PRODUCT CATALOGUE. English 2004

Transcription

1 PRODUCT CATALOGUE English 2004

2 Kemppi Oy P.O. Box 13 FIN LAHTI FINLAND Tel Fax Kemppi (U.K) Ltd. Fraser Road Martti Kemppi Building Priory Business Park Bedford MK443WH ENGLAND Tel Fax Kemppi Welding Machines Australia Pty Ltd P.O. Box 404 (2/58 Lancaster Street) INGLEBURN NSW 2565 AUSTRALIA Tel Fax Kemppi Product Catalogue 2004

3 KEMPPI OY The challenge of joining metals by electric arc has been the driving force in developing Kemppi welding machines. Throughout the history of more than 50 years Kemppi is a recognised technology leader. Our aim is to provide the customers with modern, efficient production equipment, with high quality features benefiting the users with reliable easy-to-use equipment The Joy of Welding. Today we offer a complete range of electric welding machines for MIG/MAG, MMA and TIG methods. Our range of products extends from simple weld anywhere MMA power sources to a sophisticated range of multi-process welding sets. Since the beginning of its foundation Kemppi has invested a lot in research and development of welding equipment. This work is benifiting many satisfied customers who repeatedly trust our product reliability and performance to get the job done. Our enthusiastic and innovative approach to technology and product development continuously presents new more powerful and intelligent solutions to the everlasting problem of increasing welding quality and productivity. This is the foundation of Kemppi s customer commitment as a leading welding brand. Kemppi s task is to look beyond the product. Concentrating on the satisfaction of needs essential to the customer Kemppi product extends beyond machines to include quality service levels, supporting customers to aim for the best. KEMPPI Sverige AB Upplands Väsby / Sweden tel fax KEMPPI Norge A/S Tønsberg / Norway tel fax KEMPPI Danmark A/S Skovlunde / Denmark tel fax KEMPPI Benelux B.V. Breda / The Netherlands tel fax KEMPPI (U.K) Ltd. Bedford / England tel fax KEMPPI France S.A Epone Cedex / France tel (0) fax + 33 (0) KEMPPIKONEET OY Lahti / Finland tel fax KEMPPI OY Lahti / Finland tel fax KEMPPI GmbH Butzbach / Germany tel fax KEMPPI Switzerland AG Crissier / Lausanne / Switzerland tel fax KEMPPI Spolka z.o.o. Zabki / Poland tel fax KEMPPI Welding Machines Australia Pty Ltd Ingleburn /Australia tel fax Kemppi Product Catalogue 3

4 The history of Kemppi arc-welders 1949 Kemppi Oy was founded by Martti Kemppi the 1950 s Export activities were started the 1960 s The first MIG/MAG machines and thyristor controlled rectifiers were developed 1977 Kemppi introduced the world-first series-produced multi-process inverter power source Hilarc 250 at the exhibition Schweißen & Schneiden in Essen the 1980 s New inverter generation, including the first IGBT-inverters for MMA- and TIG welding 1990 Kemppi was the first manufacturer of welding machines to receive the ISO 9001 Quality Certificate of Det Norske Veritas 1993 The first digital inverter generation was introduced at the exhibition Schweißen & Schneiden in Essen 1997 Kemppi presented the AC / DC -welding machines, the sixth generation of IGBT - technology 2001 Seventh generation of inverter welders was presented KEMPPI WELDING EQUIPMENT Kemppi Oy is committed to technical excellence that is testified with ISO 9001 quality management system received already in 1990 and ISO environmental management system since All Kemppi welding machines and accessories have CE marking. CE mark indicates that a product complies with all European directives and essential harmonized standards for health, safety, environment and consumer protection that may apply to that product. Kemppi welding machines are designed and manufactured by Kemppi Oy in Finland in conformity with following IEC and EN-standards: EN IEC EN IEC / EN IEC / EN IEC / EN IEC / EN Safety requirements for arc welding equipment Part 1 Welding power source Electromagnetic Compatibility (EMC) Welding power source - Part 2: Liquid cooling systems Welding power source - Part 5: Wire feeders Welding power source - Part 7: Welding torches Welding power source - Part 10: Electromagnetic Compatibility (EMC) Requirements Critical electronic components are carefully selected and tested by Kemppi in accordance with Kemppi s own standard requirements. Electronic units are manufactured and tested by Kemppi. After final assembly all machines are tested in Kemppi s production. Kemppi s production department keeps test files available for 10 years. Kemppi s mission is that Customers rank Kemppi s products and services to be the best on the market. Operating temperature Kemppi welding machines have a wide operation temperature from -20 C to +40 C, so machines are suitable for even the extreme conditions. 4 Kemppi Product Catalogue 2004

5 Degree of protection Degree of protection for Kemppi machines is IP 23C. IP classification, degree of protection is shown as two figures: The first figure 2 indicates guarding protection during operation and handling for solid bodies with a diameter bigger than 12 mm. The second figure 3 indicates equipment is protected against water spray falling at up to 60 degrees from the vertical. Duty cycle Rated power of Kemppi welding machines is given as amperage based on the duty cycle percentage. The duty cycle has been tested and its performance characteristics are given for the temperature of +40 C. Therefore the actual duty cycle value can be higher in normal room temperature. Duty cycle 60% means 6 min arc time and 4 min rest time. Kemppi ICS (Isolated Cooling System) In Kemppi s inverter power sources, a significant amount of heat is generated by the power semiconductors attached to the cooling elements, the transformer and the chokers. In order to guarantee reliability and optimal safety, the internal temperature of the machine has to be kept low. In Kemppi machines component heat output is moved to the air flowing through the equipment by means of a fan. Kemppi s welding inverters use modern electronics to control the welding process, to guide the power source and to improve interface usability. Best of all, these components require no fan cooling. Welders work under dusty, dirty and damp conditions in which equipment is constantly being subjected to hard mechanical stress. In response to this challenge, Kemppi has developed the Isolated Cooling System ICS to improve the reliability of Kemppi welding equipment and to minimise maintenance. With ICS it is possible to maintain low component temperatures by directing the cooling air only through those power components that need cooling and by preventing the cooling air from reaching the electronic circuit cards. ICS switches the cooling fan on only if heat is generated in the power components. The end result is less dirt inside the machine, less maintenance. Kemppi MLS (Multi Logic System) The Multi Logic System (MLS ) is Kemppi s answer to growing need for high-quality welding user interfaces. With MLS it is possible to adapt the welding equipment to the welding job to the needs of the welding company. Exchangeable and clear panels allow the welder to input the current welding functions into the characteristics of the welding equipment. The same panels can be used with numerous power sources. The panel features have been selected carefully based on the needs of welding applications and customer companies worldwide. The MLS concept is based on flexibility and updatability. Modern digital technology is used to guide both the power source operations and the operating panels. The data transfer between the power source and the panel takes place in a fast digital channel. The visible user interface (displays, controls, switches) hides versatile Set Up functions that ensure panel functions comply with different welding needs without jeopardising usability. MLS makes it possible to solve future needs without having to replace the product. The characteristics of the present panel functions are changed and developed by adapting the software Kemppi Product Catalogue 5

6 Contents Kemppi Oy 3 Kemppi welding equipment 4 MIG-welding Migger, Super Migger, Migger Kempomat 2100, 2500, 3200, 4000, 1701, 2001, Kempoweld 3200, 3200W, 4000, 4000W, 5500W, Wire 200, 400, Kempomig 3200, 3200W, 4000, 4000W 16 Feed Kemppi Pro Evolution 3200, 4200, Promig 501, 501L, 511, Promig 100, 200, 300 and Procool 10, Operation panels for Promig 21 Wire feed rolls 22 Consumable parts of wire feed mechanism 23 TIG-welding Mastertig 1500, Mastertig MLS 2000, 2500, 2503, 3500, Operation panels for Mastertig MLS 30 Mastercool 10 and Kemppi Pro Evolution in TIG-welding: Protig Operation panels for Protig 33 Mastertig AC/DC 2000, 2500, 2500W, 3500W 34 Operation panels for Mastertig AC/DC 35 MMA-welding Minarc 110, Master Master Master MLS 1600, 2500, 2503, 3500, Operation panels for Master MLS 43 Kemppi Pro Evolution in MMA-welding 44 Operation panels for Kemppi Pro Evolution in MMA-welding 45 6 Kemppi Product Catalogue 2004

7 Kemppi Pro Data Monitoring Kemppi Data Monitoring 46 Robotics Promig 520R/120R 48 MIG-guns MT MIG-guns 50 MMT MIG-guns 51 KMG MIG-guns 52 WeldSnake 53 PMT MIG-guns 54 Common features in PMT, MMT and WeldSnake 55 Common features in all Kemppi MIG-guns 56 Consumable parts 57 Liners for MIG-guns 61 Contact tips 61 KMP Kemppi Push-pull guns 62 TIG-torches TTK torches 64 TTC torches 65 TIG-torches represent top quality properties 66 Consumable parts 67 Consumable parts table 69 Scratch-start TIG-torches 70 Welding accessories Cables 70 Kemppi Datamaster 71 Remote control units 72 Welding equipments 74 Transport units 76 Alfa-welding helmet 78 Beta-welding helmet 79 Betafresh Kemppi Product Catalogue 7

8 MIG-WELDING 8 Kemppi Product Catalogue 2004

9 Kemppi Pro Evolution Synergic Pulse-MIG Kempomig - Multifunction MIG/MAG Kempoweld - basic step controlled MIG/MAG With separate feeder Kempomat - Compact step-controlled MIG/MAG Migger, Super Migger - Semi-professional MIG INCREASED FEATURES AND BENEFITS MIG/MAG welding (Metal Inert Gas / Metal Active Gas) MIG/MAG welding is a semi-automatic welding process, which can produce moderate to high weld metal deposition and is suitable for all positions and material thicknesses. MIG/MAG is the most common welding method nowadays. Wire is fed continuously from a spool. MIG welding is therefore referred to as a semiautomatic welding process. Migger, Kempomat and Kempoweld machines are conventional MIG machines with step control. Kempomig and Kemppi Pro Evolution are inverters having continuous voltage and wire feed speed control in wire feeder. Synergic MIG welding Synergic MIG refers to MIG welding where the user controls welding power with only 1-knob. A synergic MIG welding machine has programmable parameters allowing pre-selected variables to be set and locked. Typical parameters would be material, wire size and gas. Arc length can be regulated separately, depending on joint type and welding position. Kempomig and Kemppi Pro Evolution have Synergic MIG option. Pulse-MIG welding Pulse-MIG is an extension of the standard MIG welding process where short duration and high current pulses are superimposed on the welding current. In this way, spray transfer conditions are established across the entire operating current range of the equipment. Pulse-MIG method is widely used with base materials/wires that are difficult to weld: special steels, aluminium, stainless steels, copper and nickel based alloys. Double Pulse-MIG welding Double Pulse-MIG is a variation of Pulse-MIG welding with alternating Double Pulse-MIG parameters. The main purpose of the double pulse machine is to refine and extend the benefits brought by conventional synergic pulse, with greatly improved weld quality thus simplifying welding. Kemppi Pro Evolution is a multi-process welding machine that can be used for Pulse-MIG and Double Pulse-MIG welding Kemppi Product Catalogue 9

10 MIGGER, SUPER MIGGER, MIGGER 210 Versatile compact MIG welding machines The Migger product range consists of switch controlled compact MIG/MAG machines with reliable 2- wheel wire feed mechanism and original Kemppi gun connector. Technical Data MIGGER SUPER MIGGER MIGGER 210 Connection voltage (V) 1~ % % 1~ % % 3~ % % - - 3~ % % Loading capacity 20 % ED 140A/20V (15%) 150A/21.5V 200A/23V (25%) 60 % ED 70A/17.5V 85A/18.5V 130A/20.5V 100 % ED 55A/17V 76A/17.5V 100A/19V Mains cable/fuse, delayed 3 x m/16a 3 x m/16a 3 x 1.5mm²/10A Filler wires ø (mm) Dimensions (mm) L x W x H 445 x 205 x x 380 x x 392 x 655 Weight (kg) Kemppi Product Catalogue 2004

11 Ideal compact MIG for light repair, maintenance and sheet metal production 1~140/150 Amp, 3~200 Amp Wire reel 20 kg / 300 mm (Migger 5 kg / 200 mm) Reliable and user-friendly Easy-to-use voltage selection Fan-cooled power source and thermal overload protection One-piece body design for maximum strength Perfect arc due to advanced wire feed mechanism and inclined gun angle Versatile functions and design Migger MIG/MAG machines continue Kemppi s long tradition of making superior equipment for welding professionals. These machines have excellent welding characteristics. The Migger series builds on Kemppi s commitment to safe and reliable welding equipment for all welding conditions. A disturbancefree arc is the key to welding machine performance. Order Information Migger (1~ 230 V) Includes KMG 15, 2.5 m, earth cable 16 mm², connection cable 3 x 1.5 mm² 2 m, gas hose 1.5 m Super Migger (1~ 230 V) Includes KMG 17, 2.5 m, earth cable 16 mm², connection cable 3 x 1.5 mm² 5 m, gas hose 1.5 m Migger 210 (3~ 230 V, 3~ 400 V) Includes KMG 17, 3 m, earth cable 16 mm², connection cable 4 x 1.5 mm² 5 m, gas hose 1.5 m Accessory for Migger: ST5 Transport unit Kemppi Product Catalogue 11

12 KEMPOMAT Welding machines with character Kempomat 2100, 2500, 3200, 4000, 1701, 2001 and 2501 The Kempomat MIG/MAG machines are designed for professionals who expect superior performance from their welding equipment. The Kempomat product range consists of 170, 200, 250, 320 and 400 A machines with the latest coiling and rectifier technology to produce excellent welding characteristic for CO 2 and mixed gas MIG welding. Technical Data KEMPOMAT Connection voltage (V) 3~400V % % % % % % % % 1~230V 3~230V % % % % % % % % % % Loading capacity A / V 40 % ED 200/23 (25%) 250/26 (30%) 320/30 400/34 170/21 (15%) 100 %ED 100/19 140/21 205/24 260/27 76/17.5 Filler wires (mm) ø Dimensions (mm) L x W x H 910 x 410 x x 440 x x 480 x x 480 x x 392 x 750 Weight (kg) Kemppi Product Catalogue 2004

13 Easy-to use Kempomats let you focus on the job at hand. Stepless wire feed speed control together with the convenient voltage control is ideal for setting welding values. Kempomats work in all kinds of welding environments, from home, farm, and repair to demanding maintenance and production applications. To get started, just plug in and weld! User friendly Easy to move Versatile Just plug in & weld Technical Data KEMPOMAT Connection voltage (V) 1~240V % % % % Mains cable, fuse delayed 3 x 2.5 mm² / 20A 3 x 4.0 mm² / 25A Loading capacity A / V 30% ED 200/24 250/ % ED 110/ /20.5 Filler wires (mm) ø Dimensions (mm) L x W x H 910 x 420 x x 420 x 840 Weight (kg) Order Information Kempomat 1701 set (incl.230v power source, KMG 20-3 m, earth cable 16 mm², 5 m) Kempomat 2100 set (incl. 230/400V power source, MMT 25-3m, earth cable 25 mm², 5 m) KMAT21003MMT Kempomat 2100 set (incl. 230/400V power source, MMT m, earth cable 25 mm², 5 m) KMAT21004MMT Kempomat 2500 set (incl. 230/400V power source, MMT 25-3 m, earth cable 25 mm², 5 m) KMAT25003MMT Kempomat 2500 set (incl. 230/400V power source, MMT m, earth cable 25 mm², 5 m) KMAT25004MMT Kempomat 3200 set (incl. 230/400V power source, MMT 32-3 m, earth cable 35 mm², 5 m) KMAT32003MMT Kempomat 3200 set (incl. 230/400V power source, MMT m, earth cable 35 mm², 5 m) KMAT32004MMT Kempomat 4000 set (incl. 230V power source, MMT 40-3 m, earth cable 50 mm², 5 m) KMAT40003MMT230 Kempomat 4000 set (incl. 230V power source, MMT m, earth cable 50 mm², 5 m) KMAT40004MMT230 Kempomat 4000 set (incl. 400V power source, MMT 40-3 m, earth cable 50 mm², 5 m) KMAT40003MMT Kempomat 4000 set (incl. 400V power source, MMT m, earth cable 50 mm², 5 m) KMAT40004MMT Kempomat 2001 set (incl. 240V power source, MMT 25-3 m, earth cable 35 mm², 5 m) S Kempomat 2501 set (incl. 240V power source, MMT 25-3 m, earth cable 35 mm², 5 m) S KMW sync (sync. unit for push pull gun) Branch cable MSD-1 meter unit / 3200, GH 20 gun holder Kemppi Product Catalogue 13

14 KEMPOWELD The steel specialists Kempoweld 3200, 3200W, 4000, 4000W, 5500W and 2501 Kempoweld MIG machines are designed for welding professionals who demand superior performance from their welding equipment. Linking an innovative construction and design philosophy with the latest rectifier technology, Kempowelds deliver excellent welding characteristics even in demanding welding conditions. Kempowelds can also be changed according to welding requirements and their wire feed unit can be used separately from the power source. The Kempoweld semi-compact MIG product range consists of 250 (single phase), 320, 400 and 550 A power sources. The 320 and 400 A machines are also available with an in-built water cooling unit. The 550 A machine is always water cooled. Easy to use Compact and reliable Built to heavy duty use Professional performance Technical Data KEMPOWELD 3200, 3200W 4000, 4000W 5500W 2501 Connection voltage (V) 3~230V % 240+6% % 240+6% - 1~220-10% 240+6% 3~400V % 415+6% % 415+6% % 415+6% - Mains cable / fuse delayed V 4 x 2.5 mm² / 20A 4 x 6.0 mm² / 25A - 3 x 4.0 mm² / 25A V 4 x 2.5 mm² / 16A 4 x 2.5 mm² / 16A 4 x 6.0 mm² / 32A - Loading capacity (nominal values) A/V 40% ED 320 / / / 42 (60%) 250 / 26,5 (30%) 100% ED 205 / / / / 20.5 External dimensions (mm) L x W x H 3200: 990 x 530 x : 990 x 530 x x 480 x x 430 x W: 990 x 530 x W: 990 x 530 x 1090 Weight (kg) 3200: 106, 3200W: : 126, 4000W: WIRE Connection voltage (V) 50/60 Hz 30 V AC 30 V AC 30 V AC Loading capacity (Nominal values) 40% ED 400A 400A 550A (60%) 100% ED 260A 260A 430A Filler wires (mm) ø External dimensions (mm) L x W X H 570 x 210 x x 210 x x 210 x 440 Weight (kg) Kemppi Product Catalogue 2004

15 KEMPOWELD WIRE FEED UNITS Steady and disturbance-free wire feed Wire 200, 400 and 550 The efficient Wire 200 wire feeder unit features a 2-wheel-drive. Wire 400 and Wire 550 wire feeder units feature a 4-wheel-drive for a steady and disturbance-free wire feed. The Wire 200, Wire 400 and Wire 550 wire feed units have a stepless wire feed speed control for setting exact welding values. The standard automatic wire feed and wire inch control improve spool change. Wire 400 and Wire 550 feed units have automatic wire inch and adjustment for burn-back time. Wire 550 has ball bearing feed rolls as standard. The wire feed mechanism and wire spool are both housed inside a protective wire feed casing. The wire feed unit can also be attached to the power source to make a compact MIG machine. Disturbance-free wire feed Stepless wire feed speed control Wire inch control Order Information Power sources Kempoweld 3200,230/400V Gas-cooled interconnection cables KW GH Kempoweld 3200W, 230/400V KV GH (with the swing arm) Kempoweld 4000, 230V MULTIMIG 50-5-GH Kempoweld 4000, 400V MULTIMIG GH Kempoweld 4000W, 230V Water-cooled interconnection cables KW WH Kempoweld 4000W, 400V KV WH (with the swing arm) Kempoweld 5500W, 400V KW 50-5-WH Kempoweld 2501 package*, 240V S KW WH Wire feeders Wire 200 (2-roll drive) KW W Wire 400 (4-roll drive) KW 95-5-WH Wire 550 (4-roll drive) KW WH Metering unit MSD-1 V/A (standard / 5500 W) KV WH (with the swing arm) Timer unit KMW (standard in all wire feeders) Branch cable for KMP Sync. unit KMW Sync MIG welding guns MMT page 51 Swing arm KV *Package includes: Wire 200 wire feeder, KMG 25 3m MIG- gun, KW 35-5-GH, 5m interconnection cable, earth cable 5m 2004 Kemppi Product Catalogue 15

16 KEMPOMIG The flexible welding equipment range: Kempomig 3200, 3200W, 4000 and 4000W Kemppi has designed a multifunction range of welding machines for demanding welding needs. The Kempomig machines are ideal for MIG/MAG and MMA welding in which process and applications are continuously changing. Technical Data KEMPOMIG 3200 / 3200W 4000 / 4000W Connection voltage 3~50/60 Hz 400V +10% -15% 400V +10% -15% Mains cable / fuses, delayed 4 x 2.5S / 16A 4 x 2.5S / 16A Loading capacity 40/50% ED 320A/32.8V (50%) 400A / 36V (40%) 100% ED 250A / 30V 250A / 30V Control range (Stepless) MIG 10V - 35V 10V - 40V Max.welding voltage MMA 40V / 320A 40V / 400A Dimensions (mm) L x W x H 940 x 515 x x 515 x 880 Weight (kg) 3200: 46 / 3200W: : 46 / 4000W: 57 FEED 400 Loading capacity 60% / 100% ED 400A / 310A Filler wires (mm) ø Operation principle 4 roll drive Dimensions (mm) L x W x H 570 x 210 x 440 Weight (kg) machine: 15, wire reel: max Kemppi Product Catalogue 2004

17 The Kempomig machines are based on modern 320 A and 400 A inverter power sources: Both machines are available with a built in water cooling unit. The Feed 400 wire feeding system provides precise control in MIG/ MAG welding the key to versatile and reliable welding. Enhanced optional control Smart usability Versatile functions boost productivity Versatile options Kempomig wire feeder Feed 400 The Feed 400 wire feeding system is equipped with features that make adjustment of the welding process quick and easy for flexible and reliable operation. The wire feed mechanism is a 4-roll SL 400 with automatic wire inch. The maximum wire feed speed can be set to 18 or to 25 m/min by selecting the required drive gear supplied with the machine. The Kempomig Feed 400 offers 20 standard programs for synergic 1-knob control. Power adjustment can be made via the control panel or via remote control of the PMT MIG gun. In addition, the Kempomig features a new way for moving rapidly between welding positions. The MIG Minilog function allows you to change the welding power between two levels by pressing the gun trigger. From the Feed 400 s function panel, you can also adjust the MIG welding dynamics for minimal spatter. For synergic 1-knob-MIG welding, the Kempomig Feed 400 case features: Wire diameter selection Material/gas selection Crater filling properties Burn-back time regulation Order Information Power sources Kempomig Gas-cooled interconnection cables, with protective hose Kempomig 3200W KW GH Kempomig KV GH (with the swing arm) Kempomig 4000W MULTIMIG 50-5-GH Wire feed unit Feed MULTIMIG GH Metering unit MSD-1 V/A Water-cooled interconnection cables, with protective hose Remote control unit C 110D KW WH RMT 10 for PMT KV WH (with the swing arm) Sync.unit SYNC 400 for KMP KW 50-5-WH Branch cable for KMP KW WH Gas guard GG Cables MMA cable 5 m - 50 mm Gun holder GH Earth cable 5 m - 50 mm Transport unit P 500 (for Feed 400) Swing arm KV MIG welding guns Kemppi MT and PMT, pages 50, Kemppi Product Catalogue 17

18 KEMPPI PRO EVOLUTION IN MIG-WELDING Digital control with a professional edge: Kemppi Pro Evolution 3200, 4200 and 5200 The ergonomic Kemppi Pro Evolution is compact, lightweight and easy to position with minimum disturbance. The Kemppi Pro Evolution delivers optimal usability and reliability, with standard features such as storing of used welding parameters and automatic thread of MIG wire. Special functions are also easy to select and control. In today s engineering shops, profitability is based on cost-effective production and superior quality. When selecting welding equipment, you have to consider the quality and cost of weld time, the amount of required finishing work, serviceability, as well as the versatility and mobility of the equipment. At Kemppi, we built these factors into our new digital industrial welding equipment generation. The Kemppi Pro Evolution is the most versatile welding system on the market. Thanks to its modular design and excellent adjustability, you can choose the optimal equipment and welding parameters for each welding job. The Kemppi Pro Evolution is easy to install and adjust whatever the application. Pro versatility Intelligent controls Compact power Proven performance Multiple power sources All-purpose wire feeders Technical Data KEMPPI PRO EVOLUTION Connection voltage 3~50/60 Hz % +20% % +20% % +20% Loading capacity 80% % Connection cable, fuse delayed 4 x 6S-5 m /25A 4 x 6S-5 m /35A 4 x 6S-5 m /35A Welding current range MMA 10A 320A 10A 420A 10A 520A TIG 5A 320A 5A 420A 5A 520A MIG 12V 37V 12V 39V 12V 42V Power factor at nominal values Dimensions (mm) L x W x H 530 x 230 x x 230 x x 230 x 520 Weight (kg) Kemppi Product Catalogue 2004

19 KEMPPI PRO EVOLUTION WIRE FEEDERS Promig 501, 501L, 511, 530 all-purpose wire feeders The Kemppi Pro Evolution wire feeders Promigs 501, 501L, 511 and 530 feature a four-roll feed mechanism. This ensures smooth and secure wire movement with thin and soft Al wires or thick and hard solid wires. The automatic wire thread also makes changing the filler wire coil faster. All function panels can be attached to the wire feeders and include time-saving auxiliary functions. Promig 530 has inclined torch angle. The ergonomic swing arm of Promig 511 delivers improved operational range, convenient torch support and torch shielding. Technical Data PROMIG 501, 501L Working voltage (safety voltage) 50 VDC 50 VDC 50 VDC Rated power 100W 100W 100W Max. load (nominal values) 60 %ED 520A 520A 520A 100 %ED 440A 440A 440A Filler wires (mm) ø Dimensions (mm) L x W x H 620 x 230 x x 230 x x 230 x 430 Weight (kg) Kemppi Product Catalogue 19

20 KEMPPI PRO EVOLUTION ON LONG REACH PROMIG Promig 100, 200 and 300 wire feeders Promig 200 and Promig 300 are mobile Kemppi Pro Evolution wire feeders designed for dock yards and heavy metal industry. Promig 100 is a compact and highly portable tandem wire feeder for welding up to 30 meters from the main wire feeder. Procool 10 and 30 cooling units Cooling liquid units Procool 10 and 30 for Kemppi Pro Evolution are designed for cooling MIG welding guns and TIG welding torches in demanding professional use. Operation of Procool 10 and 30 is controlled with microprocessor. Procool 30 is used with trolley P40 and is placed under the power source. Procool 10 is used with trolley P30W. Technical Data PROMIG PROMIG 100 PROMIG 200 PROMIG 300 PROCOOL 10 PROCOOL 30 Mains voltage 50 V DC 50 V DC 50 V DC 230 V 50/60Hz 400 V 50/60Hz Max. load 60% 500A 460A 460A 100% 390A 355A 355A Filler wires to be welded ø Dimensions (mm) L x W x H 575 x 185 x x 230 x x 225 x x 190 x x 230 x 290 Weight (kg) Kemppi Product Catalogue 2004

21 OPERATION PANELS FOR PROMIG MC-operation panel Welding current control Selection of welding method MMA/MIG-dynamics adjustment Storage of welding parameters Display of welding parameters ML-operation panel Control of welding parameters Selector of welding method MMA/MIG dynamics control Pulsed-MIG/synergic MIG control Display of welding parameters MXE-operation panel MMA, MIG/MAG, synergic 1-knob MIG and pulsed-mig welding Gas test Memory channel Double Pulsed-MIG Start options and user tailored parameters Order Information Power sources Kemppi Pro 3200 Evolution Transport units P 30 W Kemppi Pro 4200 Evolution P Kemppi Pro 5200 Evolution P40L (with PSL 55) L Wire feeders Promig P 500 (for Promig 501) Promig 501L (left) Lift hooks for Promig Promig 511 with swing-arm for Promig Promig Intermediate cables for Promig 501, 511, 530 Water hose (Promig 511, 1.6 m) Promig100 tandem feeder Water hose (Promig 501/530,1.0 m) Promig100B special version WH, Promig GH Promig WH Operation panels MC GH ML WH MXE Protig / MIG / W / Water cooling units Procool Protig / MIG / W / Procool Intermediate cables for Promig GH Sync. unit Prosync 50/Promig 100, push-pull gun GH Remote control units R 20 (2-knob) WH RMT 10, MIG gun control WH C 100 T, wireless Intermediate cables for Promig 200, GH External metering device PMU GH Gun holders GH WH GH WH Auxiliary voltage unit PSL 55, 230/380/500 V WH Cables Earth and welding cables, page WH Kemppi Product Catalogue 21

22 WIRE FEED ROLLS All Promig and Wire, FU11, Feed 400 wire feeders, Kempomat 1701, 2100, 2500, 3200, 4000 Wire feed rolls are available for different applications. Plain V groove: Universal feed roll for all kinds of wires Knurled V groove: Special feed roll for cored wires and steel wires Trapezoidal groove with race: For heavy duty and for aluminium welding Gear wheel Ø 28 mm ** m/min Ø 28 mm steel *** * included in delivery ** included in delivery, mounted *** accessory Ø 40 mm * m/min Ø 40 mm steel *** -not FU 11 Washer for changing the feed roll groove * FEED ROLL (L)= BALL RACE Fe Plain V / /1.2 red / black Ss /0.8(L) /1.0(L) red /1.6 (L) yellow blue Al white /1.2 (L) orange /1.2 red / black Fe Knurled /1.2 (L) orange /1.6 (L) yellow blue Fe Trapezoidal 1.2/1.2(L) /1.4 (L) brown /2.0(L) (L) black Fc groove with /1.6 (L) yellow grey Ss ball race orange Al 22 Kemppi Product Catalogue 2004

23 CONSUMABLE PARTS OF WIRE FEED MECHANISM All Promig and Wire, FU11, Feed 400 wire feeders, Kempomat 1701, 2100, 2500, 3200, 4000 Fe Mc Fc mm ø 1.0 mm white mm ø 2.0 mm ** orange mm ø 4.0 mm blue, Wire 550 ø 2.0 mm ** orange, Wire 550 ø 4.0 mm * blue Wire ø 2.4 mm ** plastic ø 4.0 mm plastic ø 4.0mm brass Ss mm ø 2.0 mm * silver ø 2.0 mm * silver ø 2.4 mm plastic Al mm ø 3.0 mm yellow ø 3.0 mm yellow ø 4.0 mm plastic ø 2.4 mm brass / Promig ** yellow * yellow, Teflon * included in delivery ** included in delivery, mounted *** accessory 2004 Kemppi Product Catalogue 23

24 TIG-WELDING 24 Kemppi Product Catalogue 2004

25 Mastertig AC/DC Mastertig - Compact DC TIG Kemppi Pro Evolution - DC TIG with separate HF unit INCREASED FEATURES AND BENEFITS TIG welding (Tungsten Inert Gas) The TIG method with DC (direct current) is used to weld stainless steels, as well as carbon and low-alloy steels. TIG with AC (alternating current) finds its application in aluminium and magnesium alloys. The primary application area for TIG is welding of thin metals < 6mm. TIG welding is a commonly used high quality welding process. In TIG welding the arc is formed between a nonconsumable tungsten electrode and the metal being welded. Gas is fed through the torch to shield the electrode and molten weld pool. If filler wire is used, it is added to the weld pool separately. Kemppi TIG welding machines are inverters. Mastertig, Mastertig MLS and Kemppi Pro Evolution TIG with a separate safety voltage High Frequency unit are DC TIG welding machines, Mastertig AC/DC is an AC/DC welder Kemppi Product Catalogue 25

26 MASTERTIG Mastertig 1500 and 2200 Mastertig TIG product range is built for industrial TIG-welding. The power source is based on high quality Master MMA machines. As the dynamic welding properties are adjustable, it is possible to weld with a wide range of electrodes. Machines have a standard, adjustable gas pre and post flow time, down slope, HF/ contact ignition and 2/4 sequence latching. Technical Data MASTERTIG Connection voltage 1~220V -10% 240V +6% 3~380V -10% 415V +6% Connection cable, fuse delayed 3 x 1.5S - 3m/16A 4 x 1.5S - 5m/10A Welding current range MMA 15A / 20.5V 150A /26V 15A / 20.5V 220A / 28.8V TIG 5A / 10v 150A / 16V 5A / 10V 220A /18.8V Max. welding voltage 31V / 150A 35V / 220A Electrode sizes to be welded (mm) ø (5.0) External dimensions (mm) L x W x H 410 x 152 x x 152 x 385 Weight (kg) Kemppi Product Catalogue 2004

27 The characteristics of the machines can also be tailored with internal settings. These settings include selection of a Minilog function, by-pass for tack welding automatics, setting of the down slope time of the current, and adjustment of the post gas timer. These tailored functions make the Mastertig a real precision tool for improving productivity and welding quality. Special attention has been paid to making the control functions as clear as possible. The opportunities of modern electronics have been combined to extend the ability of the welder, in order to produce high-quality welds in the most varying circumstances. All Mastertig machines have been programmed to deliver a constant and stable welding current. With straight DC, pulse function or the Minilog function combined with pulsed TIG you can attack the most precise welding tasks. Order Information Power sources Mastertig 1500S Extension cables for remote control unit, 10 m Mastertig for remote control unit, 25 m Meter unit MSD-1 V/A for remote control unit, 50 m Remote control unit C 110C for remote control unit C 100F, 10 m C 100D Transport units T C 100F foot pedal T Torches Kemppi TTK, page 64 Cables Welding and earth cables page Kemppi Product Catalogue 27

28 MASTERTIG MLS Welding versatility for professionals Mastertig MLS 2000, 2500, 2503, 3500 and 3503 The Mastertig MLS 2000, 2500 and 3500 offer outstanding TIG performance in the most demanding welding environments. Super-efficient and compact, the Mastertig MLS is designed for professional welders who expect the most from their welding equipment. The Mastertig MLS series builds on the success of Master MLS MMA welding machines. That means you benefit from Kemppi s strong track record in innovative welding technology. Technical Data MASTERTIG MLS Connection voltage 3~ 50/60 Hz 1~230V -10% +10% 400V -15% +20% 400V -15% +20% 230V -15% +10% 230V -15% +10% Loading capacity 30% ED TIG 200A 300A 400A 300A 400A 60% ED TIG 150A 205A 285A 205A 285A 100% ED TIG 130A 160A 220A 160A 220A Connection cable / fuse delayed 3 x 2.5S - 3.3m / 16A 4 x 1.5S - 5m / 10A 4 x 2.5S - 5m / 16A 4 x 2.5S - 5m / 20A 4 x 6S - 5m / 32A Welding current (A) TIG Electrode sizes to be welded (mm) ø mm Dimensions with cooling unit (mm) L x W x H 410 x 180 x x 180 x 390 (650) 500 x 180 x 390 (650) 500 x 180 x 390 (650) 500 x 180 x 390 (650) Weight (kg) Kemppi Product Catalogue 2004

29 Convenient and safe Master performance Premium weld control Compact and portable Less maintenance Unique service channel for troubleshooting ICS technology for minimal particle intake Microprocessor controlled IGBT DC power sources Easy-to-access controls Interchangeable control panels Efficient spark transformer for high frequency ignition with cables up to 50 m The new ICS (Isolated Cooling System) prevents dust and metal particles from penetrating the machine s interior. The cooling air flows from the back of the machine forward that is towards the point being welded. As a result, the particle content of the air is smaller than if the air flowed in the opposite direction Kemppi Product Catalogue 29

30 OPERATION PANELS FOR MASTERTIG MLS All the Mastertig MLS operation panels have following features Indication for power connection, overheating and supply voltage Digital display Local/Remote/Pedal/Torch control, HF/Contact ignition, 2/4T, MMA/TIG, Gas test Adjustments for Pre-/Post-gas,Up-slope/Down-slope, limits for pedal control, Arc force and Hot Start for MMA MTL offers basic MMA and TIG welding features MTX - Pulse-TIG and 4T LOG 4T LOG function with Search Arc for start and Tail Arc to prevent welding faults Synergic Pulse TIG - synergic control for Pulse-TIG Long Pulse/Quick Pulse - individual setting for pulse current, pulse ratio, frequency and the base current level Spot welding MTM - MINILOG and memory The other functions as in MTX (except 4T LOG) A memory block for storing adjusted values. MINILOG to control the weld pool from the torch switch by periodically lowering the welding current below the actual level needed for welding. MTZ like MTX but with MINILOG MTZ operation panel includes Minilog-function, otherwise it is similar to MTX panel Spot Welding Pulse-TIG: Long Pulse, Quick Pulse and Synergic Pulse MINILOG 30 Kemppi Product Catalogue 2004

31 COOLING UNIT FOR MASTERTIG MLS Mastercool 10, 12 reliable structure - little maintenance power source panel to control functions quick connector to maintain optimal performance reliable flow controller protects torch against disturbances caused by clogging or by the rotary pump Technical Data MASTERCOOL 10 MASTERCOOL 12 Connection voltage 50/60 Hz 400V -15% +20% 230V -15% +10% Connection capacity 100% ED 250W 250W Dimensions (mm) L x W x H 500 x180 x x180 x 260 Weight (kg) Order Information Power sources Mastertig 2000 MLS Remote control units R 10, 10 m Mastertig 2500 MLS R 11F foot pedal Mastertig 3500 MLS R 11T, wireless Mastertig 2503 MLS R 10, 5 m Mastertig 3503 MLS Meter unit MSD-1 V/A Cooling units Mastercool Transport units T Mastercool T Operation panels MTL T MTX Adapters for TTK-torches, gas-cooled MTM for TTK-torches, water-cooled MTZ Cables Remote control cable,10 m (R 10) Torches Kemppi TTC and TTK, page welding and earth cables, page Kemppi Product Catalogue 31

32 KEMPPI PRO EVOLUTION IN TIG-WELDING Kemppi Pro Evolution HF ignition unit Protig 410 Protig 410 HF ignition unit ensures excellent and stable arc ignition in TIG welding. Basic or special functions can be chosen from the function panels. This includes the storing of welding parameters. Protig 410 is attached to the top of the power source, and can be transported to the workplace in its standard frame. Technical Data PROTIG 410 Connection voltage 50 V DC Loadability 60% ED 400A 100% ED 310A Dimensions (mm) L x W x H 615 x 260 x 400 Weight (kg) Kemppi Product Catalogue 2004

33 OPERATION PANELS FOR PROTIG TL operation panel Control and display of welding parameters High frequency/contact ignition MMA/TIG welding selector Recall of last welded parameters TX operation panel Control and display of welding parameters Continuous/spot/pulse welding selector Minilog control automatics /2-/4-tact latching function Preprogramming and storing of welding parameters Learning function Order Infornation Power sources Kemppi PRO 3200 Evolution Water cooling units Procool Kemppi PRO 4200 Evolution Procool Kemppi PRO 5200 Evolution Transport units P 30 W TIG-ignition unit Protig P Operation panels TIG-welding TL-operation panel P40L L TX-operation panel Intermediate cables 50-1-G Remote control units R 10 (1-knob) W R 10F, foot pedal GH R 10F, extension cable 10m WH Torches TTK-TIG torches on page 64 Cables Earth and welding cables, page Kemppi Product Catalogue 33

34 MASTERTIG AC/DC Mastertig AC/DC 2000, 2500, 2500W and 3500W welding surfers The Mastertig AC/DC series features compact TIG/MMA inverters for AC/DC current welding with both polarities in current range Amp. Mastertig AC/DC can be gas-cooled (2000, 2500) or watercooled (2500W, 3500W). Ease of use, high duty cycles and excellent mobility put the Mastertig AC/DC series in a class of its own. Technical Data MASTERTIG AC/DC /2500W 3500W Connection voltage 1~50/60 Hz 230 V ±10% - - 3~50/60 Hz V/400V/460V ±10% 400 ±10% Fuse, delayed (A) 230V 16A / 20A 20A - 400V - 16A (460V 16A) 20A Loading capacity TIG max %ED 200A (30%) 250A (70%) 350A (60%) TIG 100%ED 150A 220A 280A Welding current range (A) TIG DC AC MMA External dimensions (mm) L x W x H 540 x 260 x x 260 x 550 (2500),830 (2500W) 690 x 260 x 870 Weight (kg) (2500), 65 (2500W) Kemppi Product Catalogue 2004

35 Mastertig AC/DC benefits The versatile and user-friendly control functions are based on advanced electronics, including an integrated digital controlled electronic power source with IGBT modules. Less interferences due to optimised wave form and smart HF Reliable ignition Trouble-free Process control with three optional operation panels Clever adjustments with display Sophisticated Automatic Balance Improved weld quality due to Minilog and Pulse Programmable AC/DC PANEL Provides basic TIG and MMA welding functions and adjustments Balance Broken-arc welding AC/DC MINILOG Basic functions for TIG and MMA welding Balance AC/DC PULSE Basic functions Balance Minilog Pulse TIG Order Information Power sources Mastertig AC/DC Transport units T Mastertig AC/DC T Mastertig AC/DC 2500W Gun holder GH Mastertig AC/DC 3500W Remote control units C 100C, 5 m Operation panels AC/DC panel C 100D, 5 m AC/DC minilog panel C 100AC, 10 m AC/DC pulse panel C 100F, 5 m Torches Kemppi TTK, page 64 Cables earth- and welding cables, page Kemppi Product Catalogue 35

36 MMA WELDING 36 Kemppi Product Catalogue 2004

37 Kemppi Pro Evolution Master MLS - Professional MMA Minarc 110, 140-1ph Weld Anywhere Master 2200, 5001 INCREASED FEATURES AND BENEFITS MMA welding (Manual Metal Arc) Manual metal arc (MMA) welding refers to welding process that is carried out manually with a coated electrode. It is the most widely used welding process in the world today, although the percentage of MMA is decreasing because of the increased use of gas-shielded processes. Kemppi range of MMA welding machines offers inverters of DC constant current type from 110 to 500 Amp Kemppi Product Catalogue 37

38 MINARC Revolutionary reliability and performance Minarc 110 and 140 The Minarc MMA machines enable welders to conquer extreme challenges. Perfect examples of Kemppi s superior welding know-how, these lightweight inverters are weld-anywhere tools for DC MMA and scratch-start TIG welding. When it comes to repair or maintenance work, Minarc is the welding tool for you. Minarc requires a 230 V 1-phase power source and works with power supply cables up to 50 meters in length. The portable Minarc is also ideal for hard-to-weld places, with excellent electrode support and an impact-resistant casing. Technical Data MINARC Connection voltage 1~50/60 Hz 230V -15% +10% 230V -15% +10% Loading capacity 35% / 50%ED 110A (50%) 140A (35%) 100%ED 80A 100A Connection cable / fuse, delayed 1.5 mm²s / 2.0m 13A 2.5 mm²s / 3.3m 16A Welding current range (A) MMA 10 / 20.5V / 24.4V 10 / 20.5V / 25.6V Electrode sizes to be welded (mm) ø Dimensions (mm) L x W x H 305 x 123 x x 123 x 250 Weight (kg) Kemppi Product Catalogue 2004

39 Ideal for hard-to-weld places Revolutionary reliability and performance Latest technology Weld-anywhere mobility Reliable partner User-friendly and safe High-duty cycle with maximum welding current Increased output from single phase supply Lightweight and versatile Works with generator and long power supply cable (up to 50 m) ICS Kemppi s innovative ICS (Isolated Cooling System) delivers superior reliability even in extreme conditions. Cooling air flows only through primary components and all electonic parts are shielded against dust and dirt. Order Information Minarc incl. earth and connection cable 10mm - 3 m Minarc incl. earth and connection cable 16mm - 3 m Accessory: TTM 15V TIG-torch Kemppi Product Catalogue 39

40 MASTER Master 2200 Master 2200 has been designed to meet today s needs with MMA welding applications requiring direct current. The technology and reliability of the Master machines have been designed to serve their user for a long time. The inverter technology employed in the machines has been perfected to be lasting and reliable. The supply voltage of the Master 2200 is 400 V and is best suited for the manufacturing industry, where portability of the welding set is a serious requirement. Technical Data MASTER Mains voltage 3~50/60 Hz 380V -10% 415V +6% 400V±10% Loading capacity 60% ED 145 A 500 A (80%) 100% ED 110 A 440 A Connection cable, fuse delayed 4 x 1.5 mm²s / 10A 4 x 6S-5m / 35A Max. welding voltage 35V / 220A 50V / 500A Electrode sizes to be welded (mm) ø Dimensions (mm) L x W x H 472 x 152 x x 230 x 520 Weight (kg) Kemppi Product Catalogue 2004

41 Master 5001 Master 5001 is a 500 Amp inverter CC/CV power source suitable for MMA welding, for carbon arc gouging, for TIG welding with Contact TIG and for MIG / MAG with voltage-sensing wire feeder. Voltage-sensing wire feeder is a feeder that operates on arc voltage. Master 5001 operates on CV mode (Constant Voltage) with voltage-sensing feeder so it is suitable for short arc and spray MIG/MAG. Due to its high current and excellent welding properties as well as its small size and light weight it is very suitable for site welding as well as for repair and production welding. In order to enable easy monitoring of welding current the machine is equipped with wellvisible displays for welding current and welding voltage. Order Information Power sources Master Master Remote control units C 100C - 5m C 100D - 5m Extension cable for remote control unit 10 m m m Transport units T T T10 (5001) Cables Earth and welding cables, page 70 Torches Scratch start TIG, page Kemppi Product Catalogue 41

42 MASTER MLS Superior productivity and quality with Master MLS 1600, 2500, 2503, 3500 and 3503 The Multi Logic System (MLS ) is Kemppi s answer to the growing need for high-quality welding user interfaces. With MLS, you can adapt your welding equipment to the most demanding welding conditions. It also allows you to meet future welding needs without having to replace your Kemppi welding machine as the panel functions can be upgraded with new software. The Master MLS MMA welding machines represent Kemppi s strong track record in innovative welding technology. Kemppi has developed the Isolated Cooling System ICS to improve the reliability of Kemppi welding equipment and to minimise maintenance. Kemppi s MMA welding machines lead the way in performance-enhancing features that target arc and weld pool control. Technical Data MASTER MLS Connection voltage 3~50/60 Hz 1~230 V -10% +10% 400 V -15% +20% 400 V -15% +20% 230V -15% +15% 230V -15% +15% Loading capacity 40%ED MMA 160A (35%) 250A 350A 250A 350A 100%ED MMA 120A 160A 220A 160A 220A Welding current (A) MMA Connection cable / fuse (delayed) 3 x 2.5 S - 3.3m / 16 A 4 x 1.5 S - 5m / 10 A 4 x 2.5 S - 5m / 16 A 4 x 2.5 S - 5m /20 A 4 x 6 S - 5m / 32 A Open circuit voltage 80V 80V 80 V 80V 80V Electrode sizes to be welded ø (mm) Dimensions (mm) L x W x H 410 x 180 x x 180 x x 180 x x 180 x x 180 x 390 Weight (kg) Kemppi Product Catalogue 2004

43 Superior productivity and quality Kemppi MLS (Multi Logic System) Innovative control panels Easy-to-access controls Over voltage protection Master performance Greater adjustability, better productivity Operation panels The MEL panel includes the most common finesses used in MMA welding. MEX operation panel offers possibility for controlling the welding values based on electrode type selection rather than conventional welding current, arc force and hot start individual settings for each weld case. MEL operation panel Three warning lights (power on, overheating, under or over voltage of supply) The remote control or the panel control The welding current or alternatively the arc voltage is shown in a clear digital display, which shows both the set values and the values used Hot Start and the Arc Force controls Welding method MMA / contact TIG MEX operation panel Three warning lights (power on, overheating, under or over voltage of supply) Electrode selection Digital display Memory channels Panel control or remote control or TIG torch (RTC 10) control Hot Start and the Arc Force controls Welding method MMA / Contact TIG / Arc gouging / Broken Arc Order Information Power sources Master 1600 MLS Remote control units R10, 5m Master 2500 MLS R10, 10m Master 3500 MLS R11T wireless Master 2503 MLS R11F foot pedal Master 3503 MLS Remote control cables 10 m for R Operation panels MEL R10, 10m MEX Transport units T Cables welding and earth cables, page 72 T Torches Scratch-start TIG, page 70 T Kemppi Product Catalogue 43

44 KEMPPI PRO EVOLUTION IN MMA WELDING Kemppi Pro Evolution is a multi-process welding machine for DC. It welds all MMA electrodes, including cellulosic electrodes. Constant current (cc) characteristics are used in normal MMA welding. The power source keeps the current value stabile, regardless of changes in the arc length. Automatic Hot Start - Makes perfect first and re-ignition of electrode Automatic arc dynamics - Stable arc throughout the whole current range, minimum amount of spatters and excellent arc welding characteristics Generous voltage response - Voltage reserve for cellulosic electrodes, high efficiency and superduplex electrodes etc. Anti-freeze - Works when electrode sticks to base material, re-ignition of electrode with out damaging electrode head Constant current (cc) characteristics are used in normal MMA welding. The power source keeps the current value stabile, regardless of changes in the arc length. 44 Kemppi Product Catalogue 2004

45 PANELS FOR MMA WELDING The PL-operation panel for MMA welding Control of welding current Control of MMA dynamics Display of welding parameters The PX-operation panel for MMA welding Control of welding current Tack welding/mma/carbon arc gouging selector Adjustment of start pulse/mma dynamics Display of welding parameters Order Information Power sources Kemppi Pro Evolution Kemppi Pro Evolution Kemppi Pro Evolution Operation panels PL-operation panel PX-operation panel Remote control unit R 10 (1-knob) - 5m Transport unit T Cables PRO remote control extension cable, 10m Earth and welding cables, page Kemppi Product Catalogue 45

46 KEMPPI DATA MONITORING Kemppi Data Monitoring is a data monitoring system for Kemppi Pro product family Kemppi Pro Weld Data software together with DLI 20 and PC units establishes an integrated Data Monitoring System. The Interbus-field bus is used for data transmission in Data Monitoring System. Pro DLI 20 collects simultaneously the welding data from data bus of Pro welding machines and send via Interbus-field bus to host computer (PC). The data is monitored with Pro Weld Data Software in PC. DLI 20 Order Information Pro PC Interface Order Information Pro Weld Data Interbus host card Interbus software DLI 20 interface Cabling between PC and DLI 20 depends on application and site. Cable is a special cable for Interbus, code no (per meter) PRO-PC Interface Dli 10 RS-cable PRO-cable, 1 m PRO-PC Interface Dli 10 RS-cable PRO-cable, 5 m 46 Kemppi Product Catalogue 2004

47 Kemppi Pro Weld Data software to improve your weld quality Kemppi Pro and Kemppi Pro Evolution user is able to register and analyze easily welding values and weld quality with Pro Weld Data program. This program receives and controls data to seriel port during welding through Pro-PC Interface. Pro Weld Data shows welding data, draws in real time graphical form: voltage, current, Wf-speed and Wf-motor current. Pro Weld Data does not only register the welding parameters but it also calculates welding energy, heat input, wire consumption and the welding costs like gas, filler material, energy, labour and total costs. Pro Weld Data is an excellent tool also for creating WPS. Hierarchy in program structure guarantees that individual weld is easy to trace and individual files can be seen clearly in the PC display, so it is simple to control the jobs and welds. Pro Weld Data Sofware gives a new dimension for the quality control of the welding process. System requirements: Kemppi Pro or Kemppi Pro Evolution welding set Pro-PC Interface or DLI 20 PC Pentium 133 MHz RAM memory 32 Mb Hard disk 10 Mb CD rom Display SVGA colour Windows 95, -98, -Me, -NT, Kemppi Product Catalogue 47

48 ROBOTICS Robot welding system Promig 520R/120R The Promig 520R/120R robotic welding system is a comprehensive welding interface for robotic welding. No modifications are required when connecting the interface to most common types of robot controller, which saves time and money on installation. The small overall size and compact construction of the system offers a very small footprint in any robotic cell design. The comprehensive range of welding characteristics can be made directly from robot controller as standard. Any of the Kemppi PRO or Kemppi Pro Evolution fully microprocessor controlled inverter power sources can be used utilising this model s comprehensive range of excellent welding characteristics. The Procool has an internal detection for coolant over-temperature, electrical failure and water pressure. If a cooling unit other than the Procool is used it s internal pressure of flow switch can be connected to the 520R-interface unit. Kemppi MT 51MW basic robot gun can be used as well as major robotic torch varieties. Technical Data PROMIG 120R PROMIG 520R Working voltage 50 V DC 50 V DC Max. load (nominal values) 60% ED 500A - 100% ED 390A - Wire reel (optional) max. weight / diam kg / 300 mm Operation principle 4-roll drive Wire feed speed m / min 0 18 (25) Filler wires (mm) ø Dimensions (mm) L x W x H 319 x 152 x x 230 x 480 Weight (kg) 8 20 Push-pull, motor max current 2 A (programmable) Maximum Input/Output capacity (pcs digital inputs/outputs 18 / 14 analog inputs / outputs 8 / 2 48 Kemppi Product Catalogue 2004

49 Promig 520R The Promig 520R Interface can handle a maximum of 37 Input/Output signals, which cover the needs of most robotic welding configurations. All functions and adjustments as well as overall welding operation are microprocessor controlled ensuring accurate wire feed speed and control of welding programs when Normal, Channel-Change, Synergic or Synergic Pulsemig welding. Manual control of welding parameters and programs is possible by using MC or ML operation panels. Touch sensing is a standard feature on the 520R. The touch sensing output signal may be used to check if the wire is stuck to work piece at the end of each weld. Weld current monitoring for through arc seam tracking is available as an optional extra. Analogue and digital I/O grounds are fully isolated from each other eliminating interference related problems. Welding voltage monitoring is available as an optional extra. The in built automatic troubleshooting system directs the user to possible fault causes. Intelligent jumper functions allow user customisation of the interface and welding system. The system is easy to service and maintain with quick change main components. Printed circuit boards and components are located for easy test and removal. The Promig 520R interface has an in built test mode for interface input / output testing enabling each I/O channel to be tested either manually or automatically. Promig 120R The four wheel wire drive mechanism in Promig 120R ensures trouble free and positive wire feeding. The tacho feedback system in the wire feed motor ensures accurate wire feed speed regulation. Microprocessor controls wire feed speed according the tacho feedback signal. A push-pull torch or two 120R feeding units may be run from one 520R and power source. These combinations are made possible by using the optional Prosync 50 synchronisation unit. The gas valve may be sited in either the 120R or the 520R dependent on user requirements. Order Information Power sources Kemppi Pro Evolution Robot control connector Kemppi Pro Evolution Cable support Kemppi Pro Evolution Voltage monitor cable Wire feed units Promig 520R control unit Branch connector Promig 120R Intermediate cable assembly 5 m Cooling units Procool m Procool Welding guns MT-51MW straight neck 1.5 m Operation panels MC MT-51MW 30 bend neck 1.5 m ML MT-51MW straight neck 3.0 m Prosync MT-51MW 30 bend neck 3.0 m Voltage sensor Transport units P Current sensor P 30W Wire reel hub P Kemppi Product Catalogue 49

50 MT MIG-GUNS Welder s standard model series Stable wire feed Flexible cable Operates also in cold conditions Suitable for all machines with Euro connector All parts replaceable Technical and Order Information MT 18 MT 25 MT 38* MT 51W* Loading capacity Ar + CO² 160 A / 60 % 200 A / 60 % 300 A / 60 % 450 A / 100 % CO² 180 A / 60 % 250 A / 60 % 380 A / 60 % 500 A / 100 % Cooling gas gas gas liquid Filler wires to be welded (mm) ø Fe, Ss Cored wire Al Length / Order number 3 m m All guns with Euro-adapter, delivery equipment standard set-up: solid mild steel wire, see consumable parts. *) Availability to order 50 Kemppi Product Catalogue 2004

51 MMT MIG-GUNS The new series of MIG guns MMT MIG guns are designed to be used with Kemppi s Kempomat and Kempoweld welding machines or with any brand of MIG welding machine equipped with a Euro connector.mmt MIG guns continue the successful design and ergonomics of PMT MIG guns, having the same flexibility and lightness in handling resulting in superior welding performance. Ergonomic design with lightweight and well-balanced grip New sticky handle surface, no strain on welder s wrist Excellent gas shielding reduces porosity Easy to position for welding due to rotating neck Maintenance friendly construction Shock resistant, reliable switch Durable protective hose material Low friction DL-Teflon liner for aluminium and stainless steel No water leakage s during the maintenance (plugs) Small amounts of consumable parts (only two contact tip lengths) Euro adaptor Technical and Order Information MMT 25 MMT 27 MMT 32 MMT 35 MMT 42 MMT 30W MMT 42W MMT 52W Loading capacity 35% 250A 270A 320 A 350 A 420A % A 400A 500A Filler wires ø mm Length / Order number 3m MMT MMT MMT MMT MMT MMT MMT MMT 4,5m MMT MMT MMT MMT MMT MMT MMT MMT 2004 Kemppi Product Catalogue 51

52 KMG MIG-GUNS KMG Kemppi s gas-cooled economic series Castad coaxial cable, uniform structure Inexpensive alternative for Kempomat and Kempoweld power sources Stable wire feed Same consumable parts as in corresponding MT guns High loading capacity Suitable for all machines with Euro connector Additional wire in coaxial cable for start switch Technical and Order Information KMG 20 KMG 25 KMG 32 Loading capacity Ar + CO² 160 A / 60 % 200 A / 60 % 260 A / 60% CO² 180 A / 60 % 250 A / 60 % 320 A / 60 % Cooling gas gas gas Filler wires to be welded (mm) ø Fe, Ss Cored wire Al Length / Order number 3 m m All guns with Euro-adapter, delivery equipment standard set-up: solid mild steel wire, see consumable parts 52 Kemppi Product Catalogue 2004

53 WELDSNAKE Kemppi WeldSnake revolutionizes Aluminium and Stainless Steel MIG welding Kemppi WeldSnake is a product range of extra long water cooled MIG guns for pushing Aluminium and Stainless Steel MIG/MAG wire. Kemppi WeldSnake is an economical solution for places where you need longer range. As a lightweight and small gun it fits well to your hand and has an excellent access even to narrow places. Unique 6m /8 m length is lightweight solution giving extra work range Excellent access to narrow places due to small size Maintenance easy, simple construction Same consumable spares as in PMT and MMT MIG guns Ergonomic design, lightweight, well-balanced grip and roughened handle surface Euro connector Technical data and order information WeldSnake 30W 42W Kemppi WeldSnake products Kemppi WS 30W liquid-cooled Kemppi WS 42W liquid-cooled 6m / 8m 300 A 6m / 8m 400 A WS MIG guns are suitable to be used with 1.2 (1.6) mm Aluminium and mm Stainless Steel wires Loading capacity 100% 250 A (60 %) 300 A Filler wires Ss Al 1.2 (1.6) 1.2 (1.6) Cooling Liquid Liquid Order information 6 m Al A A12 6 m Ss S S10 6 m Ss S S12 8 m Al A A12 8 m Ss S S10 8 m Ss S S12 The order number includes MIG gun + DL-Teflon liner and Contact tips (5 pcs) 2004 Kemppi Product Catalogue 53

54 PMT MIG-GUNS PMT MIG-guns - Welding guns for new generation The PMT MIG gun series takes welding ergonomics and performance to the next level. Extremely flexible and light to handle, they minimise physical strain on your hand and deliver improved welding performance. The small gun necks allow you to reach narrow places without jeopardising wire feed, current transfer and gas shield. To ensure optimal reach, the neck of the gas-cooled guns can be turned a full 360. You can also weld in overhead positions without having to hold your wrist in an unnatural position. With the RMT remote control, you can operate the Kemppi Pro Evolution or Kempomig welding machines from your PMT gun. Technical Data and Order Information PMT 25 PMT 27 PMT 32 PMT 35 PMT 42 PMT 30W PMT 42W PMT 52W Loading capacity (A) 35% 250 A (60 %) 270 A 320 A 350 A 420 A 100 % 300 A 400 A 500 A Filler wires to be welded Fe,Ss Cored wire Al Length / Order number 3 m m Accessory RMT 10 ( ), delivery equipment: standard delivery set-up: solid mild steel wire (see consumable parts) The RMT gun control and the overheating protection for liquid cooled versions is developed only for Promig and Feed units 54 Kemppi Product Catalogue 2004

55 Kemppi PMT, MMT and WeldSnake series represent ultimate userfriendliness Excellent gas protection reduces porosity gas diffuser of gun neck minimises turbulence in shielding gas flow optimal design of gas nozzle tip prevents air from mixing with the shield gas separate gas hose in water-cooled guns Reliable wire feed supports prevent sharp bends stiff, low-friction wire liners prevent undulated bends in the filler wire low contact tip temperatures Firm hold of the handle, no strain on welder s wrist sticky, roughened handle surface ergonomic design reduces press force ball joint allows unrestricted bending of handle neck of gas cooled guns twists 360 degrees Effortless gas nozzle maintenance easy conical and roughened surface makes the maintenance of gas nozzle easy stainless steel surface will not be damaged like conventional brass gas nozzles. Protected from overheating (PMT 30W, 42W, 52W) wire feeding stops if cooling liquid is not circulating Gun regulator as accessory (RMT 10) fast regulation of welding current suitable for all PMT models Durability protective hose material endures hard wear and heat Mechanical shock and spatter resistant handle and trigger Small amount of consumable parts the same consumable parts in PMT 27, 32 and 30W the same wire liners and contact tips can be used in all PMT guns 2004 Kemppi Product Catalogue 55

56 In all Kemppi MIG-guns the following high-quality features are as standard Easy position welding necks can be turned 360 degrees ergonomic handles (two sizes) made of strong, recyclable plastic which tolerates spatter Shock-resistant, reliable switch Euro adaptor* flexible connecting pins (gold coating) of control cables guarantee good electric contact and are not vulnerable wire liner end and tightening bush are the same despite the wire diameter * the KMG 17 gun has a special Kemppi adaptor Maintenance-friendly construction parts of cable package are changeable, which reduces maintenance costs (MT and PMT series) Low-friction DL-teflon liner for aluminium and stainless steel welding ( filler wires) inner surface made of slippery special teflon neck spiral and teflon part are removable spare parts No leakages during maintenance replaceable shield plugs supports prevent water hoses from flattening Only two contact tip lengths (M6 and M8) low amount of items in stock Al and Ss wires have their own contact tip sets with markings for different wire diameters more durable silver copper and chromium-zirconium-copper sets for welding of steel and coated wires Strong, durable spiral wire liners thick spiral wire is coated to prevent oxidation liners will neither bend nor stretch when mounting in the gun long intervals between maintenance because of low friction and large inner holes plastic coating prevents gas from flowing towards wire feeder wire spirals have the same colour as Kemppi feed rolls 56 Kemppi Product Catalogue 2004

57 CONSUMABLE PARTS MT 18, MT 25, KMG 17, KMG 20, KMG 25, PMT 25, MMT 25 1) ø 14 mm ø 18 mm Insulating bush * Contact tip adapter * Insulating ring * Locking spring * Neck 45º * 2) 3) ø 14 mm ø 14 mm ø 18 mm ø 18 mm Contact tips /M6 MT 18, KMG 17, KMG 20* /M6 MT 25, KMG 25, PMT 25*, MMT 25 Gas nozzles 1) * Standard 2) For spotwelding 3) E Thick wall Wire conduits MT 18/25, KMG 20/25, PMT 25, MMT 25: Spiral m/white * MT 18, KMG Spiral m/red * MT 25, KMG 25, PMT 25, MMT Spiral m/red * MT 25, KMG 25, PMT 25, MMT 25 Wire conduits KMG 17/Migger: Spiral m/white * Spiral m/white * Suitable liners: white, red, DL-teflon MT 32, KMG 32 O-ring * 1) 2) ø 16 mm ø 16 mm ø 25 mm Contact tips M8 * M 8 M 6 Neck 45º * Gas nozzles 1) * Standard 2) For spotwelding Contact tip adapter M8 * M6 Insulating ring * Wire conduits Spiral m/red * Spiral m/red * Suitable liners: white, red, yellow, DL-teflon * standard delivery 2004 Kemppi Product Catalogue 57

58 CONSUMABLE PARTS MT 38, KMG 40 1) 2) ø 16 mm ø 16 mm ø 25 mm Contact tips * 1.2/M8 Insulating ring * Neck standard, * 3) ø 12.5 mm 86 Insulating bush * Contact tip adapter * M M6 Gas nozzles 1) Standard 86 * 2) E Long 90 3) Conical 86 Wire conduits Spiral m/red * Spiral m/red * Suitable liners: white, red, yellow, DL-teflon MT 51W ø 25 mm Insulating bush * M8 Insulating ring * Neck standard * ø 17.5 mm M6 Gas nozzle Standard * Contact tips * 1.2/M8 Contact tip adapter M8 * Contact tip adapter M6 Wire conduits Spiral m/red * Spiral m/red * Suitable liners:white, red, yellow, green, black, blue, DL-teflon * standard delivery 58 Kemppi Product Catalogue 2004

59 CONSUMABLE PARTS PMT 27, PMT 32, PMT 30W, MMT 27, MMT 32, MMT 30W, WeldSnake 30W 1) 2) 3) 4) ø 14 mm ø 12 mm ø 14 mm ø 14 mm ø 20 mm Gas nozzles 1) Standard / (M8) * 2) L Long 3) C Conical 4) Standard / (M6) Contact tips * 1.0/M8 Contact tip adapters M8 * M6 Gas diffuser * Neck 45º PMT 30W Neck 45 PMT 27/ Wire conduits Spiral m/red * Spiral m/red * Suitable liners: white, red, yellow, DL-teflon WeldSnake, see table on page 61 PMT 30, PMT 40, PMT 50, MMT 40 1) 2) 3) ø 12,5 mm ø 16 mm ø 16 mm ø 25 mm Insulating bush * Contact tip * 1.2/M8 Contact tip adapter M8 * Neck standard, Insulating ring * Gas nozzles 1) Standard * 2) E Long 3) Conical Wire conduits Spiral m/red * Spiral m/red * Suitable liners: white, red, yellow, DL-teflon * standard delivery 2004 Kemppi Product Catalogue 59

60 CONSUMABLE PARTS PMT 35, MMT 35, PMT 42W, MMT 42W, WeldSnake 42W 1) ø 16 mm ø 22 mm 77 Contact tip M * Gas diffuser * Neck 45º ) 3) ø 13 mm ø 16 mm Contact tip adapter M8 * Gas nozzle 1) Standard * 2) L Long 3) C Conical Wire conduits Spiral m/red * Spiral m/red * Suitable liners: white, red, yellow, DL-teflon WeldSnake, see table on page 61 PMT 42, MMT 42, PMT 52W, MMT 52W ø 25 mm 1) 2) 3) ø 18 mm ø 14 mm ø 18 mm Contact tip * Gas diffuser * Contact tip adapter M8 * Neck 45º Gas nozzle 1) Standard * 2) L Long 3) C Conical Wire conduits Spiral m/red * Spiral m/red * Suitable liners: white, red, yellow, DL-teflon * standard delivery 60 Kemppi Product Catalogue 2004

61 LINERS FOR MIG-GUNS Kemppi wire liners are strong and durable. Due to its stiffness, the liner provides an excellent support to the filler wire, which will not bend when assembling in the gun. The liners have the same colour as the corresponding feed rolls of the same wire diameter in Kemppi wire feeders. The selection table for consumable parts includes the liner colours which fit to the gun in question. The liners are also suitable for welding of cored filler wires of the corresponding wire diameter. Kemppi s new solution for aluminium, stainless steel and acid-resistant steel welding is the two-layer DLteflon liner (patent pending). It is suitable for all common wire diameters and materials, and all Kemppi MIG guns. Steel / cored wire Filler wire ø Order number 3 m Order number 4.5 m White Red Fe Yellow (1.2) Green Black Blue Aluminium DL-teflon liner Neck part (spiral/teflon) Stainless steel DL-teflon liner Neck part (spiral/teflon) DL-teflon liner Neck part (spiral/teflon) Migger / KMG17 liners Filler wire ø Order number 2.5m Order number 3m White Red DL-teflon liner /AL Neck part (spiral/teflon) DL-teflon liner /SS Neck part (spiral/teflon) WeldSnake Filler wire ø Order number6 m Order number 8 m DL-teflon liner /AL DL-teflon liner /SS DL-teflon liner /SS CONTACT TIPS M8 Standard contact tips M8 (DHP) for solid mild steel and flux cored wire Marking: Kemppi 1.2 Contact tips M8 (DHP) for Aluminium wire Marking: Kemppi 1.2 A Wire ø Hole ø Tolerance Order number / / / / / / / / / / / A / A / A / A / A / A Contact tips M8 (CuAg) for Fe and flux cored wire Marking: Kemppi 1.2 Ag / AG / AG Contact tips M8 (CuCrZr) for solid mild steel and flux cored wire Marking: Kemppi 1.2 CRZR / ZR / ZR Contact tips M8 (DHP) for stainless and high acid-resistant steel Marking: Kemppi 1.2 SS / SS / SS / SS / SS / SS M6 Standard contact tips M6 (DHP) for solid mild steel and flux cored wire Marking: Kemppi / / / / / / Kemppi Product Catalogue 61

62 KMP PUSH-PULL GUNS FEATURING ATC The ability to adjust the welding power during the welding with KMP 300 and KMP 400W Push-Pull Guns are widely used in places where the operator needs extended reach and the traditional wire feeder and gun can not be placed close to the weld site or the wire feeder can not be moved along with welding. The main application for a Push-Pull Gun is in aluminium welding where Al filler wire might give feeding problems due to its softness. In Al-welding Push-Pull Guns give improved feeding due to less friction in wire liner because of a bigger liner diameter. Also maintenance of liner and tip is reduced due to improved feeding. Flexible welding power, adjustable during welding Welding power regulation within desired limits (RMP 10) Easy to repeat the same welding parameters Stable and trouble free wire feeding Spare parts and consumables are available world-wide Well-known manufacturers and simple construction (Kemppi & Binzel) Order information Technical and Order information KMP 300 KMP 400W Loading capacity CO 2 300A / 60% 400A / 100% Ar + CO 2, Ar 270A / 60% 350A / 100% Filler wires to be welded (mm) ø Fe, Ss Al Connection to wire feeder Euro-connection Euro-connection Length / Order number 6 m m KMW Sync Kempomat, Kempoweld Sync 400 Kempomig Adapter Kempomat, Kempoweld Adapter Kempomig KMP for Kemppi Pro Evolution RMP: KMP 300, 6 m, RMP 10, Prosync RMP: KMP 300, 10 m RMP 10, Prosync RMP: KMP 400W, 6 m, RMP 10, Prosync RMP: KMP 400W, 10 m, RMP 10, Prosync Kemppi Product Catalogue 2004

63 Kemppi Pro Evolution and KMP Kemppi Push-Pull Guns with ATC TM - Active Trigger Control Kemppi Active Trigger Control (ATC ) combined with Kemppi Pro Evolution gives an additional unique benefit: The ability to adjust the welding power during welding. There might be situations due to poor fit up or need of position changes or need to reduce risk of over heating of work piece or due to start / end situations when the user has to control the welding values during the welding. The shape and grip of Kemppi Push-Pull Guns are designed to provide superior balance and comfort for the user. Used with Kemppi Pro Evolution feeders PROMIG 300, 501, 501L and 530 combined with regulation unit RMP 10 and synchronizing unit PROSYNC 50. The user may use all the features of the MIG operation panels with KMP Push Pull Gun the welding method can be normal MIG, Synergic MIG, Synergic Pulse-MIG or Double Pulse The user selects with the regulation unit RMP 10 the parameter to be adjusted and its operation range according to material thickness. KMP Push Pull guns with ATC will give additional benefits for Kempomat,Kempoweld and Kempomig Extended reach and larger weld sections Comfort and access to narrow places through rotating neck Regulation in gun improves productivity It is easy to use and find right welding parameters Variations in weld groove tolerances and root gap Temperature, welding position, material thickness changes in the weld sections Need for penetration changes during welding Improves weld quality in starts and stops KMP Push Pull guns with ATC for Kempomat and Kempoweld needs: Adapter KMW Sync, synchronization unit KMP Push Pull guns with ATC for Kempomig needs: Adapter Sync 400, synchronization unit Contact tips for KMP Push-Pull Mig Guns Standard contact tips M8 E - Cu, L= 30 mm (availability: to order) Order number Wire ø mm Hole ø mm Tolerance mm Contact tips M8 CuCrZr,L=30 mm (availability: to order) Order number Wire ø mm Hole ø mm Tolerance mm Contact tips M8 for Aluminium E - Cu, L=30 mm (availability: ex stock) Order number Wire ø mm Hole ø mm Tolerance mm 2004 Kemppi Product Catalogue 63

64 TTK TIG-TORCHES Technical Data TTK 130 TTK 130F TTK 160 TTK 160S TTK 220 TTK 220S TTK 300W TTK 350W TTK 250WS Loading capacity DC-40% ED 130A 130A 160A 160A 220A 220A 300A 350A 250A DC-100% ED A 250A 200A AC 40% ED 100A 100A 120A 110A 160A 120A 250A 300A 250A AC 100% ED A 200A 140A Electrode sizes ø Connection to TIG-unit gas/current R1 4 R1 4 R1 4 R1 4 R1 4 R water/current R3/8 R3/8 R3/8 gas R1 4 R1 4 R1 4 Length / Order Number 4 m m m Kemppi Product Catalogue 2004

65 TTC TIG-TORCHES Technical Data TTC 130 TTC 130F TTC 160 TTC 160S TTC 220 TTC 200W TTC 250W TTC 250WS Loading capacity DC-40% ED 130A 130A 160A 160A 220A 300 A 350 A 250 A 100% ED A 250A 200A Electrode sizes ø Connection to TIG-unit gas / current R1 4 R1 4 R1 4 R1 4 R1 4 R1 4 R1 4 R1 4 water snap conn. snap conn. snap conn. Length / Order number 4 m m m Kemppi Product Catalogue 65

66 TTC (Mastertig MLS ) and TTK (Mastertig) torches represent top quality properties Easy grip of the handle improves weld quality Ergonomic oval body design and perfect handle length High friction surface improves hold Adjustable finger grips Easy to handle in all welding positions Rubber joint allows even sharp bend of the cable package. Light weight handle minimises stress on hand and wrist. Only minimum force is needed to handle the torch because both gas and water hoses are made of flexible, fabric-reinforced material Neck can be twisted 360 degrees to a suitable position in respect of the handle Right neck angles of 90 and 105 degrees depending on the torch Handle and hand remain cool All Kemppi current cables have wide cross-sectional areas, which prevents the handle from over heating Minimised heat conduction from neck to handle Handle material does not conduct heat to welder s hand Torch head can be extended by max. 30 mm by pulling. This reduces thermal radiation from arc to the hand. Temperature of cooling liquid is kept low thanks to the cable s special structure (water hose of only 2 meters) Durable, versatile switch Suitable for all types of hand grips Long switch with large friction surface. Pressing point can be chosen according to torch position Shock-resistant structure. Operating klick of membrane switch can be heard. Current control possibility as an option in all TTC torches RTC 10: Control disc with scale from 1 to 10 RTC 20: Current control up/down Easy to mount Flexible S and F necks facilitate superb reaching of the joint especially in pipe welding Improved visibility to the weld Welding in tight grooves is easier Standard consumables Extensive selection for all operating situations and joint profiles A gas lens equipment to ensure joint quality All parts of the so called W type, excellent availability of spare parts (see consumable parts) Machine connector of TTC torches improves operating reliability and safety Can be fastened without tools Connector design prevents the hoses from bending sharply Excellent accessibility Product range includes also a 16-meter torch as standard stock item Sufficient cooling even for 16-meter torches 66 Kemppi Product Catalogue 2004

67 CONSUMABLE PARTS FOR TIG-TORCHES Big torch head: TTK 160, 220, 220S, 350W, TTC 160, 220, 250W 175 mm Electrode grey ø ø * ø ø white ø ø ø ø green ø Tightening bush ø ø * ø ø Insulating ring Gas nozzle / lens mm a b c d No No No No No Housing for tightening bush/gas lens ø ø ø ø a d d b c c O-ring Insulating ring * Housing for tightening bush ø ø * ø ø a b Electrode shield including O-ring short medium long * See the torch body from the separate table Gas nozzle mm a b c d No No No * No No No No Height / Standard gas nozzle 190 mm Height / Lens equipment 190 mm 129 mm 96.5 mm 129 mm 96.5 mm * Delivery equipment is for ø 2.4 mm electrode. Lens equipment is as accessory. The above-mentioned dimensions are directive Kemppi Product Catalogue 67

68 CONSUMABLE PARTS FOR TIG-TORCHES Small torch head: TTK 130, 130F, 160S, 250WS, 300W, TTC 130, 130F, 160S, 200W, 250WS 175 mm Electrode grey ø ø ø * white ø ø ø Gas nozzle / gas lens mm ø a b c d No No No No Tightening bush/short ø ø ø Insulating ring * Housing for tightening bush/lens ø ø ø a d b c d c Electrode shield including O-ring short medium * long O-ring Height / Standard gas nozzle 187 mm Tightening bush ø ø ø * * See the torch body from the separate table Height / Lens equipment 191 mm Housing for tightening bush ø ø ø * Gas nozzle mm ø a b c d No No * No No Special Gas nozzle mm ø a b c d No No No a b 90 mm 59 mm 95 mm 63 mm * Delivery equipment is for ø 2.4 mm electrode Lens equipment is as accessory The above-mentioned dimensions are directive 68 Kemppi Product Catalogue 2004

69 CONSUMABLE PARTS FOR TIG-TORCHES TTC / TTK TTC 130 / TTK 130 TTC 130F / TTK 130F TTC 160 / TTK 160 TTC 160S / TTK 160S TTC 220 / TTK 220 TTK 220S TTC 200 W / TTK 300 W TTC 250 W / TTK 350 W TTC 250 WS / TTK 250 WS (Flex) Standard Delivery Accessory Small Consumable Parts 2004 Kemppi Product Catalogue 69

70 SCRATCH-START TIG TORCHES The Kemppi TIG torch range includes three scratch-start TIG torches with shielding gas valves in the neck: TTM 15V 4 m (V=Valve) Can be used in all MMA-welding machines with a small power connector For example Master 1500, Minarc 110 and 140 Loading capacity: 150 A / 35% DC- Order number: TTM 15V BC 4 m (BC=Big Connector) Equal to TTM 15V but equipped with big power connector Can be used in all MMA-welding machines with a big power connector For example Master 2200, Master 2850 Loading capacity: 150 A / 35% DC- Order number: TTC 220GV 4 m (GV= Gas Valve) The torch is equipped with a big power connector Designed to be used with the Master 2500 MLS and Master 3500 MLS machines The current is on only when the start switch is pressed The current is regulated from potentiometer in the handle Loading capacity: 220 A / 40% DC- Order number: CABLES WELDING CABLE EARTH CABLE Order number Order number ø mm max.welding voltage A/ED 60% length m * EXTENSION CABLE Order number ø mm max.welding current A/ED 60% length m Kemppi Product Catalogue 2004

71 KEMPPI DATAMASTER Field programming tool for MLS products Datamaster is a programming tool for Master & Mastertig MLS products. Datamaster can be used to update the software in power source or in operation panel and to store or transfer the panel parameters. Datamaster makes easy to set the parameters, jumpers and program updates. Datamaster box is a field programming tool, that is excellent to do any update at site. PC Datamaster software is a program package that makes PC compatible with Datamaster and makes possible to update and store panel parameters also directly from PC (in MLS TIG panels). Datamaster features Panel and power source programs of MLS machines can be updated Programs can be copied from MLS panel to another MLS panel or from MLS power source to another MLS power source Pro and Mastertig AC/DC power source program can be updated MLS Panel CH s and SETUP can be copied from panel to panel MLS Panel CH s and SETUP can be erased Calibration of Master MLS and Mastertig MLS on field conditions Program updates in Mastertig AC/DC PC Datamaster software is used to transfer data from PC to Datamaster box or from Datamaster to PC or directly from PC to power source or to panel. PC Datamaster makes possible to use also as temporary memory for panel parameters or program versions. Compatibility Master MLS / Mastertig MLS MLS operation panels MTL, MTX and MTM (In MEX only program update) Kemppi Pro Evolution power sources Mastertig AC/DC power sources Order Information Datamaster set Including: - Datamaster Box - PC Software - Cables (RS, flat, Pro) - Battery Charger 2004 Kemppi Product Catalogue 71

72 REMOTE CONTROL UNITS C 100D m m for MMA/TIG -welding used with Master-, Multisystem- and Kempotig-machines. Coarse / fine adjustment C 100C m m for MMA/TIG -welding current, used with Master-, Multisystem- and Kempotig-machines C 100 AC m for MMA/TIG -welding with Mastertig AC/DC -power sources. Selection of welding method MMA/TIG C 110D m R m m R m R 11T for MIG/MAG-welding. For adjustment of wire feeder and voltage with Multisystem and Kempomig power sources for MMA and TIG welding current used with Kemppi Pro Evolution, Master and Mastertig MLS. Adjustment of wire feed speed and welding power and selection of channel in MIG welding for MIG/MAG-welding. For adjustment of wire feed speed and voltage used with Kemppi Pro Evolution. Selection of channel with selecto-function and current control in MMA welding Wireless, with Master MLS - and Mastertig MLS -power sources RTC Control unit for TTC torches, can be installed to replace the original start-switch. Mastertig MLS RTC Control unit for TTC torches, can be installed to replace the original start-switch. Mastertig MLS RMT Control unit for PMT MIG gun, adjustment of wire feed speed and voltage used with Kemppi Pro Evolution and Kempomig. Selection of channel with selecto-function 72 Kemppi Product Catalogue 2004

73 Foot remote control units C 100F m for TIG welding used with Master-, Multisystemand Kempotig-machines. Start-function, min/max selection of welding current R 10F m in TIG welding for Kemppi Pro Evolution. Startfunction. min/max selection of welding current R 11F m for Mastertig MLS - power sources C 100T C 100T PST 11 Wireless remote control unit for MMA welding used with Kemppi Pro Evolution, Master 2850 and 5001, Master or Multisystem PS- power sources together with PST 11 -receiver C 120S Preprogramming unit for MIG/MAG- and MMAwelding with Multisystem- and Kempomig. Adjustment of wire feed speed and voltage C 100P Long pulse unit for TIG welding used with Multisystem power sources 2004 Kemppi Product Catalogue 73

74 WELDING ACCESSORIES Remote control extension cables Order number Remote control extension cable (10 m) C 110D Remote control extension cable (25 m) C 110D Remote control cable (1.5 m) C 120S/SU Remote control cable (10 m) C 120S/SU Remote control cable (1.5 m) C 120P Remote control cable (10 m) C 120P Remote control extension cable (10 m) C 100M, C 110M, C 100F, C 100P Distribution box PSS/TU, FU/C 100M- C 110M PRO-remote control extension cable, 10 m PRO-remote control start extension cable (for R 10F), 10 m Digital meter unit Order number MSD-1 Digital meter unit for Master 2850, Mastertig 2850/2850W, Kempomat, Kempoweld and Kempomig power sources Auxiliary voltage unit Order number PSL 55 auxiliary voltage unit 230/380/500 V for Kemppi power sources Earth clamps Current rating Cable size /Connection Order number Kemppi A mm, cable shoe connection Ø 6 mm Kemppi A mm, cable shoe connection Ø 6mm copper braiding between the jaws Kemppi A mm, cable shoe connection Ø 8 m copper braiding between the jaws Kemppi G A mm, cable connection with hexa-conal screw, body of brass Electrode holders A 60/35 % ED, Current rating Weight (g) / Cable size (mm²) Order number KEMPPI / 200, 300A 321 / KEMPPI /250, 400A 421 / KEMPPI /300, 500A 500 / KEMPPI /400, 600A 855 / MYKING A 285 / MYKING A 85 / In all electrode holders: body of brass, cable fastening with hexaconal screw MYKING A 535 / Kemppi Product Catalogue 2004

75 Gun Holders Model Order number GH 10 The holders are primarily meant to be mounted on the welding machines, but also GH 20 on transport units or on welding tables, to all Kemppi MIG / TIG welding machines GH Alu Kit Order number for 1.0 mm wire 4 feed rolls with V-or trapezoid grooves, Alu Kit is a KIT by which the user can for 1.2 mm wire ball bearings, press spring, press divider, improve wire feeding in Al-welding if for 1.6 mm wire spring bushing, necessary accessories you have an old Kemppi feeder: Promig, Wire, Feed or Kempomat (3200/4000) Cable connectors Current durability A Cable mm² Order number, male Order number, female BRANCH CONNECTORS 70/90 1 male, 2 female Contact plugs Connecting machines to the mains supply Order number Contact plug 16 A, 5 poles, 380 V Contact plug 32 A, 5 poles, 380 V Contact plug 64 A, 5 poles, 380 V Gas guard Order number GG 400, is an accessory to be used with wire feeders to control the gas flow and to guard the gas, gas flow regulation range 5-25 l/min, if there is no sufficient gas pressure GG 400 will stop the welding Connection cables number of conductors, cross-section and type mm² Outer diameter max. mm Nominal voltage max. Uo/U V Order number 4 X 1.5 mm² / X 2.5 mm² / X 6 mm² / The nominal voltage Uo/U, has been marked to the cable charts where Uo = the highest allowed voltage between conductor and earth, and U = the highest allowed voltage between conductor Kemppi Product Catalogue 75

76 TRANSPORT UNITS T 100 T 110 T 120 T 130 MASTER MLS 1600, 2500, 3500 MASTERTIG MLS , W, 3500W MASTERTIG MASTERTIG AC/DC , 2500W, 3500W P 20 P 40/P 40 L P 30W P (L) KEMPPI PRO EVOLUTION 3200, 4200, , 4200, Promig / Protig (P 40) 3200, 4200, Promig / Protig +Procool 30 (PSL 55) 3200, 4200, Promig / Protig +Procool 10 PROMIG 200, 300, 501 KEMPOWELD / WIRE KEMPOMIG / FEED 76 Kemppi Product Catalogue 2004

77 T 10 T 22 ST 6 T MASTERTIG MLS , W, 3500W MASTERTIG MASTERTIG AC/DC , 2500W, 3500W KEMPPI PRO EVOLUTION 3200, 4200, , 4200, Promig / Protig 3200, 4200, Promig / Protig +Procool , 4200, Promig / Protig +Procool 10 MASTER 5001 T 120 ST 5 KV KEMPPI PRO EVOLUTION 3200, 4200, , 4200, Promig / Protig 3200, 4200, Promig / Protig +Procool , 4200, Promig / Protig +Procool 10 MASTER 5001 KEMPOWELD / WIRE KEMPOMIG / FEED MIGGER 2004 Kemppi Product Catalogue 77

78 WELDING HELMETS Alfa Welding Helmet Kemppi Alfa is a welding helmet for arc welding, carbon arc gouging and plasma cutting, used to protect the welder s eyes and face against arc radiation and welding spatter. In the upper position of the flip-up welding filter lens, protection during de-slagging is possible. Order Information Alfa welding helmet Welding filter lens 60 x 110 mm EN Welding filter lens 90 x 110 mm EN Welding filter lens 60 x 110 mm EN Welding filter lens 90 x 110 mm EN Welding filter lens 60 x 110 mm EN Welding filter lens 90 x 110 mm EN Welding filter lens 60 x 110 mm EN Welding filter lens 90 x 110 mm EN Welding filter lens 60 x 110 mm EN Welding filter lens 90 x 110 mm EN Welding filter lens 60 x 110 mm EN Welding filter lens 90 x 110 mm EN Welding filter lens 60 x 110 mm EN Welding filter lens 90 x 110 mm EN Protection glass 60 x 110 mm Glass retaining spring Protection glass, polykarb. 60 x 110 mm Headband Viewing lens Sweatband Kemppi Product Catalogue 2004

79 Beta Welding Helmet Kemppi Beta gives you full protection without compromising your visibility or comfort. Kemppi s Beta welding helmets have been designed to let you focus on the task at hand. To weld with optimum visibility without the need to intermittently remove or adjust your helmet. To make it easier for you to maneuver into tight positions without compromising your safety, and to deliver maximum comfort throughout. Kemppi Beta comes with a spring mounted flip-front lens. Lift the filter lens and keep working. The 100% clear safety lens underneath is safety assured for grinding. Weld without restraint! Full protection against arc radiation and spatter Perfect visibility with a flip-front lens Auto Darkening lens (models 90 A, 90 X) Optimized viewing area Lightweight, balanced and comfortable Durable, resistant and reliable Protects chin, ears and throat Interchangeable filter lenses Modern, narrow design Kemppi Beta Auto Darkening welding helmets 90 A and 90 X The Beta 90 A comes with fixed shade and sensitivity (shades 3/ 10.5 and 3/ 11 respectively). The Beta 90 X comes with shade and sensitivity adjustments. It easily adjusts for MMA, MIG or TIG arcs (shades 4/9-13). This model is the perfect choice for the most demanding welding applications. Protection glas and magnifying glases for Beta Magnifying glas 1,0 51 x 108 mm Magnifying glas 1,5 51 x 108 mm Magnifying glas 2,0 51 x 108 mm Magnifying glas 2,5 51 x 108 mm Colourful Protection glas 90 x 110 x 1,0 Polycarb. DIN Magnifying glas can be fixed easily with double-sided sticker. The protection plate complies the test requirements of UV radiation and filtrates also infrared light, but a bit less than test requirements. This plate is generally used in welding helmets. Technical Data and Order Information BETA 60 BETA 90 BETA 90 A BETA 90 X Welding filter size mm 60 x x x x 110 Viewing area 90 x x x x 95 Filter shade range EN 8-14 * EN 8-14 * EN 3 / 11 EN 4 / 9-13 Sensitivity - - Fixed Adjustable Switching time s s Delay (dark ->bright) s 0.4 s Order number *) Beta 60/90 filter shade EN 10 in the delivery 2004 Kemppi Product Catalogue 79

80 BETAFRESH Betafresh consist of Kemppi Beta welding helmet and Clean-air respiratory unit. The Betafresh 90 and 90X motorised respirator masks meet industrial safety requirements in dust, solid/liquid aerosol and smoke protection. There is also available an active carbon filter for unpleasant smells and ozone as well as a pre-filter, which increases the service life of the main filter. Betafresh 90 Basic 2000 Dual Flow Beta 90 welding helmet (EN 12941) - dark welding screen Basic 2000 Dual Flow ( TH1P ) - Motorized flow unit ( TH1P ) - air flow adjustment 160 or 210 l/min - rechargeable, ecological NiMH battery, operation time with a single charge appr. 7 h - P3 particle filter - weight 900g For arc welding, carbon arc gouging and plasma cutting, provides optimum protection from arc radiation and spatter Screening factor 100 % Ergonomic Betafresh 90X Basic 2000 Flow Control Beta 90X welding helmet (EN 12941) - automatic screen Basic 2000 Flow control ( TH2P ) - 8-step flow rates l/min. - acoustic and optical alarm if the flow drops below 140 l/min - control of the battery and filter capacity - rechargeable, ecological NiMH power battery, operation time with a single charge 7-10 h - P3 particle filter - weight 900 g For arc welding, carbon arc gouging and plasma cutting, provides optimum protection from arc radiation and spatter Screening factor 100 % Ergonomic Order information Betafresh 90 AF Motor unit + airhose Basic 2000 Flow Control AF incl.: welding helmet, blower unit, battery, hose, support belt, charger P-3 dustfilter Basic 2000 AF Betafresh 90X AF Prefilter 10 pack Basic 2000 AF incl.: welding helmet, blower unit, battery, hose, support belt, charger Dust/odour filter 10 pack Basic 2000 AF Spare parts Battery NiMH Basic 2000 AF Beta 90 helmet BETAFRESH 90 AF Battery NiMH Basic 2000 Flow Control AF Beta 90X helmet BETAFRESH 90X AF Heavy duty belt AF Motor unit + airhose Basic 2000 AF Protective hose for Plastic tube AF SPP 80 Kemppi Product Catalogue 2004