PMT Torch User Manual - Rapid Welding and Industrial Supplies Ltd
Contents
1. 11 PMT Kemppi Oy 1130 EN PMT Kemppi Oy 1130 EN 12 PMT 25 PMT 27 PMT 32 When adjusting the neck always make sure that the fastening thread of the gun neck has been tighthened almost completely If you twist the neck too much outwards the connection between the neck and the cable becomes loose which increases the voltage drop As a result parts may overheat and become damaged USE AND MAINTENANCE The amount of use and working environment should be taken into consideration when planning the frequency of maintenance of MIG guns Careful use and preventive maintenance will help to ensure trouble free operation and a long lifespan for the gun Due to high temperatures and wear the welding end of MIG gun requires most maintenance but the condition of other parts should also be checked regularly Welding end Remove welding spatter and check the condition of insulations contact tip and gas nozzle Replace damaged and worn out parts with new ones Use only original Kemppi spare parts Check the condition of insulations Replace damaged insulations immediately with new ones Check that there is no spatter or dirt in the discharge holes for the shielding gas Use the gun properly Do not remove welding spatter by hitting the work piece with the gun Do not use sharp tools because damaging of surfaces will increase the sticking of spatter Do not bend the neck body of the gun or fasten th2. KEMPPI The Joy of Welding PMT 25 27 32 35 42 30W 42W 52W Operating manual English K ytt ohje Suomi Bruksanvisning Svenska Bruksanvisning Norsk Brugsanvisning Dansk Gebrauchsanweisung Deutsch Gebruiksaanwijzing Nederlands Manuel d utilisation Francais FI SV NO DA DE NL FR RU OPERATING MANUAL English PMT Kemppi Oy 1130 EN PMT Kemppi Oy 1130 EN CONTENTS 1 a I MEEC ICI 1 2 Product Introduction 1 3 Operation Safety ins 2 CONNECTING THE GUN 5 3 USING THE PMT GUN WITH UNITS OTHER THAN PROMIG AND FEED 6 3 1 Changing the connection 6 4 MOUNTING THE GUN REGULATOR 10 8 5 USING THE GUN REGULATOR 10 9 5 1 Regulating the wire feed speed and welding 9 5 2 Selecting the selecto channel 9 6 OPERATION OF THE THERMAL SHIELD 11 7 TWISTING THE NECK ten 11 8 USE AND MAINTENANCE ten 12 9 OPERATION DISTURBANCES ee 13 10 ORDERING NUMBERS 14 11 TECHNICAL ciini ni boot 15 1 1 PREFACE GENERAL Congratulations on having purchased this product Used correctly Kemppi products can significantly increase the prod
3. 127018 MOSCOW RUSSIA Tel 7 495 739 4304 Telefax 7 495 739 4305 info ru kemppi com 000 1 6 127018 Tel 7 495 739 4304 Telefax 7 495 739 4305 info ru kemppi com KEMPPI TRADING BEIJING COMPANY LIMITED Room 420 3 Zone Building B No 12 Hongda North Street Beijing Economic Development Zone 100176 Beijing CHINA Tel 86 10 6787 6064 86 10 6787 1282 Telefax 86 10 6787 5259 sales cn kemppi com THERE Ite SIR A RK BIA 16125 IF A IS BS 420 100176 88 18 86 10 6787 6064 86 10 6787 1282 J amp Ei 86 10 6787 5259 sales cn kemppi com KEMPPI INDIA PVT LTD LAKSHMI TOWERS New No 2 770 First Main Road KAZURA Gardens Neelangarai CHENNAI 600 041 TAMIL NADU Tel 4 91 44 4567 1200 Telefax 91 44 4567 1234 sales india kemppi com 0505661
4. arc range 10 20 l min is to be used Distance between the gun and the work piece is too long In short arc welding keep the gas nozzle at a distance of 10 15 mm and in hot arc welding at a distance of 15 30 mm from the work piece Angle of tilt of the gun is too large There is too much draught at the welding location 10 ORDERING NUMBERS Gun PMT PMT PMT PMT PMT PMT PMT PMT 14 Length 3 0 m Length 4 5 m 25 6252513 6252514 27 6252713 6252714 32 6253213 6253214 35 6253513 6253514 42 6254213 6254214 30W 6253043 6253044 42W 6254203 6254204 52W 6255203 6255204 11 TECHNICAL DATA Gun Loading Duty Wire Type of Cooling data capacity cycle diameters cooling Ar mm Max Min Min Max C02 A temp flow pressure pressure ininlet rate bar bar I min PMT 25 250 35 0 6 1 2 Air PMT 27 270 35 0 6 1 2 Air PMT 32 320 35 0 8 1 6 Air PMT 35 350 35 0 8 1 6 Air PMT42 420 35 0 8 1 6 Air PMT30W 300 100 0 8 1 6 Liquid 50 1 1 5 PMT42W 400 100 0 8 1 6 Liquid 50 1 1 5 PMT52W 500 100 0 8 1 6 Liquid 50 1 1 5 Connection to Mig unit Euro adapter Make sure that the gun in use is designed for the maximum welding current needed The guns meet construction and safety requirements according to norm IEC EN 60974 7 15 PMT Kemppi Oy 1130 EN KEMPPI OY Hennalankatu 39 PL13 FIN 15801 LAHTI FINLAND Tel 358 3 899 11 Telefax 358 3 899 428 export kemppi com www kemppi com K
5. described in the operation instructions for Promig and Feed wire feeder units SELECTING THE SELECTO CHANNEL When you are using a wire feeder fitted with a panel with Selecto mode you can also select the channels 1 5 from the PMT gun by using the gun regulator RMT 10 The use of the Selecto mode is described in the operation instructions for the Promig Positions 1 5 of the potentiometer on the RMT 10 correspond to the Selecto channels 1 5 see sticker on the potentiometer In order to find correct position of the potentiometer and to feel channel positions when turning the potentiometer you should release the spring loaded bearing of the RMT 10 On the outer edge of the potentiometer there are grooves corresponding to Selecto channels 1 5 into which the bearing slides PMT Kemppi Oy 1130 EN Kemppi Oy 1130 EN 10 1 5 mm IN Z Lit ILLIC Di Loosen the hexagon socket head screw 1 until the bearing 2 is released and pressed against the outer edge of potentiometer 3 look in the gap between the regulator frame and the potentiometer Restoring the RMT 10 into its normal state where potentiometer positions corresponding to Selecto channels are not felt Turn the potentiometer 3 a little so that the bearing 2 is forced out of the groove on the potentiometer edge Tighten the screw 1 OPERATION OF THE THERMAL SHIELD Inside the
6. fastening screw of the cover plate Release the cover plate from the handle by pushing it out on its guides Under the rear end of the cover plate you will now see a connector to which the gun regulator connects Make sure the regulator RMT 10 its connectors and the connectors of the gun are free of metal powder dirt etc Clean carefully if necessary Push the gun regulator RMT 10 onto the guides but not completely to the end Make sure that the connector on the handle side is in the correct position and that the connectors are correctly connected to each other Push the regulator carefully to its place Tighten the screw 5 1 5 2 USING THE GUN REGULATOR RMT 10 Depending on the panel used in the Promig or Feed wire feeder the gun regulator RMT 10 will enable you to regulate wire feed speed in MIG welding as well as the welding power of synergic MIG or pulsed MIG welding You can also select preprogrammed welding parameters from Selecto channels 1 5 according to your wishes Selecting and regulating signals of Selecto channel are transmitted along the start lines of the gun through a Euro adapter The gun regulator RMT 10 works only with the Promig and Feed wire feeders REGULATING THE WIRE FEED SPEED AND WELDING POWER The means to regulate the wire feed speed for MIG welding and regulation of welding power for synergic MIG or pulsed MIG welding as well as other relevant regulations fine adjustment and selections are
7. plastic protection of the snap connector head PMT W guns have as an extension for a liquid current cable a PTC thermal shield which in Promig or Feed equipment switches off the welding when gun overheats The thermal shield prevents overheating of the liquid current cable and other parts of the gun in case the cooling liquid for some reason should not circulate in the gun When the thermal shield switches off the welding a pilot lamp for the thermal shield of the Promig wire feed unit is lit It is possible to continue welding when the gun has cooled down enough NOTE The thermal shield operates only with the Promig and Feed units The thermal shield does not operate if the internal connections of the gun are changed into position FU If the thermal shield switches off the welding it is likely that cooling liquid does not circulate in the gun or that the flow is very weak Do not continue welding until you have cleared up the reason for the disturbance and repaired the fault Check the following The ccooling unit is running and has enough cooling liquid The cooling liquid hoses of the gun and interconnecting cable are correctly connected and they do not have any sharp bends TWISTING THE NECK If necessary you can twist gun neck of PMT 25 PMT 27 PMT 32 PMT 35 and PMT 42 360 in the direction of the handle see picture Grip the handle firmly with one hand and twist the neck with your other hand into the wanted position
8. trigger is pulled If the RMT 10 gun control unit is installed the use of the PMT gun in other units than Promig or Feed may cause a malfunction as described above eventhough you have changed the internal couplings of the gun If the RMT 10 gun control unit is coupled at its place using the PMT gun in units other than Promig or Feed may cause malfunctions as described above eventhough you have changed the internal coupling of the gun CHANGING THE CONNECTION Under the plastic cover of the snap connector head of the PMT gun there is an electronics card on which there is a shorting jumper for changing the connection Release the fastening screws 4 pcs of the plastic cover protector of the snap connector head Lift the cover approximately 50 mm Do not bend the cooling liquid hoses Take the electronics card out of the plastic protector Gently pull the insulating hose covering the card to the direction of the snap connector so that the shorting jumper becomes accessible Handle the wires of card and their connections carefully In the delivery state the shorting jumper is mounted to the connectors next to which at the base of the card there is a printed symbol text PRO Disconnect the shorting jumper and connect it to the another connector pair with the symbol text FU Pull the insulating hose back onto the card Mount the card back in its original place Make sure that clamper rings of wires rem
9. ain in their original position Make sure the plastic cover does not press against the card when it is reattached to the gun Press the cover of the plastic protection back in place Make sure that the cooling liquid hoses and their bending protections are placed inside plastic protection without any sharp bends and make that they retain the original shape of the hose Tighten the screws of the cover Mark the sticker on the cover to signify that the connection has been changed into the position FU RA KATSO K YTT OHJE SE BRUKSANVISNING SEE OPERATION INSTRUCTIONS SIEHE GEBRAUCHSANHE I SUNG ZIE GEBRUIKSRRNHI JZING VOIR MANUEL D UTILISATION The gun is now ready for use in devices other than Promig or Feed e g in FU wire feeders of Multisystems You can use the PMT gun with the FU connection also with the Promig and Feed but control and thermal protection operations will not be available Kemppi Oy 1130 PMT EN PMT Kemppi Oy 1130 EN MOUNTING THE GUN REGULATOR RMT 10 In the handle of the PMT gun there is a place for the gun regulator RMT 10 6185475 which is available as an accessory This regulator enables you to ragulate the welding power of synergic MIG or pulsed MIG welding with the Promig and Feed or select preprogrammed welding parameters according to your wishes In the delivery state there is a cover plate in place of the gun regulator 1 Release the
10. ction in the gun This might cause the gun handle and neck body to heat up considerably more than usual When connecting the liquid and gas hoses make sure there is no dirt metal powder or other waste in the connectors Waste may block the liquid circulation damaging the gun and stopping or breaking the pump Before you start welding make sure that the wire liner is according to recommendations see colour code in the consumable parts sheet and that the contact tip corresponds to the wire diameter used Look out for wire coming out of the welding end of gun Do not direct the gun towards people or the work piece but make sure that the wire exits the gun without obstruction PMT Kemppi Oy 1130 EN PMT Kemppi Oy 1130 EN 3 3 1 USING THE PMT GUN WITH UNITS OTHER THAN PROMIG AND FEED In the PMT guns in addition to start operations gun control and thermal protection operations are also transmitted along the control lines of the snap connector PMT 30W PMT 42W PMT 52W Hence the delivery state of the guns is such that without any alternations to the internal connections the guns are suitable to be used only with Promig and Feed wire feed units The use of PMT guns in other MIG units without any alternations to the connections may cause following erratic behaviour Start is always switched on and wire is being fed continuously eventhough the trigger is not pulled Start does not operate even if the
11. ding cables on the welding machine or on other electric equipment Do not press MIG gun switch if the gun is not directed towards a work piece Welding fumes Make sure that there is sufficient ventilation during welding Take special safety precautions when welding metals which contain lead cadmium zinc mercury or beryllium CONNECTING THE GUN In its delivery state internal connections of PMT guns are made so that they are suitable to be used only with Promig and Feed wire feeders Do not use the PMT gun in any other wire feeder than Promig and Feed before you have changed internal connections of gun according to the instructions in the following paragraph Do not use the PMT gun in units other than Promig and Feed before you are certain that the RMT 10 gun control unit is not installed on the gun Set the snap connector carefully in its place so that control connectors will not get damaged Tighten the snap connector carefully in order to avoid voltage loss A loose connection will heat up the gun and the feeder unit Inspect the tightness of the connection daily Connect liquid hoses of the gun and interconnecting cable according to operation instructions of the wire feeder Fix liquid hoses in such a way that ones having a red code are always connected to corresponding red counter connectors and the blue ones respectively to blue counter connectors If the connections are crossed cooling liquid will circulate in the wrong dire
12. e gun by its neck toa workbench etc for it may damage the neck of the gun Do not use the gun as a hammer Gun cable Clean the wire liner when replacing the wire reel or more frequently Checkon a daily basis that the insulations of the handle and the gun cable are undamaged Checkthat there are no sharp bends in the gun cable OPERATION DISTURBANCES Welding is stopped and the pilot lamp of thermal shield of the Promig unit is lit Thermal shield of the gun has stopped welding Find the fault before you continue welding Especially check connections of the cooling liquid hoses also in the interconnecting cable Start does not operate although you pull the trigger or start is always switched on although you do not pull the trigger Internal connection of the gun is in position PRO although you are using the gun in a wire feeder other than Promig or Feed Change connection according to the instructions RMT 10 gun control unit is coupled although you use gun in other units than Promig or Feed Detach the gun control unit Welding wire does not run smoothly or wire is sticking in the wire liner arc length varies you can feel shaking in the handle e Wire liner is dirty or blocked up Clean with compressed air Replace if necessary Wrong wire liner or contact tip Make sure that the wire liner and contact tip are according to recommendations for the welding wire in use see the consumable parts sheet deliv
13. ered with the gun The contact tip has heated up too much Check the cooling liquid circulation The contact face of the contact tip is damaged due to spatter or sparking caused by impurities Replace contact tip The gun cable has sharp bends straighten The welding wire has a lot of dirt rust or bends etc which increases friction and results in contact disturbances Check operation of the wire feed unit Check that the drive roll size and type are suitable for the wire in use Check that the drive roll pressure is not too low or too high Gas shielding is bad weld pool is boiling arc is unstable There is too much welding spatter on the inner face of the gas nozzle or in the contact tip and the contact tip holder clean There is spatter or other dirt in the discharge hole for shielding gas clean There are impurities in the shielding gas moisture air There are impurities in the base material rust base coat grease 13 PMT Kemppi Oy 1130 EN PMT Kemppi Oy 1130 EN Pressure cumulated in long gas hoses will cause a burst of shielding gas at the beginning of welding which may cause turbulence or mixing of air into the shielding gas The reason for this might also be a faulty or a poorly adjusted relief valve which puts too much pressure into the gas hoses Flow of shielding gas is too low or too high causes turbulence In short arc range a flow of 8 15 l min in hot
14. otimaan myynti Tel 358 3 899 11 Telefax 358 3 734 8398 myynti fi kemppi com KEMPPI SVERIGE AB Box 717 S 194 27 UPPLANDS V SBY SVERIGE Tel 46 8 590 783 00 Telefax 46 8 590 823 94 sales se kemppi com KEMPPI NORGE A S Postboks 2151 Postterminalen N 3103 T NSBERG NORGE Tel 47 33 346000 Telefax 47 33 346010 sales no kemppi com DANMARK A S Literbuen 11 DK 2740 SKOVLUNDE DANMARK Tel 45 4494 1677 Telefax 45 4494 1536 sales dk kemppi com KEMPPI BENELUX B V Postbus 5603 NL 4801 EA BREDA NEDERLAND Tel 31 765717750 Telefax 31 765716345 sales nl kemppi com www kemppi com KEMPPI UK Ltd Martti Kemppi Building Fraser Road Priory Business Park BEDFORD MK44 3WH UNITED KINGDOM Tel 44 0 845 6444201 Telefax 44 0 845 6444202 sales uk kemppi com KEMPPI FRANCE S A S 65 Avenue de la Couronne des Pr s 78681 EPONE CEDEX FRANCE Tel 33 1 30 90 04 40 Telefax 33 1 30 90 04 45 sales fr kemppi com KEMPPI GmbH Otto Hahn StraBe 14 D 35510 BUTZBACH DEUTSCHLAND Tel 49 6033 88 020 Telefax 49 6033 72 528 sales de kemppi com KEMPPI SP KA Z 0 0 Ul Borzymowska 32 03 565 WARSZAWA POLAND Tel 48 22 7816162 Telefax 48 22 7816505 info pl kemppi com KEMPPI AUSTRALIA PTY LTD 13 Cullen Place Box 5256 Greystanes NSW 2145 SMITHFIELD NSW 2164 AUSTRALIA Tel 61 2 9605 9500 Telefax 61 2 9605 5999 info au kemppi com 000 KEMPPI Polkovaya str 1 Building 6
15. s for manual welding are designed for demanding professional use They are suitable to be used in all MIG units equipped with a Euro adapter OPERATION SAFETY Please study these Operation safety instructions and respect them when installing operating and servicing the machine Welding arc and spatters The welding arc hurts unprotected eyes Also be careful with reflecting arc flashes The welding arc and spatter burn unprotected skin Use safety gloves and protective clothing Danger of fire or explosion Pay attention to fire safety regulations Remove flammable or explosive materials from the welding location Always reserve sufficient fire fighting equipment at the welding location Be prepared for hazards in special welding jobs e g the danger of fire or explosion when welding container type work pieces NOTE Fire can break out from sparks even several hours after welding has been finished Mains voltage Never take the welding machine inside a work piece e g container or truck Do not place the welding machine on a wet surface Always check cables before operating the machine Change damaged cables without delay Damaged cables may cause injury or start a fire Connection cable must not be compressed or touch sharp edges or hot work pieces Welding power circuit Isolate yourself by using proper protective clothing do not wear wet clothing Never work on a wet surface or use damaged cables Do not put the MIG gun or wel
16. uctivity of your welding and provide years of economical service This operating manual contains important information on the use maintenance and safety of your Kemppi product The technical specifications of the equipment can be found at the end of the manual Please read the manual carefully before using the equipment for the first time For your own safety and that of your working environment pay particular attention to the safety instructions in the manual For more information on Kemppi products contact Kemppi Oy consult an authorised Kemppi dealer or visit the Kemppi web site at www kemppi com The specifications presented in this manual are subject to change without prior notice Important notes Items in the manual that require particular attention in order to minimise damage and personal harm are indicated with the NOTE notation Read these sections carefully and follow their instructions Disclaimer While every effort has been made to ensure that the information contained in this guide is accurate and complete no liability can be accepted for any errors or omissions Kemppi reserves the right to change the specification of the product described at any time without prior notice Do not copy record reproduce or transmit the contents of this guide without prior permission from Kemppi PMT Kemppi Oy 1130 EN PMT Kemppi Oy 1130 EN 1 2 1 3 PRODUCT INTRODUCTION Kemppi PMT MIG MAG gun
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