gas purge when pressed
Gas valve is mounted inside the feeder unit but it can also be moved into the control unit where there is a place for it.
A gas pressure switch can be mounted inside the control unit.
Inside the control unit there is a 20 kg MIG wire spool system.
6. JUMPERS
1. Selection of wire feeder address
102, set 1
105, set 2
2. Robot control input voltage range for analog channels:
0-10 V
0-5 V
3. Selection of max. wire feed speed for feed unit 1
0-18 m, delivery setting
0-25 m
4. Selection of max. wire feed speed for feed unit 2
0-18 m / min
0-25 m / min
16 – Promig 540R, Promig 120R/0425
© KEMPPI OY
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
5,6 Wire feed and motor pistol selection
for one feeding unit only
for one feeding unit and motor pistol
for two feeding units (dual)
not used
7,8 Motor pistol selection
Hulftegger (3,3 kohm)
Binzel, water cooled (6,8 kohm)
Binzel, gas cooled (10 kohm)
Dinse (22 kohm)
9. Not used
10. Not used
11. Dynamic adjustment for 1-knob and normal MIG
Dynamic adjustment from MXE-control panel
(or without control panel A001/R165)
Dynamic adjustment through eldbus
12. Gas valve control
Gas valve is controlled by the eldbus
Gas valve is controlled internally by PROMIG 540R
Promig 540R, Promig 120R/0423 – 17
© KEMPPI OY
8. SERVICE AND OPERATION DISTURBANCES
The amount of use and 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.
Following maintenance operations should be carried out at least every six months:
Check:
– Feed roll grooves. Excessive wear of grooves causes wire feed
problems.
– Wire guide tubes. Badly worn feed rolls and wire guide tubes
should be discarded.
– Wire guide tube in the gun should be set as near the feed rolls
as possible and the wire must follow a straight line from the end of the tube to the groove of the feed roll.
– Reel brake adjustment.
– Electrical connections:
* Oxidized couplings must be cleaned
* Loose couplings must be tightened
Clean dust and dirt from the equipment.
twice a year
When using compressed air, always protect your eyes with proper eye protection.
In case of problems contact your KEMPPI dealer.
7. ERROR CODES OF PANELS
Error codes inform the user about welding system malfunctions. They are displayed on MC/ML panels.
Err 1 Robot identication failed. Robot identication is done using XW114 on A003 X8.
Err 2 Power source has been started for MMA or TIG mode.
Err 3 Same as Err 2 but up (+) / down (–) buttons are active on PX panel (optional).
Err 4 Cooling unit (Procool 10 / 30) is not starting (check gas/water switch).
Err 5 Cooling unit (Procool 10 / 30) has a cooling failure (overheating sensor or pressure
switch has reacted or unit is missing supply voltage).
Err 6 Water unit (Procool 10 / 30) has been started normally, but wire feed unit (Promig 540R) has lost serial communication link to cooling unit (check interconns).
Err 7 Emergency stop is active. Input relay K2 must be active on A003 to cancel emergency stop (only Promig 540R - KU).
Err 9 Overload of wire feed motor which may be caused by blocked wire guide of gun or by gun cable which is too curved.
Err 10 PRO power supply reports error when start message from Promig 540R is sent. Operation of thermal protection of PRO power source has stopped welding.
Err 14 Supply overvoltage in Promig 540R.
Error code display is cleared by next start if the cause of error code has been eliminated.
18 – Promig 540R, Promig 120R/0425
© KEMPPI OY
9. ORDERING NUMBERS
Wire feed units
Promig 540R wire feed control unit ................................................. 6231540
Promig 120R wire feed unit ............................................................. 6236320
Fieldbus cards
Fieldbus card Interbus s.................................................................... 9774120IBC
Fieldbus card Interbus s optical........................................................ 9774120IBO
Fieldbus card Probus
...................................................................... 9774120PRF
Fieldbus card Devicenet ................................................................... 9774120DEV
Accessories of Promig 540R
MXE function panel ......................................................................... 6263504
Prosync 50 synchronisation set ........................................................ 6263121
Voltage sensor
................................................................................... 4289560
Current sensor................................................................................... 4288790
Wire reel hub...................................................
................................. 4289880
Power sources
Kemppi Pro Evolution 3200............................................................. 6131320
Kemppi Pro Evolution 4200............................................................. 6131420
Kemppi Pro Evolution 5200............................................................. 6131520
Cooling unit
PROCOOL 10................................................................................... 6262012
PROCOOL 30
................................................................................... 6262016
Cabels
Voltage monitor cable ....................................................................... 4288700
Branch connector.............................................................................. 9771637
Intermediate cable assembly..................... 5 m................................. 6260421
...................................................................................... 10 m .......... 6260425
Earth cable ............................................... 50 mm2...... 5 m ............ 6184511
.................................................................. 50 mm2...... 10 m .......... 6184512
Earth cable................................................ 70 mm2...... 5 m ............ 6184711
.................................................................. 70 mm2...... 10 m .......... 6184712
MIG guns for robotic and automated welding
MT-51MW.................................................................... 1,5 m / SK . 6255156
MT-51MW
.................................................................... 1,5 m / K30 6255157
MT-51MW
.................................................................... 3,0 m / SK . 6255158
MT-51MW
.................................................................... 3,0 m / K30 6255159
Transport wagons
P 20................................................................................................... 6185261
P 30W
............................................................................................... 6185262
P 40
................................................................................................... 6185264
Promig 540R, Promig 120R/0423 – 19
© KEMPPI OY
10. TECHNICAL DATA
Promig 540R, Promig 120R
Operating voltage (safety voltage) 50 V DC
Rated power 100 W
Max. load 80 % ED 520 A
(nominal values) 100 % ED 400A
Operation principle 4-roll feed
Diameter of feed roll 32 mm
Wire feed speed I 0...18 m/min
II 0...25 m/min
Filler wires ø Fe, Ss 0,6...2,4 mm
ø Cored wires 0,8...2,4 mm
ø Al 1,0...2,4 mm
Wire reel max. weight 20 kg
max. size ø 300 mm
Gun connector Euro
Operation temperature range -20...+40 oC
Storage temperature range -40...+60 oC
Degree of protection IP 23
Promig 540R
Dimensions (without handle)
length 620 mm
width 230 mm
height 480 mm
weight 20 kg
Promig 120R
Dimensions length 319 mm
width 152 mm
height 167 mm
weight 8 kg
The products meet conformity requirements for CE marking.
KEMPPI OY PL 13 FIN – 15801 LAHTI FINLAND Tel (03) 899 11 Telefax (03) 899 428 www.kemppi.com
KEMPPIKONEET OY PL 13 FIN – 15801 LAHTI FINLAND Tel (03) 899 11 Telefax (03) 7348 398 e-mail: myynti.@kemppi.com
KEMPPI SVERIGE AB Box 717 S – 194 27 UPPLANDS VÄSBY SVERIGE Tel (08) 59 078 300 Telefax (08) 59 082 394 e-mail: sales.se@kemppi.com
KEMPPI NORGE A/S Postboks 2151, Postterminalen N – 3103 TØNSBERG NORGE Tel 33 34 60 00 Telefax 33 34 60 10 e-mail: sales.no@kemppi.com
KEMPPI DANMARK A/S Literbuen 11 DK – 2740 SKOVLUNDE DANMARK Tel 44 941 677 Telefax 44 941 536 e-mail:sales.dk@kemppi.com
KEMPPI BENELUX B.V. Postbus 5603 NL – 4801 EA BREDA NEDERLAND Tel (076) 5717 750 Telefax (076) 5716 345 e-mail: sales.nl@kemppi.com
KEMPPI (UK) Ltd Martti Kemppi Building Fraser Road Priory Business Park BEDFORD, MK443WH ENGLAND Tel 0845 6444201 Fax 0845 6444202 e-mail: sales.uk@kemppi.com
KEMPPI FRANCE S.A. S.A. au capital de 5 000 000 F. 65 Avenue de la Couronne des Prés 78681 EPONE CEDEX FRANCE Tel (01) 30 90 04 40 Telefax (01) 30 90 04 45 e-mail: sales.fr@kemppi.com
KEMPPI GmbH Otto – Hahn – Straße 14 D – 35510 BUTZBACH DEUTSCHLAND Tel (06033) 88 020 Telefax (06033) 72 528 e-mail:sales.de@kemppi.com
KEMPPI SP. z o.o. Ul. Piłsudskiego 2 05-091 ZA¸BKI Poland Tel +48 22 781 6162 Telefax +48 22 781 6505 e-mail: info.pl@kemppi.com
KEMPPI SWITZERLAND AG Chemin de la Colice 4 CH-1023 Crissier/ Lausanne SUISSE Tel. +41 21 6373020 Telefax +41 21 6373025 e-mail: sales.ch@kemppi.com
KEMPPI WELDING MACHINES AUSTRALIA PTY LTD P.O. Box 404 (2/58 Lancaster Street) Ingleburn NSW 2565, Australia Tel. +61-2-9605 9500 Telefax +61-2-9605 5999 e-mail: info@kemppi.com.au
Ver. 7
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