Protig 410 User Manual - Rapid Welding and Industrial Supplies Ltd
Contents
1. 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 2 4 MAIN SWITCH I O When you turn the main switch of the Pro power source into I position pilot lamp close to it is lighted and the equipment is ready for welding The equipment is returned to that welding method with which the welding was last carried out before the main switch was turned to zero position A Always start and switch off the machine with the main switch never use the mains plug as a switch 2 5 OPERATION OF COOLING UNIT PROCOOL 10 30 Operation of cooling unit is controlled in such a way that pump is started when welding is started After welding stop pump is rotating for approx 5 min cooling the liquid to ambient tem perature Purpose of this operation is to make maintenance intervals of pump longer Read in operation instructions for the Procool 10 Procool 30 unit the trouble situat2. when on display P25 for post gas time appear for two seconds horizontal lines The parameters which are shown last in display and welded or stored last are kept in storage though electricity would be disconnected from unit At connection electricity is restored to the channel on which you were last All channels have reference values which don t disappear from memory though you would store to channnels anything You can cancel program of channel from memory as follows 1 Select channel number to display CH 2 Press at the same time both arrow keys All lights on panel are lighted at the same time and the program is cancelled and original reference values are restored to channel 4 ACCURACY OF PANEL DISPLAY Accuracy of digital meters in TL and TX panels as follows Accuracy of current set value in ratio to true value is 42 5 96 2 A 18 PROTIG 410 0537 KEMPPI OY nnn 9 REMOTE CONTROL UNIT Control of welding current min max Control of welding current min max No operation R10F Foot pedal control unit for TIG welding Start operation Control for welding current with movement on pedal Limiting of welding current range with min and max potentiometers reference scale 1 10 6 MAINTENANCE The amount of use and the working environment should be taken into consideration when plan ning the frequency of maintenance of Protig 410 unit Careful use and preventive maintenance will
3. Begin trial operation of unit with this mode of switch in order to avoid confusion Go through all operations and controls of panel 4 function Press torch switch down shielding gas begins to flow Release the switch up welding is started as above Welding is continued when the switch is released Press the switch again down welding is continued Release the switch up welding is stopped as above Stopping unintentional start With spark ignition If arc is not ignited e g torch has not been directed towards work piece ignition spark will go out within s from pressing down the torch switch If eletrode is fastened on the work piece when the torch is pressed down welding current will be switched off immediately and there comes no ignition spark With contact ignition If electrode is fastened on the work piece when torch is switched down and electrode is not lifted off from the work piece welding current is switched off within 1 s 3 1 4 Adjustment of control unit lt P Adjustable operation is selected with arrow keys welding current current FT down slope time or post gas time With and keys parameters time or current are adjusted to higher or lower values Adjustment speed is growing during adjustment 12 PROTIG 410 0537 KEMPPI OY 3 1 5 Parallel control unit for welding current Controlling is directed only on welding current in which case changing current is rapid in ope r
4. automatics you don t need to change times in many welding cases when you change current 3 2 4 Controls for pulsed TIG welding H32 H31 H33 H34 H35 P31 Select TIG welding Demo 2 function switch operation and pulsed welding S24 2 Adjust welding parameters as above in point Controls for continuous welding Automatics of unit set pulse parameters automatically according to start values in storage Automatics of unit calculate a new average value for current when pulse values are changed Automatics make the operations in that way easier that you need not always adjust again other parameters of pulse when pulse or mean current value is changed 3 Adjust pulse values in turns by going with arrow keys S27 to required adjustment point pulse current H31 pulse ratio H32 cycle time H33 and pause current H34 Control values can be seen in display P31 However it is impossble to distinguish separate pulses from arc during rapid pulse cycle times 2 4 8 and 16 ms controls are working in the normal way Welding of thin materials can be considered as one application because there directing arc to narrow range is very important or if slow transportation speed is necessary 16 PROTIG 410 0537 KEMPPI OY nnn 3 2 5 Controls for fusion spot welding 1 Select TIG welding Demo 2 function operation and fusion spot welding S24 2 Adjust welding parameters as above in point Controls for continuous welding 3 Go with arrow
5. help to ensure trouble free operation 6 1 WELDING TORCH Due to high temperatures and wear the welding end of TIG torch requires most maintenance but also condition of other parts should be checked regularly Welding end Check that all insulations of welding end are undamaged and at their place gaz nozzle is undamaged and suitable for work flow of shielding gas is free and even electrode is undamaged Use electrode size and tip sharpening angle which is suitable for welding case Make sharpening grinding lengthwise of electrode fastening parts of electrode are undamaged and electrode is fastened tightly at ist place KEMPPI OY PROTIG 410 0537 19 N ee Torch cable Check that insulations of handle and torch cable are undamaged there are no sharp bends in torch cable Replace damaged parts immediately by new ones Follow in all maintenance and reparation measures instructions given by torch manufacturer 6 2 CABLES Check the condition of welding and connection cables daily Don t use any damaged cables Make sure that the mains connection cables in use are safe and according to regulations The repair and mounting of mains connecting cables must be carried out only by an authorised electrician T OPERATION DISTURBANCES The most usual operation disturbances Arc is not ignited Cable is loose or there is a bad connection Electrode of torch is highly oxidized gr
6. level H43 with keys Reading will come to display P42 5 Stop welding with long pressing when releasing switch you go to down slope current and post gas time You can start down slope from any point operation cycle you like 3 2 7 Breaking down slope operations 2m In 2 function position of torch switch welding current begins to slope down when torch switch is released If you press the torch switch again current begins to slope up Em in its maximum to the reference value with the same speed as it was earlier sloping down With the operation the slope down can be controlled without interfering the SA down slope time In 4 function and Minilog positions the respective operation can be produced by short pressing of the torch switch Current down slope can also be stopped to value of that moment by keeping the switch pressed down When the switch is released current down slope is continued until the down slope time is at end KEMPPI OY PROTIG 410 0537 17 hee 3 2 8 Program storing of Selectotig m EMORY The unit has as standard 20 channels For all channels there are stored reference values which you can change and store as changed Numeric channels are channel numbers from 0 to 9 without dot Dot channels are CHANNEL channel numbers from 0 9 with dots a r Ranges from 0 to 4 are directly in use to range from 5 to 9 and back you can get with T long pressing of CH key S51 Dot channels
7. should be used to store values which you would like to keep in storage more permanently You can store values of dot channel only in Demo state S22 Welding takes always place on respective numeric channel to which you go automatically from respective dot channel or with CH key Dot channel values are copied only to respective numeric channel and destroy previous values when you start welding from this dot channel 3 2 9 Programming of numeric channels On numeric channel there are always the last welded values The storing is made by welding automatically always when the post gas time begins after normal stopping Reference values don t get lost even though you cancel the welding program made by you in the below mentioned way 3 2 10 Programming of dot channels 1 Select dot channel number and dot or numeric channel with key CH 2 On dot channel Carry out necessary controls and selections S22 in Demo position You cannot make storing in position for spark or contact ignition On numeric channel If you want to store the welding values used by you permanently you can go to Demo state and store the values as in point 3 in which case the values are stored on corresponding dot channel 3 Start the program with torch switch to welding current and press key CH when capital letter P comes to CH display P51 4 Go over to weld stop from torch switch and wait until the post gas time begins Your pro gram has been stored to dot channel
8. 0 RIOF Remote control cable Start extension cable Return current cable MMA welding cable TTK welding torch TTK 130 4m 627063004 8m 627063008 16m 627063016 TTK 220 4m 627072004 8m 627072008 16m 627072016 TTK 2205 4m 627072304 8m 627072308 16m 627072316 Intermediate cable 50 1 G Intermediate cable 50 10 GH Procool 10 Procool 30 P30W P 40 P40L Intermediate cable 50 1 W Intermediate cable 50 10 WH Promig 501 Promig 501 L Promig 511 Promig 530 Promig 501 Protig TTK 130F 627063104 627063108 627063116 TTK 300W 627080504 627080508 627080516 Intermediate cable PROTIG MIG 501 III W Promig 511 Protig Intermediate cable PROTIG MIG 511 III W KEMPPI OY 10m 10m 5m 50 mm 5m 50 mm TTK 160 627066004 627066008 627066016 TTK 350W 627085504 627085508 6270855 16 1 m 50 mm 10 m 50 mm 1 m 50 mm 10 m 50 mm Im 50 mm Im 50 mm 6271261 6131320 6131420 6131520 6185409 6185419 6185406 6185481 6185482 6184511 6184501 TTK 1605 627066204 627066208 627066216 TTK 250WS 627075704 627075708 627075716 6271906 6271913 6262012 6262016 6185262 6185264 6185264L 6271907 6271914 6232501 6232505 6232511 6232530 3135780 3135790 PROTIG 410 0537 21 10 TECHNICAL DATA Protig 410 Working voltage safety voltage Rated power Max load 60 ED 100 ED Pressure endurance of gas hose Connection of gas hose Weldin
9. 501 511 530 R10 R20 22b Pro 3200 4200 5200 Power source Procool 10 30 Cooling liquid circulation unit Promig 501 511 530 MIG MAG wire feeder PROCOOL 10 PROCOOL 30 230 V 1 PRO 3200 PRO 4200 PRO 5200 ld Control cable 5 Cooling liquid hose R3 8 Snap connector 5b Cooling liquid hose Snap conn Snap conn 5c Cooling liquid hose Bridge element 8 Shielding gas hose Snap connector 0 9a Welding current cable 16d Extension cable for remote control 17d Start extension cable 20 Earth cable 21 MMA welding cable 22b Mig gun liquid cooled 23b TIG torch liquid cooled 23d TIG extension cable liquid cooled 6 PROTIG 410 0537 KEMPPI OY nnn 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 container type work pieces Note Fire can break out from sparks even several hour
10. A welding from panel of one or the other unit when remote control for MMA welding is operating from remote control unit which is connected to device in question At welding and at no load of MMA welding also other welding tools are exposed to voltage depending on polarity Be careful that welding tools won t produse any A short circuits 8 PROTIG 410 0537 KEMPPI OY nnn 2 1 9 Remote control units Connect remote control unit as shown in figures on page 4 or 5 Operation of remote control unit is explained on page 19 2 2 INSTALLATION OF TIG MMA EQUIPMENT Fasten earthing press of ground cable carefully preferably direct to welding piece Contact surface of press always should be as large as possible Clean the fastening surface from paint and rust Use in your TIG MMA equipment 50 mm cables Thinner cross sectional areas might cause overheating of connectors and insulations Make sure that the torch being in your use is designed for max welding current needed by you Never use a damaged torch 2 2 1 Choice of electrode and flow amount of shielding gas Use argon as TIG shielding gas Electrode size and shielding gas flow rate are defined by wel ding current size The table below is given only as a guide Welding current Electrode Gas nozzle Gas flow rate A 9 mm 9 mm 415 6 5 8 0 70 150 4 5 6 65 80 95 2 3 SHIELD GAS Ta 0 A Handle gas bottle with care There is a risk for injury if g
11. ILOG operation and control for start current 17 3 2 7 Breaking down slope operations LE 3 2 8 Program storing of Selectotig 18 3 2 9 Programming of numeric channels ek eese nnne nnn nennen nane nnn 18 3 2 10 Programming of dot channels i ie Ee Re RR EE ee ee ee RR Ee ee ee ee RR nnn ee ee 18 d ACCURACY OF PANEL DISPLAY iese cates ed Ge ee eo Nee Ge oe dee S E Oe ee Ku ee ees ed 18 5 REMOTE CONTROL UNIT EE redeat n ee du tics eenden dat auia headed ade 19 6 MAINTENANCE esiti ads tanend iut manut cup dente o dp eis tcu eiue GE UU ER uU eain 19 6 1 V Lilo Inte TONG g NRI RTL TE 19 6 2 Ola cc DIT 20 T OPERATION DISTURBANCES 5 2 0 ee ee SN gee UD EUER dennen UE nah YE Fa Les van ee ee YA ew eed 20 8 DISPOSAL OF THE MACHINE Es EO Ee nn rte ee ee dec VA POOR tte 20 9 ORDERING NUMBERS ii SEE nn C n ENG ES Siva Ra A ESE REG Ee Oe Gee ER ORE Ne ee De 21 10 TEGHNICAL DATA tesi cantus iunt er Ge GE tt o pe ee Ge E 22 11 TERMS OF GUARANTEE ee nine nn nine LER i 23 2 PROTIG 410 0537 KEMPPI OY nnn 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 mainten
12. Operation instructions english Gebrauchsanweisung deutsch Gebruiksaanwijzing nederlands Manuel d utilisation francais PROTIG 410 1927340E 0537 GEMPo V KEMPPI The Joy of Welding CONTENTS 1 PR PARER E eM EE Ge GE GE OE N de die 3 1 1 mMrOdUCION EE E TO OT 3 1 2 PFOGUGCE IMMOOUCION EE RE r Ea o a o 3 1 2 1 Operation control and connectors Ee ee ee ke ee sana ee 3 1 2 2 ACCESSONES and Cables m d 5 1 8 Operation SIEN RE mec 7 2 INSTALLATION pe NE GE EG EG Ee Eg ee Ee OO oe ie ee ee Dei ge Nee oe Ge were 7 2 1 Assembly of TIG MMA equipment css Haein cst ette nacer e eed es cd ee ecw es 7 2 1 1 Installation of pow r SOUFGO ite ie one E ERG Ee GE denderen Eene 7 2 1 2 Assembly of transport wagon and mounting of Pro power source to wagon esse 7 2 1 3 Mounting of Protig 410 unit onto the power source 7 2 1 4 Mounting of Protig 410 control panel 8 2 1 5 COMMCE HNO tables suce ete ento tet a e enit ue eene 8 2 1 6 Connecting torch and extension cable 8 2 T T Use as ermina UE MERE Em 8 2 1 8 Assembly and controls of MIG TIG MMA equipment 8 2 1 9 Remote contel UNIS mr seine dde descendre see dessein os 9 2 2 Installation of TIG MMA equipment sis 9 2 2 1 Choice of electrode and flow amount of shielding gas 9 2 3 Shielding 0 AS NETTE TED TET TL TU ENTE 9 2 3 1 Installiig das DONO beoe err a iudei doleo tit eee 9 2 4 M
13. ain Swen ie Pe X Si id ie Ee ne Se nu 10 2 0 Operation of cooling unit Procool 10 30 10 3 OPERATION OF PANELS tiid Ge EER ESE ee ae nes cas 11 3 1 Control panel TE 62171299 te cetera tuna edu eed im blu ea LU oce N ee 11 Add Selection of MMA TIG welding 11 3 1 2 Selection of TIG ignition method 11 Sl Selection of torch switch operation VV 12 3 1 4 Adustnent or contorn ERR Es 12 du 45 Parallel control unit for welding current ee ee ke ee ee ee 13 3 1 6 Pre gas time display and current up slope time display 13 3 1 7 Display of current down slope time 13 3 1 8 Display OF DOSE aas WIIG eoe tne EE e te Loi a austr at eat eno apo nea 13 3 1 9 Display Or welding CUITert RE EE Ee ER as REY atu EE EE RE DE oe ee 13 3 1 10 Local and remote control of welding current 13 3 1 11 Controls Tor TIGWeldiNg ssr n pa cue sc n pex a oren tante 13 3 1 12 Controls for MMA WOIGITIO s si vtro qe oe RE tenen vira e Dope pitis 14 3 2 Control panel EN 627 1260 dai EORR tea oe bennen ae rea Dea Ne eneen 14 3 2 1 Control ranges for time and per cent 15 3 2 2 Demo Learning and control state 15 3 2 3 Controls for continuous welding esses eese 16 3 2 4 Controls for pulsed TIG welding Ee ER EE ee ER EE EE ee ee ee RE Ee ee ee ee RR Ee nna nns 16 3 2 5 Controls for fusion spot welding unu ER EE eese nnns 17 3 2 6 MIN
14. ance 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 AN 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 Protig 410 is a TIG ignition unit for demanding professional use The unit is controlled by means of a microprocessor and ignition spark is generated by means of thyristors These operation instructions are for Protig 410 ignition unit assembly and installation of TIG equipment as well as panel functions In addition instructions describe assembly of Mig TIG MMA equipment cables and main operations of installation 1 2 1 Operation control and connectors Start connection of torch Air cooled torch Liquid cooled torch Cooling liquid connection welding torch X16 X15 XIS Switch for air liquid cooled torch X14 X11 Welding current connections Supply X17 X12 Welding current connections Supply X13 Earth connection X13 X14 Connection of welding torch X15 Connection for c
15. as 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 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 3 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 KEMPPI OY PROTIG 410 0537 9 Parts of gas flow regulator Gas bottle valve Press regulation screw Connecting nut Hose spindle Jacket nut HOO W gt Gas bottle pressure meter G Gas hose pressure meter The following installing 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 impurities from the bottle valve Turn the press regulation screw B of the regulator until no spring pressure can be felt Close needle valve if there is one in the regulator Install the regulator on bottle valve and tighten connecting nut C with a wrench Install hose spindle D and jacket nut E into gas hose and tighten with hose clamp ON tn A N Connect the hose with the regulator and the other end with the wire feed unit
16. ation mode Control unit is operating in parallel with key S39 on right lower corner of panel if welding current is adjusted from them Parallel control unit cannot be used for adjusting times or per cents 3 1 m Pre gas time display and current up slope time display EL Control ranges are 0 9 s BLEUE uH No N Control range is 0 30 s TITIT i 11 3 1 8 Display of post gas time E E Control range is 0 99 s 3 1 9 Display of welding current 3 1 7 Display of current down slope time On no load the meter shows set value of welding current and at welding true value A 3 1 10 Local and remote control of welding current REMOTE Local control is carried out from keys Remote control unit R10 can be E put into operation by pressing the selection key for remote control PEDAL 3 1 11 Controls for TIG welding TL REMOTE LOCAL Starting situation Torch is switched but start switch EES vba is not pressed Select TIG welding ne 2 Select spark ignition 3 Select 2 function position j N i 4 Press one or the other of arrow keys until light PERIGEE PEPER aera H23 will be lighted 5 Press the or the key and adjust the needed current value to display P23 You can test suitability of current by welding and adjust current again if necessary 6 Press arrow key once to right until lamp H24 will be lighted Adjust the down slope time as suitable Seconds are displayed in P24 7 Press aga
17. be continued to the end of the original guarantee period KEMPPI OY PROTIG 410 0537 23
18. ent functions You can go to available controls by selected welding mode It is indicated by pilot lamp in which stage of operation flow chart you are now and which parameters can be controlled by you KEMPPI OY PROTIG 410 0537 15 3 2 3 Controls for continuous welding H22 H23 H24 H25 mn ve P22 P24 P25 1 Select Demo 2 function switch operation and continuous welding S24 Adjust welding current with parallel control S29 or go over to adjustment for welding current with arrow keys S27 and adjust current with keys S28 Reading will be visible in display P23 Go with arrow keys S27 to pre gas point H21 Adjust pre gas time P21 with keys S28 Go to up slope point of current H24 Adjust up slope time P22 with keys Go to down slope point of current H24 Adjust down slope time P24 with keys Nn 4 Lo Go to post gas point H25 Adjust post gas time P25 with keys By pressing the torch switch you can go through the whole operation cycle and after that go to welding by selecting the ignition mode You can use as operation models of torch switch also the 4 function and Minilog operations Note the up and down slope times changing with current control and adjust when necessary If arc is not ignited within s from start the unit will automatically go to stop without timing Values of up and down slope times change automatically when set values of welding current are changing Due to
19. ey Sharp again lengthwise Check that post gas time is long enough Check ignition by using pre gas e g by 4 function operation of torch There are impurities in shielding gas moisture air Protective hose of torch is broken and ignition spark is escaping from elsewhere than from eletrode of torch Torch or extension cable is wet There are leakages due to moisture or dirt in connectors or cables of Protig 410 unit At low current too big or blunt electrode If with operation disturbances there comes to current display continuously error code in form E number take contact with Kemppi service work shop and tell them also above mentioned error code 8 DISPOSAL OF THE MACHINE ex Do not dispose of electrical equipment together with normal waste R In observance of European Directive 2002 96 EC on Waste Electrical and Electronic Equipment and its implementation in accordance with national law electrical equipment that has reached the end of its life must be collected separately and returned to an environmentally compatible recycling facility As the owner of the equipment you should get information on approved collection systems from our local representative By applying this European Directive you will improve the environment and human health 20 PROTIG 410 0537 KEMPPI OY nnn ORDERING NUMBERS Protig 410 Kemppi Pro Evolution 3200 Kemppi Pro Evolution 4200 Kemppi Pro Evolution 5200 R10 R2
20. g cable connectors Torch connection adapter Operation temperature range Storage temperature range Temperature class Degree of protection Dimensions length width height Weight 50 VDC 50 W 400 A 310 A 600 kPa max snap connector DIX 70 Multi function 20 40 C 40 60 C B 130 C IP 34 615 mm 260 mm 400 mm 17 kg The product meets conformity requirements for CE marking D P 34 means that the device is protected against water coming from any direction directly or splashing Control panels Main operations of Protig 410 panels TL and TX are in enclosed table Spark ignition Contact ignition 2 function 4 function torch operation Fusion point timer Pulsing Minilog operation Up slope timer for current Down slope timer for current Selectotig memory channels Current display digital 22 PROTIG 410 0537 TL 6271265 TX 6271266 yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes KEMPPI OY nnn 11 TERMS OF GUARANTEE Kemppi Oy provides a guarantee for products manufactured and sold by them if defects in manufacture and materials occur Guarantee repairs must be carried out only by an Authorised Kemppi Service Agent Packing freight and insurance costs to be paid by orderer The guarantee 1s effected on the date of purchase Verbal promises which do not comply with the terms of guarantee are not binding on guarantor Limitations on
21. guarantee The following conditions are not covered under the terms of guarantee defects due to natural wear and tear non compliance with operating and maintenance instructions connection to incorrect or faulty supply voltage including voltage surges outside equipment spec incorrect gas pressure overloading transport or storage damage fire of damage due to natural causes 1 e lightning or flooding This guarantee does not cover direct or indirect travelling costs daily allowances or accommodation Note Under the terms of guarantee welding torches and their consumables feeder drive rolls and feeder guide tubes are not covered Direct or indirect damage due to a defective product is not covered under the guarantee The guarantee is void if changes are made to the product without approval of the manufacturer or if repairs are carried out using non approved spare parts The guarantee is also void if repairs are carried out by non authorised agents Undertaking guarantee repairs Guarantee defects must be informed to Kemppi or authorised Kemppi Service Agents within the guarantee period Before any guarantee work is undertaken the customer must provide proof of guarantee or proof of purchase and serial number of the equipment in order to validate the guarantee The parts replaced under the terns of guarantee remain the property of Kemppi Following the guarantee repair the guarantee of the machine or equipment repaired or replaced will
22. in arrow key and H25 will be lighted Adjust post gas time as suitable Seconds are displayed in P25 8 Keep pressing the arrow key and adjust the pre gas time and current up slope time correspon dingly H21 ja H 22 Breaking of down slope time at 2 function of torch is done by pressing down the switch when current starts to go up to set value with the same speed with which it had gone down At 4 fun ction down slope of current is stopped when torch switch is pressed down and down slope ope ration will be continued by releasing the switch Intermittent up and down slope operations are produced by pressing the switch for a short time KEMPPI OY PROTIG 410 0537 13 3 1 12 Controls for MMA welding TL Sa KEMPP A PSLOPE T DOWNSLOPE S S Select the MMA welding 2 Adjust with the keys current needed Set value can be seen in display P23 on no load At welding the display shows welding current When the light H26 for remote control is lighted you can control welding current from remote control unit R10 Don t forget to change polarity of welding current by changing connection of cables as shown in figures on page 4 or 5 3 2 CONTROL PANEL TX 6271266 H26 P23 S29 TX vs GIEEMPPI The Joy of Welding REMOTE m PEDAL DOWNSLOPE Ni P25 S28 S21 822 823 824 SSI P51 S27 Read following paragraphs in operation instructions for panel TL Selection of MMA TIG welding S21 Selectio
23. ions of the liquid circulation system and protection against torch etc damage 10 PROTIG 410 0537 KEMPPI OY 3 OPERATIONS OF PANELS 3 1 CONTROL PANEL TL 6271265 H26 P23 P24 P25 The Joy br Welding PEDAL H24 P21 N C i H22 H25 RONDEN S S p22 S28 S21 S22 S23 S27 Selection of MMA TIG welding S21 Selection of TIG ignition method S22 Selection of operating mode of torch switch S23 Selection of adjustable parameter S27 adjustment of selected parameter S28 Display for pre gas time P21 Display for current up slope time P22 Display of welding current P23 Display of down slope time of current P24 Display of post gas time P25 Led lamp is illuminated to show those selections and operations which are used 3 1 1 Selection of MMA TIG welding Don t forget to change polarity of voltage when you go over from one method to another TIG welding generally in torch MMA welding generally in eletrode holder see connection on page 4 or 5 3 1 2 Selection of TIG ignition method Contact ignition Spark generation is prevented and arc will be ignited as follows 1 Touch work piece with an electrode 2 Start power source with the torch switch 3 Lift electrode off from work piece in which case arc will be ignited If arc is not ignited within 1 s the ignition must be repeated Scratch ignition is not recommended Control of ignition spark Spark p
24. keys S27 to fusion welding point H35 Adjust spot welding time P31 with keys S28 Spot welding is working also in 4 function position then torch switch needs not be pressed until at start 3 2 6 Minilog operation and control for start current H42 H41 H43 P41 P42 Operation of Minilog is based on two pressings of different length short and long over 0 7 s on torch switch With long pressing you make first the gas to flow When the switch is released you go through pre gas time and up slope current to start current when lamps H41 and or H42 are lighted If start current has been adjusted onto different value from welding current you go to welding current with short pressing If start current is the same as the welding current you go directly to welding current without any additional pressing After that you can alternate with short pres sings between welding current and basic current levels Select TIG welding Demo Minilog operation S23 and continuous or pulsed welding 2 Adjust the welding parameters as above in point Controls for continuous welding 3 You can adjust start current value with keys S28 either to lower or higher value by means or display P41 Control range for start current is approx 30 150 of welding cur rent value When upper pilot lamp H41 is lighted there is in display reading exceeding 100 When lower pilot lamp H42 is lighted there is in display reading under 100 Adjust basic current
25. n and mounting of Pro power source to wagon P20 6185261 air cooled TIG equipment P30W 6185262 liquid cooled TIG equipment P40 P40L 6185264 6185264L air cooled TIG equipment Lifting of wagon together with bottle is forbidden due to safety reasons 2 1 3 Mounting of Protig 410 unit onto the power source figure page 4 Lock the Protig unit carefully as shown in fig onto pro power source Loose unit A might cause a danger situation KEMPPI OY PROTIG 410 0537 7 N 2 1 4 Mounting of Protig 410 control panel TL 6271265 TX 6271266 2 1 5 Connecting cables Follow enclosed figures Air cooled equipment on page 4 Liquid cooled equipment on page 5 When connecting cables take into consideration the fact that the most generally used polarity in TIG welding is the torch and ground cable In MMA welding the polarity is generally on the contrary Electrode holder Follow instructions as shown on page 4 and 5 when changing welding method 2 1 6 Connecting torch and extension cable Connection to the Protig 410 unit is shown on page 4 air cooled torch and on page 5 liquid cooled torch Tighten connector of torch carefully in order to avoid heating contact disturbances and mechanical damage of connector as well as gas leakage to inside of connector Check by connection of water and gas hoses that there is no dirt metal powder or other waste Waste might cause blockage of water circulation throughburning of torch
26. n of TIG ignition method S22 Selection of operation mode of torch switch 823 Operation of control unit S27 S28 Display for post gas time P25 Local and remote control of welding current H26 Welding current display P23 Controls for MMA welding 14 PROTIG 410 0537 KEMPPI OY nnn In panel TX there are also following operation and controls Demo learning and control state Controls for continuous welding Controls for pulsed TIG welding Controls for fusion spot welding Minilog function and control of start current Breaking the down slope operations Program storing of selectotig 3 2 1 Control ranges for time and per cent Pre gas time 0 9 s Current up slope time 0 9 s Start current 30 150 Minilog basic current 10 90 Pulse ratio 10 80 Length of cycle 0 002 4 s max 500 Hz Pause current of pulse 10 80 Spot welding time 0 9 s Current down slope time 0 30 s Post gas time 0 99 s Minilog pressing short less than 0 7 s long more than 0 7 s Per cent values of table are calculated from control value 3 2 2 Demo Learning and control state 1 In demo state coming of ignition spark and gas are stopped All other controls ope zm rate as during welding Basic controls for current times and per cent can be carried ye out safely in this state and after that you can go over to welding using either spark or contact ignition Use arrow keys when you go over to control differ
27. ontrol cable Pro power source X16 Connection for control cable Procool iin X17 Connection for control cable Remote control unit X11 X18 Start connection Remote control unit KEMPPI OY PROTIG 410 0537 3 Remote control unit R20 R10F PROTIG 410 23b 20 Pro Power source ESE ld Control cable 8 Shielding gas hose Snap connector 0 9 Welding current cable 16d Extension cable for remote control PRO 3200 20 Earth cable 21 MMA welding cable PRO 4200 PRO 5200 23b TIG torch air cooled 21 4 PROTIG410 0537 OKEMPPIOY nnn 1 2 2 Accessories and cables 23c TIG extension cable air cooled 16d EE EET EE NE OLD juan P TS cm pP Remote control unit R20 R10F L ef 1 PROTIG 410 Pro 1d Procool 10 230 V 1 PROCOOL 10 Procool 30 PROCOOL 30 ld 5 0 230 V X16 8 9 3 PRO 3200 PRO 4200 PRO 5200 16d Extension cable for remote control 20 Earth cable 21 MMA welding cable _20 Power source Cooling liquid circulation unit Control cable Cooling liquid hose R3 8 Snap connector Shielding gas hose Snap connector 0 Welding current cable 21 23b TIG torch 23d TIG extension cable KEMPPI OY liquid cooled liquid cooled PROTIG 410 0537 5 ae Sart 17d 10m n n 5m eg lo 0m an 5m Y L L r x18 pg 16d 10m 4 3m BN Y Remote control unit R10 EE a VAE RE me hy EE 20 21 HEER ae PROMIG
28. or stopping or breaking of pump Procool 10 Procool 30 Connect water hoses of torch and interconnecting cable as shown in figure on page 5 These are fixed to tube frame Fix water hoses torch interconnecting cable Procool in such a way that those having red code always are connected to corresponding red counter connectors and the blue ones respectively to blue counter connectors A If connections cross cooling liquid is circulating to wrong direction in torch and torch handle and neck body might be considerably heatened 2 1 7 Use as terminal unit Between power source and the Protig 410 unit are available 10 m interconnecting cables which are inside of mutual power On page 4 are shown following mecanical operations which are involvel in use of unit 2 1 8 Assembly and controls of MIG TIG MMA equipment Connecting cables are shown on page 6 liquid cooled Circulation systems of liquid cooled torches are series connected Read carefully warnings in paragraph 6 Do not forget to change polarity according to paragraph 5 when you go over from MMA wel ding to TIG welding Equipment will automatically select Mig welding method and controls when you press operation switch of Mig gun and respectively TIG welding method when you press switch of TIG torch Remote controls for Mig or TIG welding operate from remote control units which are connected to respective Promig 501 511 530 and Protig 410 units You can select MM
29. ower may cause interference with eletronics equipment which are not properly pro tected If there is interference use contact ignition KEMPPI OY PROTIG 410 0537 11 In order to reduce spark voltage in difficult interference situations take contact with authorized Kemppi service work shop Spark ignition Arc is ignited with high frequency with high voltage spark without touching work piece Use of torch switch starts spark generation Spark strikes from electrode to work piece and arc is ignited Welding current is immediately set at set value Spark distance shielding gas flow and current through earthing press have a profound effect on igni tion If arc is not igniteed within 1s the ignition must be repeated A Be careful that the torch tip is not touching near skin clothes or components which are sensitive for damage like panels connectors or switches 3 1 3 Selection of torch switch operation 2 function After having pressed torch switch down shielding gas starts to flow Welding starts after ca 0 3 s pregas time welding current goes immediately up to current level according to settings When you release torch switch up welding current begins to go down smoothly and current is cut off after time defined by down slope time When welding cur rent is zero there begins post gas time Tack weld automatics with 2 function if welding time was less than 3s there won t come any down slope time
30. s 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 precautions when welding metals which contain lead cadmium zinc mercury or beryllium 2 INSTALLATION 2 1 ASSEMBLY OF TIG MMA EQUIPMENT Assemble the equipment in below mentioned order and follow mounting and operation instruc tions which are delivered with packages 2 1 1 Installation of power source Connection of mains cable and mounting operations as well as change of plug should only be carried out by a competent electrician Read paragraph Installation in operation instructions 1913130 for Pro power sources and carry out the installation according to that 2 1 2 Assembly of transport wago
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