Kemppi Promig 540R User Manual
1923740E
0425
2 – Promig 540R, Promig 120R/0425
© KEMPPI OY
Promig 540R, Promig 120R/0423 – 3
© 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 specications. 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.
Specications 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 amplied
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
Promig 540R, Promig 120R/0423 – 5
© 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 reecting 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 sufcient 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 sufcient 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
Promig 540R, Promig 120R/0423 – 7
© 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
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