Pro 3200 Evolution
Pro 3200 Evolution
Pro 3200 Evolution
2 – Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 © COPYRIGHT KEMPPI OY
1. PREFACE
1.1. INTRODUCTION
Congratulations on having purchased this product. Properly installed Kemppi products should
prove to be productive machines requiring maintenance at only regular intervals. This manual
is arranged to give you a good understanding of the equipment and its safe operation. It also
contains maintenance information and technical 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:
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.
© COPYRIGHT KEMPPI OY Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 – 3
1.2.1. Operation control and connectors
H12 F11 Fuse for connetion for control table 6,3 A slow-blow
H11 Signal lamp I/O
H11 H12 Warning lamp for thermal protection
S11 Main switch I/O
02 X11, Welding connection parallel
S11
X12
X13 Earth connection
X14, Connection for control cable parallel
X15
01 Inlet of mains cable
02 Inspection cover for control panel PL, PX Accessories
01
X14
F11
X15
X16
F12
4 – Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 © COPYRIGHT KEMPPI OY
1.3. ACCESSORIES
1.3.1. Remote control devices
R10 6185409
R61
R20 6185419
R63 R61
MIG-MAG remote control device with controls for wire feed (R63) and voltage (R61), memory
scales 1 … 10.
You can use control device also for control of MMA current from potentiometer R63.
© COPYRIGHT KEMPPI OY Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 – 5
1.3.3. Cables
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 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.
6 – Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 © COPYRIGHT KEMPPI OY
2. INSTALLATION
© COPYRIGHT KEMPPI OY Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 – 7
If changing the mains cable take into consideration the following:
The cable is entered into the machine through the inlet ring on the rear panel of the machine and
fastened with a cable clamp (05). The phase conductors of the cable are coupled to connectors
L1, L2 and L3. The earth protection coloured green-yellow is coupled to connector
If you are using 5-lead cable, you must connect neutral conductor with
terminal N.
05
Sizes of the mains cables and fuse ratings for the machine at 100% duty cycle
are specified in the table below:
8 – Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 © COPYRIGHT KEMPPI OY
3.2. PILOT LAMPS
The pilot lamps of the machine report the electric operation:
The green pilot lamp H11 when illuminated indicates that the machine is on and ready for
use and it is connected to the mains supply with the main switch in the I-position.
H12 indicates when illuminated that the thermal protection of the machine has been
activated due to over heating. the cooloing fan will continue to run and cool the machine
downn and when the lamp is off the machine ia ready to weld.
4. ACCESSORIES
4.1. PL AND PX CONTROL PANELS’ OPERATION IN
MMA WELDING
4.1.1. Control for MMA welding dynamics (PL, PX)
With control for electrode dynamics you can influence arc behaviour in different kinds of
operation situations.
When arc is roughened, blowing is increasing and at the same time also spatter.
Soft arc. Object to reduce amount of spatter in welding at the upper end of recommen-
ded currents for electrode.
Factory setup (PX). Normal setting for all electrode types.
Rough arc. Object e.g. cellulose covered electrodes and thin stainless electrode in
welding at the lower end of the recommended curents for electrode.
I2
9 Roughening
0 0 = Factory set up
Softening
-9
© COPYRIGHT KEMPPI OY Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 – 9
4.1.2. Control of ignition pulse current (PX)
Display 0 corresponds to factory set up of ignition pulse. Number of ignition pulses depends on
electrode type and diameter which are used. Ignition pulse changes with set value of welding
current in such a way that at low values ignition pulse is low and short and at high values it
is higher and longer.
Low, short ignition pulse. Object e.g. small stainless electrodes.
I2
9
0 = factory set up
0
-9
max.
I2
statically constant current
10 – Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 © COPYRIGHT KEMPPI OY
Point to point welding
Point to point welding is necessary then when the seam to be welded doesn’t withstand heat
of continuous arc and welding has to carried out by interrupting arc. The reason is usually thin
materials or variable fittings.
The machine has characteristic curve which makes interrupting of arc easier when electrode is
drawn further from seam.
U2
U2=20V+0,04xI2
I2
statically constant current U is limited below max. voltage
of machine
I2
6. MAINTENANCE
The amount of use and the working environment shoud be taken into consideration when
planning the frequency of maintenance of the machine. Careful use and preventive maintenance
will help to ensure trouble-free operation.
6.1. CABLES
Check the condition of welding and connection cables daily. Do not use damaged cables.
Make sure that the mains cables in use are safe and according to laid down regulations.
The repair and mounting of a mains connection cables should be carried out only by an
authorized electrician.
© COPYRIGHT KEMPPI OY Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 – 11
6.2. POWER SOURCE
Note! Disconnect the plug of the machine from the mains socket and wait
approx. 2 minutes (capacitor charge) before removing the cover plate.
Check at least every half year:
- Electric connectors of the machine - clean the oxidized parts and tighten the loosened ones.
- Note! You must know correction tension torques before starting the reparation of the joints.
- Clean the inner parts of the machine from dust and dirt e.g. with a soft brush and vacuum
cleaner. Also clean the ventilation net behind the front grate.
- Do not use compressed air, there is a risk that dirt is packed even more tightly into gaps
of cooling profiles.
- Do not use pressure washing device.
- Only authorized electrician shall carry out repairs to the machines.
7. OPERATION DISTURBANCES
In case of problems contact the Kemppi works in Lahti, Finland, or your local Kemppi dealer.
Check the maintenace objects before the machine is sent to the Service Repair Shop.
12 – Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 © COPYRIGHT KEMPPI OY
7.3. UNDER- AND OVERVOLTAGES IN THE MAINS SUPPLY
Primary circuits of machine are protected against sudden, transient overvoltages.
Machine is designed to withstand 3 x 440 V voltage continiously (see technical data). See to
it that voltage is kept within admissble limits especially when mains supply is taken e.g. from
combusition engine generator.
If the mains has undervoltage (under approx. 300 V), machine control stops to operate automa-
tically.
8. ORDERING NUMBERS
Pro 3200 Evolution 6131320
Pro 4200 Evolution 6131440
Pro 5200 Evolution 6131520
Return current cable 5 m - 50 mm2 6184511
Return current cable 5 m - 70 mm2 6184711
Cable for MMA welding 5 m - 50 mm2 6184501
Cable for MMA welding 5 m - 70 mm2 6184701
PL 6185801
PX 6185802
R10 6185409
R20 6185419
Remote controlled interconnecting cable 10 m 6185481
T10 6185231
T120 6185252
P40 6185264
P40L 6185264L
P30W 6185262
© COPYRIGHT KEMPPI OY Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 – 13
9. TECHNICAL DATA AND TERMS
OF GUARANTEE
14 – Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 © COPYRIGHT KEMPPI OY
9.2. 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 Authorized
KEMPPI Service Agent. Packing, freight and insurance costs to be paid by third party. The
guarantee is effected on the day of purchase. Verbal promises which do not comply with the
terms of guarantee are not binding on guarantor.
Limitations on guarantee
The following conditions are not covered under 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 or damage due to natural causes
i.e. ligthning or flooding.
This guarantee does not cover direct or indirect travelling costs, daily allowances or accomoda-
tion.
Note: Under the terms of the guarantee, welding torches and their consumables, feed, drive
rollers 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.
Guarantee period
The guarantee is valid for one year from date of purchase, provided that the machine is used
for single-shift operation.
The guarantee period for double and treble shift operation is six months and four months
respectively.
© COPYRIGHT KEMPPI OY Pro 3200 Evolution, Pro 4200 Evolution, Pro 5200 Evolution/0109 – 15
KEMPPI OY KEMPPI (U.K) Ltd.
PL 13 4-6 Sergeants Way
FIN – 15801 LAHTI Elms Industrial Estate
FINLAND BEDFORD, MK 41 OEH
Tel (03) 899 11 ENGLAND
Telefax (03) 899 428 Tel (01234) 213 581
www.kemppi.com Telefax (01234) 215 128
e-mail: sales.uk@kemppi.com
KEMPPIKONEET OY
PL 13 KEMPPI FRANCE S.A.
FIN – 15801 LAHTI S.A. au capital de 5 000 000 F.
FINLAND 65 Avenue de la Couronne des Prés
Tel (03) 899 11 78681 EPONE CEDEX
Telefax (03) 7348 398 FRANCE
e-mail: myynti.fi@kemppi.com Tel (01) 30 90 04 40
Telefax (01) 30 90 04 45
KEMPPI SVERIGE AB e-mail: sales.fr@kemppi.com
Box 717
S – 194 27 UPPLANDS VÄSBY KEMPPI GmbH
SVERIGE Otto – Hahn – Straße 14
Tel (08) 59 078 300 D – 35510 BUTZBACH
Telefax (08) 59 082 394 DEUTSCHLAND
e-mail: sales.se@kemppi.com Tel (06033) 88 020
Telefax (06033) 72 528
KEMPPI NORGE A/S e-mail:sales.de@kemppi.com
PB 2151 Postterminalen
KEMPPI OY
N – 3103 TØNSBERG
Oddzial w Polsce
NORGE
Ul. Pilsudskiego 2
Tel 33 35 80 80
05091 ZA¸BKI
Telefax 33 35 80 90
Poland
e-mail: sales.no@kemppi.com
Mobile phone +48 601 35 2272
KEMPPI A/S e-mail: jacek.rutkowski@kemppi.com
Literbuen 11
KEMPPI SWITZERLAND SA
DK – 2740 SKOVLUNDE
Chemin de la Colice 4
DANMARK
CH-1023 Crisser/ Lausanne
Tel 44 941 677
SUISSE
Telefax 44 941 536
Tel. +41 21 6373020
e-mail:sales.dk@kemppi.com
Telefax +41 21 6373025
KEMPPI BENELUX B.V. mobile +41 79 6303794
Postbus 5603 e-mail: sales.ch@kemppi.com
NL – 4801 EA BREDA Manager Felix Baumgartner
NEDERLAND
KEMPPI WELDING
Tel (076) 5717 750
MACHINES AUSTRALIA PTY LTD
Telefax (076) 5716 345
P.O. Box 404 (2/58 Lancaster Street)
e-mail: sales.nl@kemppi.com
Ingleburn NSW 2565, Australia
Tel. +61-2-9605 9500
Telefax +61-2-9605 5999
mobile (Kent E.) +61 417784287
e-mail: info.au@kemppi.com
Manager Kent Eimbrodt
www.kemppi.com
Ver. 2