PRODUCT CATALOGUE
English 2004
2 3Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
Kemppi OyP.O. Box 13FIN-15801 LAHTIFINLANDTel. +358 3 899 11Fax +358 3 899 428
Kemppi (U.K) Ltd.Fraser RoadMartti Kemppi BuildingPriory Business ParkBedfordMK443WHENGLANDTel. +44 845 6444201Fax +44 845 6444202
Kemppi Welding MachinesAustralia Pty LtdP.O. Box 404(2/58 Lancaster Street)INGLEBURN NSW 2565AUSTRALIATel. +61 2 9605 9500Fax +61 2 9605 5999
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KEMPPI Sverige ABUpplands Väsby / Swedentel. + 46 8 590 783 00fax + 46 8 590 823 94
KEMPPIKONEET OYLahti / Finlandtel. + 358 3 899 11fax + 358 3 734 8398
KEMPPI Norge A/STønsberg / Norwaytel. + 47 33 34 60 00fax + 47 33 34 60 10
KEMPPI Danmark A/SSkovlunde / Denmarktel. + 45 4494 1677fax + 45 4494 1536
KEMPPI Benelux B.V.Breda / The Netherlandstel. + 31 76 571 7750fax + 31 76 571 6345
KEMPPI (U.K) Ltd.Bedford / Englandtel. + 44 845 644 4201fax + 44 845 644 4202
KEMPPI France S.AEpone Cedex / Francetel. + 33 (0) 1 30 90 04 40fax + 33 (0) 1 30 90 04 45
KEMPPI GmbHButzbach / Germanytel. + 49 6033 88 020fax + 49 6033 72 528
KEMPPI Switzerland AGCrissier / Lausanne / Switzerlandtel. + 41 21 637 3020fax + 41 21 637 3025
KEMPPI Spolka z.o.o.Zabki / Polandtel. + 48 22 781 6162fax + 48 22 781 6505
KEMPPI WeldingMachines Australia Pty Ltd Ingleburn /Australiatel. + 61 2 9605 9500fax + 61 2 9605 5999
KEMPPI OYLahti / Finlandtel. + 358 3 899 11fax + 358 3 899 428
Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
KEMPPI OYThe 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.
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The history of Kemppi arc-welders
1949 Kemppi Oy was founded by Martti Kemppithe 1950’s Export activities were startedthe 1960’s The first MIG/MAG machines and thyristor controlled rectifiers were developed1977 Kemppi introduced the world-first series-produced multi-process inverter power source
Hilarc 250 at the exhibition Schweißen & Schneiden in Essenthe 1980’s New inverter generation, including the first IGBT-inverters for MMA- and TIG welding1990 Kemppi was the first manufacturer of welding machines to receive the ISO 9001 Quality
Certificate of Det Norske Veritas1993 The first digital inverter generation was introduced at the exhibition Schweißen &
Schneiden in Essen1997 Kemppi presented the AC / DC -welding machines, the sixth generation of IGBT -
technology2001 Seventh generation of inverter welders was presented
KEMPPI WELDING EQUIPMENTKemppi Oy is committed to technical excellence that is testified with ISO 9001 quality management system received already in 1990 and ISO 14001 environmental management system since 2001. 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 60974-1 Safety requirements for arc welding equipmentIEC 60974-1 Part 1 Welding power sourceEN 501199 Electromagnetic Compatibility (EMC)IEC / EN 60974-2 Welding power source - Part 2: Liquid cooling systemsIEC / EN 60974-5 Welding power source - Part 5: Wire feedersIEC / EN 60974-7 Welding power source - Part 7: Welding torchesIEC / EN 60974-10 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.
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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.
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Contents
Kemppi Oy 3Kemppi welding equipment 4
MIG-welding
Migger, Super Migger, Migger 210 10Kempomat 2100, 2500, 3200, 4000, 1701, 2001, 2501 12Kempoweld 3200, 3200W, 4000, 4000W, 5500W, 2501 14Wire 200, 400, 550 15Kempomig 3200, 3200W, 4000, 4000W 16Feed 400 17Kemppi Pro Evolution 3200, 4200, 5200 18Promig 501, 501L, 511, 530 19Promig 100, 200, 300 and Procool 10, 30 20Operation panels for Promig 21Wire feed rolls 22Consumable parts of wire feed mechanism 23
TIG-welding
Mastertig 1500, 2200 26Mastertig MLS™ 2000, 2500, 2503, 3500, 3503 28Operation panels for Mastertig MLS™ 30Mastercool 10 and 12 31Kemppi Pro Evolution in TIG-welding: Protig 410 32Operation panels for Protig 33Mastertig AC/DC 2000, 2500, 2500W, 3500W 34Operation panels for Mastertig AC/DC 35
MMA-welding
Minarc 110, 140 38Master 2200 40Master 5001 41Master MLS™ 1600, 2500, 2503, 3500, 3503 42Operation panels for Master MLS™ 43Kemppi Pro Evolution in MMA-welding 44Operation panels for Kemppi Pro Evolution in MMA-welding 45
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Kemppi Pro Data Monitoring
Kemppi Data Monitoring 46
Robotics
Promig 520R/120R 48
MIG-guns
MT MIG-guns 50MMT MIG-guns 51KMG MIG-guns 52WeldSnake™ 53PMT MIG-guns 54Common features in PMT, MMT and WeldSnake™ 55Common features in all Kemppi MIG-guns 56Consumable parts 57Liners for MIG-guns 61Contact tips 61KMP Kemppi Push-pull guns 62
TIG-torches
TTK torches 64TTC torches 65TIG-torches represent top quality properties 66Consumable parts 67Consumable parts table 69Scratch-start TIG-torches 70
Welding accessories
Cables 70Kemppi Datamaster 71Remote control units 72Welding equipments 74Transport units 76Alfa-welding helmet 78Beta-welding helmet 79Betafresh 80
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MIG-WELDING
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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 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
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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.
MIGGER, SUPER MIGGER, MIGGER 210
MIGGER SUPER MIGGER MIGGER 210
Connection voltage (V) 1~220 -10 % … 240 +6 % 1~220 -10 % … 240 +6 % 3~220 -10 % … 240 +6 %
- - 3~380 -10 % … 415 +6 %
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 1.5 - 1.5 m/16A 3 x 1.5 - 1.5 m/16A 3 x 1.5mm²/10A
Filler wires ø (mm) 0.6…1.0 0.6…1.0 0.6…1.2
Dimensions (mm) L x W x H 445 x 205 x 475 770 x 380 x 650 826 x 392 x 655
Weight (kg) 26 43 53
Technical Data
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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 disturbance-free arc is the key to welding machine performance.
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
Order Information
Migger (1~ 230 V) 6211150
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) 6211170
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) 621121001
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 6185219
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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 CO2 and mixed gas MIG welding.
Technical Data
KEMPOMAT 2100 2500 3200 4000 1701
Connection voltage (V) 3~400V 380 -10 %…415 +6 % 380 -10 %…415 +6 % 380 -10 %…415 +6 % 380 -10 %…415 +6 % 1~230V
3~230V 220 -10 %…240 +6 % 220 -10 %…240 +6 % 220 -10 %…240 +6 % 220 -10 %…240 +6 % 220 -10 %…240 +6 %
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 0.6…1.2 0.6…1.2 0.6…1.6 0.6…1.6 0.6…1.2
Dimensions (mm) L x W x H 910 x 410 x 820 930 x 440 x 860 970 x 480 x 970 970 x 480 x 970 850 x 392 x 750
Weight (kg) 54 80 118 130 47
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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
Order Information
Technical Data
KEMPOMAT 2001 2501
Connection voltage (V) 1~240V 220 -10 %…240 +6 % 220 -10 %…240+6 %
Mains cable, fuse delayed 3 x 2.5 mm² / 20A 3 x 4.0 mm² / 25A
Loading capacity A / V 30% ED 200/24 250/26.5
100% ED 110/19.5 135/20.5
Filler wires (mm) ø 0.6…1.2 0.6…1.2
Dimensions (mm) L x W x H 910 x 420 x 840 910 x 420 x 840
Weight (kg) 76 82
Kempomat 1701 set (incl.230V power source, KMG 20 - 3 m, earth cable 16 mm², 5 m) 6214171
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 25 - 4.5 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 25 - 4.5 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 32 - 4.5 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 40-4.5 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 40 - 4.5 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) S6211200
Kempomat 2501 set (incl. 240V power source, MMT 25 - 3 m, earth cable 35 mm², 5 m) S6211250
KMW sync (sync. unit for push pull gun) 6219100
Branch cable 3151360
MSD-1 meter unit / 3200, 4000 6185666
GH 20 gun holder 6256020
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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
KEMPOWELD 3200, 3200W 4000, 4000W 5500W 2501
Connection voltage (V) 3~230V 220-10%…240+6% 220-10%…240+6% - 1~220-10%…240+6%
3~400V 380-10%…415+6% 380-10%…415+6% 380-10%…415+6% -
Mains cable / fuse delayed 200-240V 4 x 2.5 mm² / 20A 4 x 6.0 mm² / 25A - 3 x 4.0 mm² / 25A
380-415V 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 / 30 400 / 34 550 / 42 (60%) 250 / 26,5 (30%)
100% ED 205 / 24 260 / 27 430 / 36 135 / 20.5
External dimensions (mm) L x W x H 3200: 990 x 530 x 880 4000: 990 x 530 x 880 1075 x 480 x 1140 940 x 430 x 750
3200W: 990 x 530 x 1090 4000W: 990 x 530 x 1090
Weight (kg) 3200: 106, 3200W:118 4000: 126, 4000W: 138 194 66
WIRE 200 400 550
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 0.6…1.6 0.6…1.6 0.6…2.4
External dimensions (mm) L x W X H 570 x 210 x 440 570 x 210 x 440 570 x 210 x 440
Weight (kg) 12 12 13
Technical Data
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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 InformationPower sources Kempoweld 3200,230/400V 621532001 Gas-cooled interconnection cables KW 50-1.3-GH 6260350
Kempoweld 3200W, 230/400V 621632001 KV 400 50-1.5.GH (with the swing arm) 6260351
Kempoweld 4000, 230V 621540201 MULTIMIG 50-5-GH 626010401
Kempoweld 4000, 400V 621540401 MULTIMIG 50-10-GH 626010601
Kempoweld 4000W, 230V 621640201 Water-cooled interconnection cables KW 50-1.5-WH 6260352
Kempoweld 4000W, 400V 621640401 KV 400 50-1.7-WH (with the swing arm) 6260353
Kempoweld 5500W, 400V 6216554 KW 50-5-WH 626035401
Kempoweld 2501 package*, 240V S6211255 KW 50-10-WH 626035601
Wire feeders Wire 200 (2-roll drive) 6217200 KW 95-1.5-W 6260391
Wire 400 (4-roll drive) 6217400 KW 95-5-WH 6260393
Wire 550 (4-roll drive) 6217550 KW 95-10-WH 6260394
Metering unit MSD-1 V/A (standard / 5500 W) 6185666 KV 400 95-1.9-WH (with the swing arm) 6260392
Timer unit KMW (standard in all wire feeders) 6219200 Branch cable for KMP 3151360
Sync. unit KMW Sync 6219100 MIG welding guns MMT page 51
Swing arm KV 400 6185247
*Package includes: Wire 200 wire feeder, KMG 25 3m MIG- gun, KW 35-5-GH, 5m interconnection cable, earth cable 5m
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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 880 940 x 515 x 880
Weight (kg) 3200: 46 / 3200W:57 4000: 46 / 4000W: 57
FEED 400
Loading capacity 60% / 100% ED 400A / 310A
Filler wires (mm) ø 0.6…1.6
Operation principle 4 roll drive
Dimensions (mm) L x W x H 570 x 210 x 440
Weight (kg) machine: 15, wire reel: max. 20
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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 3200 6227320 Gas-cooled interconnection cables, with protective hose
Kempomig 3200W 6227325 KW 50-1.3-GH 6260350
Kempomig 4000 6227400 KV 400 50-1.5-GH (with the swing arm) 6260351
Kempomig 4000W 6227405 MULTIMIG 50-5-GH 626010401
Wire feed unit Feed 400 6237400 MULTIMIG 50-10-GH 626010601
Metering unit MSD-1 V/A 6185666 Water-cooled interconnection cables, with protective hose
Remote control unit C 110D 6185421 KW 50-1.5-WH 6260352
RMT 10 for PMT 6185475 KV 400 50-1.7-WH (with the swing arm) 6260353
Sync.unit SYNC 400 for KMP 6263120 KW 50-5-WH 626035401
Branch cable for KMP 3151370 KW 50-10-WH 626035601
Gas guard GG 400 6237405 Cables MMA cable 5 m - 50 mm 6184501
Gun holder GH 10 6256010 Earth cable 5 m - 50 mm 6184511
Transport unit P 500 (for Feed 400) 6185265 Swing arm KV 400 6185247
MIG welding guns Kemppi MT and PMT , pages 50, 54
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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 3200 4200 5200
Connection voltage 3~50/60 Hz 400-15%…+20% 400-15%…+20% 400-15%…+20%
Loading capacity 80% - 420 520
100% 320 400 440
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 0.93 0.93 0.93
Dimensions (mm) L x W x H 530 x 230 x 520 530 x 230 x 520 530 x 230 x 520
Weight (kg) 37 41 48
18 19Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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 511 530
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 0.6…2.4 0.6…1.6 0.6…2.4
Dimensions (mm) L x W x H 620 x 230 x 480 620 x 230 x 670 640 x 230 x 430
Weight (kg) 22 25 21
20 21Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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.
KEMPPI PRO EVOLUTION ON LONG REACH PROMIG
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 0.8…1.6 0.6…1.6 0.6…2.0
Dimensions (mm) L x W x H 575 x 185 x 200 500 x 230 x 315 600 x 225 x 415 450 x 190 x 420 610 x 230 x 290
Weight (kg) 8.9 13 17 16 12.5
20 21Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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
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
ML-operation panel
• Control of welding parameters• Selector of welding method• MMA/MIG dynamics control• Pulsed-MIG/synergic MIG control• Display of welding parameters
Order Information
Power sources Kemppi Pro 3200 Evolution 6131320 Transport units P 30 W 6185262
Kemppi Pro 4200 Evolution 6131420 P40 6185264
Kemppi Pro 5200 Evolution 6131520 P40L (with PSL 55) 6185264L
Wire feeders Promig 501 6232501 P 500 (for Promig 501) 6185265
Promig 501L (left) 6232505 Lift hooks for Promig 501 3135870
Promig 511 with swing-arm 6232511 for Promig 530 4298180
Promig 530 6232530 Intermediate cables for Promig 501, 511, 530 Water hose (Promig 511, 1.6 m) 4269330
Promig100 tandem feeder 6236305 Water hose (Promig 501/530,1.0 m) 4269340
Promig100B special version 6236306 70-5-WH, 6260312
Promig 200 6231520 70-10-GH 6260313
Promig 300 6231530 70-10-WH 6260314
Operation panels MC 6263501 70-15-GH 6260315
ML 6263502 70-15-WH 6260316
MXE 6263504 Protig / MIG / W / 501 3135780
Water cooling units Procool 10 6262012 Protig / MIG / W / 511 3135790
Procool 30 6262016 Intermediate cables for Promig 100 50-15-GH 6260211
Sync. unit Prosync 50/Promig 100, push-pull gun 6263121 50-25-GH 6260213
Remote control units R 20 (2-knob) 6185419 70-15-WH 6260225
RMT 10, MIG gun control 6185475 70-25-WH 6260227
C 100 T, wireless 6185412 Intermediate cables for Promig 200, 300 70-15-GH 6260325
External metering device PMU 10 6265010 70-20-GH 6260327
Gun holders GH 20 6256020 70-15-WH 6260335
GH 30 6256030 70-20-WH 6260337
Auxiliary voltage unit PSL 55, 230/380/500 V 6185627 70-15-WH 6260335
Cables Earth and welding cables, page 70 70-20-WH 6260337
22 23Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
WIRE FEED ROLLSAll 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 wiresKnurled V groove: Special feed roll for cored wires and steel wiresTrapezoidal groove with race: For heavy duty and for aluminium welding
FEED ROLL (L)= BALL RACE
Ø 28 mm4265240 **0...18 m/minØ 28 mm steel4287860 ***
* included in delivery** included in delivery, mounted*** accessory
Ø 40 mm4265250 *0...25 m/minØ 40 mm steel4297270 ***-not FU 11
Washer for changing the feed roll groove
4292030 *
Gear wheel
Fe Plain V 3133810 0.6/0.8 3133210 1.0/1.2 red 3133820 1.4-1.6/2.0 3133880 2.4 black
Ss 3143180 0.8/0.8(L) 3138650 1.0/1.0(L) red 3141120 1.6/1.6 (L) yellow 3133910 3.2 blue
Al white 3137390 1.2/1.2 (L) orange
Fe Knurled
3133940 1.0/1.2 red 3133990 1.4-1.6/2.0 3134030 2.4 black
3137380 1.2/1.2 (L) orange 3141130 1.6/1.6 (L) yellow 3134060 3.2 blue
Fe Trapezoidal 1.2/1.2(L) 3142220 1.4/1.4 (L) brown 3142230 2.0/2.0(L) 3142240 2.4(L) black
Fc groove with 3142210 3142200 1.6/1.6 (L) yellow grey
Ss ball race orange
Al
22 23Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
CONSUMABLE PARTS OF WIRE FEED MECHANISMAll Promig and Wire, FU11, Feed 400 wire feeders, Kempomat 1701, 2100, 2500, 3200, 4000
* included in delivery** included in delivery, mounted*** accessory
0.6…0.8 mm ø 1.0 mm 3134140 white
0.9…1.6 mm ø 2.0 mm 3133700** orange
Fe
Mc
Fc
1.6…2.4 mm ø 3.0 mm 3134710 yellow
0.8…1.6 mm ø 2.0 mm 3134290* silver
Ss
Al
1.6…2.4 mm ø 4.0 mm 3134130 blue, Wire 550
ø 2.0 mm 3134120**orange, Wire 550
ø 2.0 mm 3134300*silver
ø 4.0 mm 3134110*blueWire 550 3134130
ø 3.0 mm 3134720yellow
ø 2.4 mm 4266970brass / Promig 511
ø 2.4 mm 4267220**plastic
ø 4.0 mm 4270180plastic
ø 2.4 mm 4267220plastic
ø 4.0 mm 4270180plastic
ø 4.0mm 4267030brass
4268210** yellow4268560* yellow, Teflon
24 25Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
TIG-WELDING
24 25Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
Mastertig AC/DC
Kemppi Pro Evolution - DC TIG with separate HF unit
Mastertig - Compact DC TIG
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.
INCREASED FEATURES AND BENEFITS
26 27Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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.
MASTERTIG 1500 2200
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 1.5…3.25 1.5…4.0 (5.0)
External dimensions (mm) L x W x H 410 x 152 x 385 472 x 152 x 385
Weight (kg) 14 16.5
Technical Data
26 27Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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 613015801 Extension cables for remote control unit, 10 m 6185451
Mastertig 2200 613023101 for remote control unit, 25 m 6185452
Meter unit MSD-1 V/A 6185666 for remote control unit, 50 m 6185453
Remote control unit C 110C 6185410 for remote control unit C 100F, 10 m 6185310
C 100D 6185413 Transport units T110 6185251
C 100F foot pedal 6185405 T120 6185252
Torches Kemppi TTK , page 64 Cables Welding and earth cables page 70
28 29Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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™ 2000 2500 3500 2503 3503
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 5…200 5…300 5…400 5…300 5…400
Electrode sizes to be welded (mm) ø mm 1.5…4.0 1.5…5.0 1.5…6.0 1.5…5.0 1.5…6.0
Dimensions with cooling unit (mm) L x W x H 410 x 180 x 390 500 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) 15 22 23 22 23
28 29Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
• 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.
30 31Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
OPERATION PANELS FOR MASTERTIG MLS™
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
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
30 31Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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
Order Information
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 260 500 x180 x 260
Weight (kg) 10 10
Power sources Mastertig 2000 MLS™ 6112200 Remote control units R 10, 10 m 618540901
Mastertig 2500 MLS™ 6114250 R 11F foot pedal 6185407
Mastertig 3500 MLS™ 6114350 R 11T, wireless 6185442
Mastertig 2503 MLS™ 6112250 R 10, 5 m 6185409
Mastertig 3503 MLS™ 6112350 Meter unit MSD-1 V/A 6185666
Cooling units Mastercool 10 6122350 Transport units T 100 6185250
Mastercool 12 6122360 T130 6185222
Operation panels MTL 6116000 T200 6185258
MTX 6116005 Adapters for TTK-torches, gas-cooled 3148720
MTM 6116010 for TTK-torches, water-cooled 3148720
MTZ 6116015 Cables Remote control cable,10 m (R 10) 6185481
Torches Kemppi TTC and TTK, page 64 - 65 welding and earth cables, page 70
32 33Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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.
KEMPPI PRO EVOLUTION IN TIG-WELDING
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) 17
32 33Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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 InfornationPower sources Kemppi PRO 3200 Evolution 6131320 Water cooling units Procool 10 6262012
Kemppi PRO 4200 Evolution 6131420 Procool 30 6262016
Kemppi PRO 5200 Evolution 6131520 Transport units P 30 W 6185262
TIG-ignition unit Protig 410 6271262 P40 6185264
Operation panels TIG-welding TL-operation panel 6271265 P40L 6185264L
TX-operation panel 6271266 Intermediate cables 50-1-G 6271906
Remote control units R 10 (1-knob) 6185409 50-1-W 6271907
R 10F, foot pedal 6185406 50-10-GH 6271913
R 10F, extension cable 10m 6185482 50-10-WH 6271914
Torches TTK-TIG torches on page 64 Cables Earth and welding cables, page 70
34 35Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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 200 - 350 Amp. Mastertig AC/DC can be gas-cooled (2000, 2500) or water-cooled (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 2000 2500/2500W 3500W
Connection voltage 1~50/60 Hz 230 V ±10% - -
3~50/60 Hz - 230 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 3…200 3…250 3…350
AC 10…200 10…250 10…350
MMA 11…160 10…250 10…350
External dimensions (mm) L x W x H 540 x 260 x 510 690 x 260 x 550 (2500),830 (2500W) 690 x 260 x 870
Weight (kg) 30 39 (2500), 65 (2500W) 74
34 35Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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
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
Order Information
Power sources Mastertig AC/DC 2000 6162000 Transport units T120 6185252
Mastertig AC/DC 2500 6162500 T 22 6185256
Mastertig AC/DC 2500W 6162505 Gun holder GH 20 6256020
Mastertig AC/DC 3500W 6163505 Remote control units C 100C, 5 m 6185410
Operation panels AC/DC panel 6162801 C 100D, 5 m 6185413
AC/DC minilog panel 6162802 C 100AC, 10 m 6185417
AC/DC pulse panel 6162803 C 100F, 5 m 6185405
Torches Kemppi TTK, page 64 Cables earth- and welding cables, page 70
36 37Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
MMA WELDING
36 37Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
INCREASED FEATURES AND BENEFITS
Kemppi Pro Evolution
Master MLS™ - Professional MMA
Master 2200, 5001
Minarc 110, 140 - 1ph ”Weld Anywhere”
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.
38 39Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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 110 140
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...110 / 24.4V 10 / 20.5V...140 / 25.6V
Electrode sizes to be welded (mm) ø 1.5…2.5 1.5…3.25
Dimensions (mm) L x W x H 305 x 123 x 250 305 x 123 x 250
Weight (kg) 4.6 4.8
38 39Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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 110 6102110
incl. earth and connection cable 10mm - 3 m
Minarc 140 6102140
incl. earth and connection cable 16mm - 3 m
Accessory: TTM 15V TIG-torch 6271432
40 41Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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 2200 5001
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 1.5…4.0 1.5…6.0
Dimensions (mm) L x W x H 472 x 152 x 302 530 x 230 x 520
Weight (kg) 12.5 48
40 41Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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 2200 613022101
Master 5001 6130512
Remote control units C 100C - 5m 6185410
C 100D - 5m 6185413
Extension cable for remote control unit 10 m 6185451
25 m 6185452
50 m 6185453
Transport units T100 6185250
T110 6185251
T10 (5001) 6185231
Cables Earth and welding cables, page 70
Torches Scratch start TIG, page 70
42 43Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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™ 1600 2500 3500 2503 3503
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 10…160 10…250 10…350 10…250 10…350
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) 1.5…4.0 1.5…5.0 1.5…6.0 1.5…5.0 1.5…6.0
Dimensions (mm) L x W x H 410 x 180 x 390 500 x 180 x 390 500 x 180 x 390 500 x 180 x 390 500 x 180 x 390
Weight (kg) 14 20 21 20 21
42 43Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
• 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 InformationPower sources Master 1600 MLS™ 6102160 Remote control units R10, 5m 6185409
Master 2500 MLS™ 6104250 R10, 10m 618540901
Master 3500 MLS™ 6104350 R11T wireless 6185442
Master 2503 MLS™ 6102250 R11F foot pedal 6185407
Master 3503 MLS™ 6102350 Remote control cables 10 m for R 10 6185481
Operation panels MEL 6106000 R10, 10m 618540901
MEX 6106010 Transport units T100 6185250
Cables welding and earth cables, page 72 T110 6185251
Torches Scratch-start TIG, page 70 T130 6185222
44 45Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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 45Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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 3200 6131320
Kemppi Pro Evolution 4200 6131420
Kemppi Pro Evolution 5200 6131520
Operation panels PL-operation panel 6185801
PX-operation panel 6185802
Remote control unit R 10 (1-knob) - 5m 6185409
Transport unit T 10 6185231
Cables PRO remote control extension cable, 10m 6185482
Earth and welding cables, page 70
46 47Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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 6265003Interbus host card 9774110Interbus software 9774112
DLI 20 interface 6265008
Cabling between PC and DLI 20 depends on application and site.Cable is a special cable for Interbus, code no 9720770 (per meter)
PRO-PC Interface 6265006 Dli 10 RS-cable PRO-cable, 1 m
PRO-PC Interface 6265007 Dli 10 RS-cable PRO-cable, 5 m
46 47Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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, -2000
48 49Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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. - 20 kg / 300 mm
Operation principle 4-roll drive
Wire feed speed m / min 0…18 (25)
Filler wires (mm) ø 0.6…2.4
Dimensions (mm) L x W x H 319 x 152 x 167 620 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 49Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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 3200 6131320 Robot control connector 9770204
Kemppi Pro Evolution 4200 6131420 Cable support 9770140
Kemppi Pro Evolution 5200 6131520 Voltage monitor cable 4288700
Wire feed units Promig 520R control unit 6231510 Branch connector 9771637
Promig 120R 6236320 Intermediate cable assembly 5 m 6260421
Cooling units Procool 10 6262012 10 m 6260425
Procool 30 6262016 Welding guns MT-51MW straight neck 1.5 m 6255156
Operation panels MC 6263501 MT-51MW 30˚ bend neck 1.5 m 6255157
ML 6263502 MT-51MW straight neck 3.0 m 6255158
Prosync 50 6263121 MT-51MW 30˚ bend neck 3.0 m 6255159
Voltage sensor 4289560 Transport units P 20 6185261
Current sensor 4288790 P 30W 6185262
Wire reel hub 4289880 P 40 6185264
50 51Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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 0.6 - 1.0 0.6 - 1.2 0.6 - 1.6 0.8 - 1.6
Cored wire 0.8 - 1.0 0.8 - 1.2 0.8 - 1.6 0.8 - 2.4
Al 0.8 - 1.0 0.8 - 1.2 1.0 - 1.6 1.0 - 1.6
Length / Order number 3 m 6251013 6252023 6253038 6255046
4.5 m - 6252024 6253039 6255047
All guns with Euro-adapter, delivery equipment standard set-up: solid mild steel wire, see consumable parts . *) Availability to order
50 51Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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 - - -
100% - - - - - 300A 400A 500A
Filler wires ø mm 0.6 - 1.2 0.6 - 1.2 0.8 - 1.6 0.8 - 1.6 0.8 - 1.6 0.8 - 1.6 0.8 - 1.6 0.8 - 1.6
Length / Order number 3m 6252513MMT 6252713MMT 6253213MMT 6253513MMT 6254213MMT 6253043MMT 6254203MMT 6255203MMT
4,5m 6252514MMT 6252714MMT 6253214MMT 6253514MMT 6254214MMT 6253044MMT 6254204MMT 6255204MMT
52 53Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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 0.6 - 1.0 0.6 - 1.2 0.6 - 1.2
Cored wire 0.8 - 1.0 0.8 - 1.2 0.8 - 1.2
Al 0.8 - 1.0 0.8 - 1.2 0.8 - 1.2
Length / Order number 3 m 6251113 6252123 6253033
4.5 m - 6252124 6253034
All guns with Euro-adapter, delivery equipment standard set-up: solid mild steel wire, see consumable parts
52 53Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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
Kemppi WeldSnake™ products
Kemppi WS™ 30W 6m / 8mliquid-cooled 300 A
Kemppi WS™ 42W 6m / 8mliquid-cooled 400 A
WS™ MIG guns are suitable to be used with 1.2 (1.6) mm Aluminium and 1.0-1.2 mm Stainless Steel wires
WELDSNAKE™
Technical data and order information
WeldSnake™ 30W 42W
Loading capacity 100% 250 A (60 %) 300 A
Filler wires Ss 1.0 - 1.2 1.0 - 1.2
Al 1.2 (1.6) 1.2 (1.6)
Cooling Liquid Liquid
0.8 - 1.2 0.8 -1.2
Order information 6 m Al 1.2 6253046A12 6254206A12
6 m Ss 1.0 6253046S10 6254206S10
6 m Ss 1.2 6253046S12 6254206S12
8 m Al 1.2 6253048A12 6254208A12
8 m Ss 1.0 6253048S10 6254208S10
8 m Ss 1.2 6253048S12 6254208S12
The order number includes MIG gun + DL-Teflon liner and Contact tips (5 pcs)
54 55Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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 0.6 - 1.2 0.6 - 1.2 0.8 - 1.6 0.8 - 1.2 0.8 - 1.6 0.8 - 1.6 0.8 - 1.6 0.8 - 1.6
Cored wire 0.8 - 1.2 0.8 - 1.2 0.8 - 1.6 0.8 - 1.2 0.8 - 1.6 0.8 - 1.6 0.8 - 1.6 0.8 - 1.6
Al 0.8 - 1.2 0.8 - 1.2 1.0 - 1.6 0.8 - 1.2 1.0 - 1.6 0.8 - 1.6 0.8 - 1.6 0.8 - 1.6
Length / Order number 3 m 6252513 6252713 6253013 6253213 6254013 6253043 6254203 6255203
4.5 m 6252514 6252714 6253014 6253214 6254014 6253044 6254204 6255204
Accessory RMT 10 (6185475), 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 55Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
Kemppi PMT, MMT and WeldSnake series represent ultimate user-friendliness
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
56 57Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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 (0.8-1.6 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 57
1)
2)
ø 16
mm
ø 16
mm
M 8
M 6
1)
2)
3)
ø 14
mm
ø 14
mm
ø 14
mm
ø 25 mm
ø 18 mm
ø 18 mm
ø 18 mm
Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
CONSUMABLE PARTS
Insulating bush9591010*
Contact tip adapter9580173*
Insulating ring9591079* Locking spring
4275240*Neck 45º4153040*
Contact tips9876635 0.8/M6 MT 18, KMG 17, KMG 20*9876636 1.0/M6 MT 25, KMG 25, PMT 25*, MMT 25
Gas nozzles1) 9580101* Standard2) 4113470 For spotwelding3) 9580101E Thick wall
Wire conduits MT 18/25, KMG 20/25, PMT 25, MMT 25:4188571 Spiral 0.6-0.8 3m/white * MT 18, KMG 204188581 Spiral 0.9-1.2 3m/red * MT 25, KMG 25, PMT 25, MMT 254188582 Spiral 0.9-1.2 4.5m/red * MT 25, KMG 25, PMT 25, MMT 25
Wire conduits KMG 17/Migger:4188578 Spiral 0.6-0.8 2.5m/white *4188579 Spiral 0.6-0.8 3m/white *Suitable liners: white, red, DL-teflon
O-ring9520518*
Contact tips9580123 M8 *
Neck 45º4259480*
Gas nozzles1) 4259120* Standard2) 4259240 For spotwelding
Contact tip adapter4259210 M8 *4290490 M6
Insulating ring *4259160
Wire conduits4188581 Spiral 0.9-1.2 3m/red *4188582 Spiral 0.9-1.2 4.5m/red *Suitable liners: white, red, yellow, DL-teflon
* standard delivery
MT 18, MT 25, KMG 17, KMG 20, KMG 25, PMT 25, MMT 25
MT 32, KMG 32
58 59
M8
M6
86
1)
2)
3)
ø 25 mm
ø 16
mm
ø 16
mm
ø 12
.5 m
m
ø 25 mm
ø 17
.5 m
m
86
90
Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
CONSUMABLE PARTS
Contact tips 9580124 * 1.2/M8
Insulating ring4254670*
Neck standard, 45°3127990*
Insulating bush4248710 *
Contact tip adapter4255421* M84255091 M6
Gas nozzles1) 4255530 Standard 86 *2) 4255530E Long 903) 4273510 Conical 86
Wire conduits4188581 Spiral 0.9-1.2 3m/red *4188582 Spiral 0.9-1.2 4.5m/red *Suitable liners: white, red, yellow, DL-teflon
Insulating bush9591049*
Insulating ring9580265*
Neck standard 45°3120850*
Gas nozzle4247200 Standard *
Contact tips9580124* 1.2/M8
Wire conduits4188581 Spiral 0.9-1.2 3m/red *4188582 Spiral 0.9-1.2 4.5m/red *Suitable liners:white, red, yellow, green, black, blue, DL-teflon
* standard delivery
MT 38, KMG 40
MT 51W
Contact tip adapter 9580261 M8 *Contact tip adapter 9582581 M6
58 59
1)
2)
3)
4)
1)
2)
3)
76
76
79
70
ø 20 mm
ø 25 mm
ø 14
mm
ø 14
mm
ø 12
mm
ø 14
mm
86
86
90
ø 12
,5 m
mø
16 m
mø
16 m
m
Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
CONSUMABLE PARTS
Contact tips9580123* 1.0/M8 Gas diffuser
4294880*
Neck 45° PMT 27/323146780
Contact tip adapters4295740 M8 *4294890 M6
Neck 45º PMT 30W3146800
Gas nozzles1) 4295760 Standard / (M8) *2) 4295760L Long3) 4295760C Conical4) 4294970 Standard / (M6)
Wire conduits4188581 Spiral 0.9-1.2 3m/red *4188582 Spiral 0.9-1.2 4.5m/red *Suitable liners: white, red, yellow, DL-teflonWeldSnake, see table on page 61
Insulating bush4248710 *
Contact tip adapter426964001 M8 * Neck standard,45°
4270750
Contact tip9580124* 1.2/M8
Insulating ring4270290 *
Gas nozzles1) 4255530 Standard *2) 4255530E Long3) 4273510 Conical
Wire conduits4188581 Spiral 0.9-1.2 3m/red *4188582 Spiral 0.9-1.2 4.5m/red *Suitable liners: white, red, yellow, DL-teflon
* standard delivery
PMT 30, PMT 40, PMT 50, MMT 40
PMT 27, PMT 32, PMT 30W, MMT 27, MMT 32, MMT 30W, WeldSnake™ 30W
60 61
1)
2)
3)
ø 16
mm
ø 13
mm
ø 16
mm
1)
2)
3)
ø 18
mm
ø 14
mm
ø 18
mm
ø 22 mm
ø 25 mm
77
77
80
80
80
83
Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
CONSUMABLE PARTS
Contact tip M89580124 1.2 *
Gas diffuser4298290 * Neck 45º
3149600
Contact tip adapter4295740 M8 *
Gas nozzle1) 4300260 Standard *2) 4300260L Long3) 4300260C Conical
Wire conduits4188581 Spiral 0.9-1.2 3m/red *4188582 Spiral 0.9-1.2 4.5m/red *Suitable liners: white, red, yellow, DL-teflonWeldSnake, see table on page 61
Contact tip9580124 1.2 *
Gas diffuser4298300 *
Neck 45º3149640
Gas nozzle1) 4300380 Standard *2) 4300380L Long3) 4300380C Conical
Contact tip adapter4300390 M8 *
Wire conduits4188581 Spiral 0.9-1.2 3m/red *4188582 Spiral 0.9-1.2 4.5m/red *Suitable liners: white, red, yellow, DL-teflon
* standard delivery
PMT 35, MMT 35, PMT 42W, MMT 42W, WeldSnake™ 42W
PMT 42, MMT 42, PMT 52W, MMT 52W
60 61Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
LINERS FOR MIG-GUNSKemppi 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 DL-teflon liner (patent pending). It is suitable for all common wire diameters and materials, and all Kemppi MIG guns.
CONTACT TIPSM8 Standard contact tips M8 (DHP) for solid mild steel and flux cored wire
Marking:Kemppi 1.2
Wire ø Hole ø Tolerance Order number
0.8 0.9 +0.1/-0.0 9580122
0.9 1.05 +0.05/-0.02 9580121
1.0 1.15 +0.05/-0.02 9580123
1.2 1.4 +0.05/-0.05 9580124
1.4 1.6 +0.05/-0.05 9580125
1.6 1.8 +0.1/-0.0 9580126
2.0 2.3 +0.0/-0.1 9580127
2.4 2.7 +0.05/-0.05 9580128
2.8 3.1 +0.1/-0.0 9580129
3.2 3.6 +0.05/-0.05 9580130
Contact tips M8 (DHP) for Aluminium wire
Marking:Kemppi 1.2 A
0.8 1.05 +0.05/-0.02 9580122A
0.9 1.15 +0.05/-0.02 9580121A
1.0 1.4 +0.05/-0.05 9580123A
1.2 1.6 +0.05/-0.05 9580124A
1.4 1.8 +0.10/-0.00 9580125A
1.6 2.3 +0.00/-0.10 9580126A
Steel / cored wire Filler wire ø Order number 3 m Order number 4.5 m
White 0.6 - 0.8 4188571 4188572
Red 0.9 - 1.2Fe 4188581 4188582
Yellow 1.4 - 1.6 (1.2) 4188591 4188592
Green 1.6 - 2.0 4188601 4188602
Black 2.0 - 2.4 4188611 4188612
Blue 2.4 - 2.8 4188621 4188622
Aluminium
DL-teflon liner 0.8 - 1.6 4300840 4300850
- Neck part (spiral/teflon) 4302150 4302150
Stainless steel
DL-teflon liner 0.8 - 1.0 4302680 4302690
- Neck part (spiral/teflon) 4302740 4302740
DL-teflon liner 1.2 - 1.6 4302700 4302710
- Neck part (spiral/teflon) 4302750 4302750
Migger / KMG17 liners Filler wire ø Order number 2.5m Order number 3m
White 0.6 - 0.8 4188578 4188579
Red 0.9 - 1.2 4188588 4188589
DL-teflon liner /AL 0.8 -1.2 4302090 4302100
- Neck part (spiral/teflon) 4302150 4302150
DL-teflon liner /SS 0.8 - 1.0 4302720 4302730
- Neck part (spiral/teflon) 4302740 4302740
Contact tips M8 (CuAg) for Fe and flux cored wire
Marking:Kemppi 1.2 Ag
1.0 1.15 +0.05/-0.02 9580123AG
1.2 1.4 +0.05/-0.05 9580124AG
Contact tips M8 (CuCrZr) for solid mild steel and flux cored wire
Marking:Kemppi 1.2 CRZR
1.0 1.15 +0.05/-0.02 9580123ZR
1.2 1.4 +0.05/-0.05 9580124ZR
Contact tips M8 (DHP) for stainless and high acid-resistant steel
Marking:Kemppi 1.2 SS
0.8 1.15 +0.05/-0.02 9580122SS
0.9 1.4 +0.05/-0.05 9580121SS
1.0 1.6 +0.05/-0.05 9580123SS
1.2 - 1.4 1.8 +0.10/-0.00 9580124SS
1.6 2.3 +0.00/-0.10 9580126SS
M6 Standard contact tips M6 (DHP) for solid mild steel and flux cored wire
Marking:Kemppi 1.2
0.6 0.8 +0.05/-0.02 9876634
0.8 0.95 +0.05/-0.02 9876635
0.9 1.05 +0.05/-0.02 9876633
1.0 1.15 +0.05/-0.02 9876636
1.2 1.37 +0.05/-0.02 9876637
1.6 1.8 +0.05/-0.02 9876639
WeldSnake™ Filler wire ø Order number6 m Order number 8 m
DL-teflon liner /AL 1.0 - 1.6 4304100 4304110
DL-teflon liner /SS 1.0 4304120 4304130
DL-teflon liner /SS 1.2 - 1.6 4304140 4304150
62 63Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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)
Technical and Order information
KMP 300 KMP 400W
Loading capacity CO2 300A / 60% 400A / 100%
Ar + CO2, Ar 270A / 60% 350A / 100%
Filler wires to be welded (mm) ø Fe, Ss 0.8…1.2 0.8…1.2
Al 0.8…1.2 0.8…1.6
Connection to wire feeder Euro-connection Euro-connection
Length / Order number 6 m 6257306 6257406
10 m 6257310 6257410
Order information
KMW Sync Kempomat, Kempoweld 6219100
Sync 400 Kempomig 6263120
Adapter Kempomat, Kempoweld 3151360
Adapter Kempomig 3151370
6257306RMP: KMP 300, 6 m, RMP 10, Prosync 50
6257310RMP: KMP 300, 10 m RMP 10, Prosync 50
6257406RMP: KMP 400W, 6 m, RMP 10, Prosync 50
6257410RMP: KMP 400W, 10 m, RMP 10, Prosync 50
KMP for Kemppi Pro Evolution
62 63Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
Kemppi Pro Evolution and KMP Kemppi Push-Pull Guns with ATCTM - 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 M8E - Cu, L= 30 mm (availability: to order)
Contact tips M8CuCrZr,L=30 mm (availability: to order)
Contact tips M8 for AluminiumE - Cu, L=30 mm (availability: ex stock)
Order number Wireø mm
Holeø mm
Tolerancemm
Order number Wireø mm
Holeø mm
Tolerancemm
Order number Wireø mm
Holeø mm
Tolerancemm
140.0114 0.8 1.0 - 0.1 140.0117 0.8 0.93 + - 0.03 141.0003 0.8 1.1 - 0.1
140.0313 1.0 1.2 - 0.1 140.0316 1.0 1.16 + - 0.03 141.0008 1.0 1.5 - 0.1
140.0442 1.2 1.5 - 0.1 140.0445 1.2 1.36 + - 0.03 141.0015 1.2 1.7 - 0.1
140.0533 1.4 1.7 - 0.1 140.0536 1.4 1.62 + - 0.03 141.0055 1.4 1.8 - 0.1
140.0587 1.6 1.9 - 0.1 140.0590 1.6 1.83 + - 0.03 141.0022 1.6 2.0 - 0.1
64 65Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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 - - - - - - 200A 250A 200A
AC 40% ED 100A 100A 120A 110A 160A 120A 250A 300A 250A
AC 100% ED - - - - - - 140A 200A 140A
Electrode sizes ø 1.0…2.4 1.0…2.4 1.0…2.4 1.0…2.4 1.0…3.2 1.0…3.2 1.0…2.4 1.0…4.0 1.0…4.0
Connection to TIG-unit gas/current R1⁄4 R1⁄4 R1⁄4 R1⁄4 R1⁄4 R1⁄4 - - -
water/current - - - - - - R3/8 R3/8 R3/8
gas - - - - - - R1⁄4 R1⁄4 R1⁄4
Length / Order Number 4 m 627063004 627063104 627066004 627066204 627072004 627072304 627080504 627085504 627075704
8 m 627063008 627063108 627066008 627066208 627072008 627072308 627080508 627085508 627075708
16 m 627063016 627063116 627066016 627066216 627072016 627072316 627080516 627085516 627075716
64 65Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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 - - - - - 200A 250A 200A
Electrode sizes ø 1.0…2.4 1.0…2.4 1.0…2.4 1.0…2.4 1.0…3.2 1.0…2.4 1.0…4.0 1.0…4.0
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 627013004 627013104 627016004 627016204 627022004 627020504 627025504 627025704
8 m 627013008 627013108 627016008 627016208 627022008 627020508 627025508 627025708
16 m 627013016 627013116 627016016 627016216 627022016 627020516 627025516 627025716
66 67Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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 67
190 mm
96.5 mm
190 mm
129 mm
96.5 mm
129 mm
10
42.5
138.0
175 mm
a b
c
d
a
d
b
c
Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
CONSUMABLE PARTS FOR TIG-TORCHESBig torch head: TTK 160, 220, 220S, 350W, TTC 160, 220, 250W
Electrodegrey ø 1.6 9873532 ø 2.4 9873533 * ø 3.2 9873534 ø 4.0 9873535white ø 1.6 9873521 ø 2.4 9873522 ø 3.2 9873523 ø 4.0 9873524green ø 4.0 9873505
Gas nozzle / lens mm a b c dNo. 5 7990783 25.0 12.5 7.5 42.0No. 6 7990784 25.0 14.0 9.0 42.0No. 7 7990785 25.0 15.5 11.0 42.0No. 8 7990786 25.0 16.5 12.0 42.0No. 11 7990787 25.0 22.0 17.0 42.0
Housing for tighteningbush/gas lensø 1.6 7990711ø 2.4 7990712ø 3.2 7990713ø 4.0 7990714
Tightening bushø 1.6 9876867ø 2.4 9876868 *ø 3.2 9876869ø 4.0 9876870
Insulating ring9876860
Insulating ring9580266 *
Electrode shieldincluding O-ringshort 7990731medium 7990735long 7990741 *
See the torch body from the separate table
O-ring7990791
Housing for tightening bushø 1.6 7990681ø 2.4 7990682 *ø 3.2 7990683ø 4.0 7990684
Gas nozzle mm a b c dNo. 4 7990766 18.0 11.5 6.5 47.5No. 5 7990770 18.0 12.5 8.0 47.5No. 6 7990771 * 18.0 14.5 9.5 47.5No. 7 7990772 18.0 16.0 11.0 47.5No. 8 7990773 18.0 18.0 12.5 47.5No. 10 7990775 21.0 21.0 16.0 47.5No. 12 7990776 24.0 24.0 19.0 47.5
Height / Standard gas nozzle Height / Lens equipment
* Delivery equipment is for ø 2.4 mm electrode.Lens equipment is as accessory.The above-mentioned dimensions are directive.
68 69
187 mm
90 mm
59 mm
191 mm
95 mm
63 mm
10
41.5
138.0
175 mm
a
d
b
c
a b
c
d
Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
CONSUMABLE PARTS FOR TIG-TORCHESSmall torch head: TTK 130, 130F, 160S, 250WS, 300W, TTC 130, 130F, 160S, 200W, 250WS
Electrodegrey ø 1.0 9873531 ø 1.6 9873532 ø 2.4 9873533 *white ø 1.0 9873520 ø 1.6 9873521 ø 2.4 9873522
Gas nozzle / gas lens mm ø a b c dNo. 4 7990779 18.5 10.5 7.0 25.5No. 5 7990780 18.5 12.0 8.0 25.5No. 6 7990781 18.5 13.5 9.5 25.5No. 7 7990782 18.5 15.0 11.0 25.5
Housing for tightening bush/lensø 1.0 7990700ø 1.6 7990701ø 2.4 7990702
Tightening bush/shortø 1.0 7990640ø 1.6 7990641ø 2.4 7990642
Insulating ring9878013 *
Electrode shieldincluding O-ringshort 7990730medium 7990734 *long 7990740
O-ring7990790
Tightening bushø 1.0 7990635ø 1.6 7990636ø 2.4 7990637 *
Housing for tightening bushø 1.0 7990660ø 1.6 7990661ø 2.4 7990662 *
* See the torch body from the separate table
Gas nozzle mm ø a b c dNo. 4 7990760 14.5 10.0 6.5 30No. 5 7990761* 14.5 11.0 8.0 30No. 6 7990762 14.5 14.5 10.0 30No. 7 7990763 14.5 14.5 11.0 30
Special Gas nozzle mm ø a b c dNo. 4 9878019 15.0 10.5 6.5 48No. 5 9878020 15.0 11.5 8.0 48No. 6 9878021 15.0 13.5 9.5 48
Height / Standard gas nozzle Height / Lens equipment
* Delivery equipment is for ø 2.4 mm electrodeLens equipment is as accessoryThe above-mentioned dimensions are directive
68 69
TTC / TTK
TTC
130
/ TTK
130
TTC
130F
/ TT
K 13
0F
TTC
160
/ TTK
160
TTC
160S
/ TT
K 16
0S
TTC
220
/ TTK
220
TTK
220S
TTC
200
W /
TTK
300
W
TTC
250
W /
TTK
350
W
TTC
250
WS
/ TTK
250
WS
4285650
9878040 (Flex)
4270580
4285660
4270600
4276530
4276300
4276290
4276550
Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
CONSUMABLE PARTS FOR TIG-TORCHES
Standard Delivery Accessory ”Small” Consumable Parts
70 71Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
SCRATCH-START TIG TORCHES
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: 6271432
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: 627143201
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: 627022304
The Kemppi TIG torch range includes three scratch-start TIG torches with shielding gas valves in the neck:
CABLESEXTENSION CABLE
Order number ø mmmax.welding
current A/ED 60%length m
6183210 25 250 10
6183310 35 300 10
6183510 50 400 10
6183525 50 400 25
6183710 70 600 10
6183725 70 600 25
WELDING CABLE EARTH CABLE
Order number Order number ø mmmax.welding
voltage A/ED 60%length m
6184005 6184015 16* 200 5
6184103 6184113 16 200 5
6184201 6184211 25 250 5
6184202 6184212 25 250 10
6184301 6184311 35 300 5
6184302 6184312 35 300 10
6184501 6184511 50 400 5
6184502 6184512 50 400 10
6184701 6184711 70 600 5
6184702 6184712 70 600 10
70 71Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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 InformationDatamaster set 6265040
Including:- Datamaster Box - PC Software- Cables (RS, flat, Pro)- Battery Charger
72 73Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
REMOTE CONTROL UNITS
C 100D6185413 5 m6185414 10 m
for MMA/TIG -welding used with Master-, Multisystem- and Kempotig-machines.Coarse / fine adjustment
C 100C6185410 5 m6185411 10 m
for MMA/TIG -welding current, used with Master-, Multisystem- and Kempotig-machines
C 100 AC6185417 10 m
for MMA/TIG -welding with Mastertig AC/DC -power sources. Selection of welding method MMA/TIG
C 110D6185421 5m
for MIG/MAG-welding. For adjustment of wire feeder and voltage with Multisystem and Kempomig power sources
R 106185409 5 m618540901 10 m
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
R 206185419 5 m
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
R 11T6185442
Wireless, with Master MLS™ - and Mastertig MLS™ -power sources
RTC 106185477
Control unit for TTC torches, can be installed to replace the original start-switch. Mastertig MLS™
RTC 206185478
Control unit for TTC torches, can be installed to replace the original start-switch. Mastertig MLS™
RMT 106185475
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 73Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
Foot remote control units
C 100F6185405 5 m
for TIG welding used with Master-, Multisystem- and Kempotig-machines. Start-function, min/max selection of welding current
R 10F6185406 5 m
in TIG welding for Kemppi Pro Evolution. Start-function. min/max selection of welding current
R 11F6185407 5 m
for Mastertig MLS™- power sources
C 100T6185412 C 100T6185613 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 120S6185427
Preprogramming unit for MIG/MAG- and MMA-welding with Multisystem- and Kempomig. Adjustment of wire feed speed and voltage
C 100P6185424
Long pulse unit for TIG welding used with Multisystem power sources
74 75Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
WELDING ACCESSORIES
Remote control extension cables Order number
Remote control extension cable (10 m) C 110D 6185451
Remote control extension cable (25 m) C 110D 6185452
Remote control cable (1.5 m) C 120S/SU 6185454
Remote control cable (10 m) C 120S/SU 6185455
Remote control cable (1.5 m) C 120P 6185457
Remote control cable (10 m) C 120P 6185458
Remote control extension cable (10 m) C 100M, C 110M, C 100F, C 100P 6185456
Distribution box PSS/TU, FU/C 100M- C 110M 6185710
PRO-remote control extension cable, 10 m 6185481
PRO-remote control start extension cable (for R 10F), 10 m 6185482
Digital meter unit Order number
MSD-1 Digital meter unit for Master 2850, Mastertig 2850/2850W, Kempomat, Kempoweld and Kempomig power sources
6185666
Auxiliary voltage unit Order number
PSL 55 auxiliary voltage unit 230/380/500 V for Kemppi power sources 6185627
Earth clamps Current rating Cable size /Connection Order number
Kemppi 200 200 A 25…35 mm, cable shoe connection Ø 6 mm 9871531
Kemppi 350 350A 50…70 mm, cable shoe connection Ø 6mm copper braiding between the jaws
9871540
Kemppi 500 500A 70…95 mm, cable shoe connection Ø 8 m copper braiding between the jaws
9871541
Kemppi G- 600 600A 35…120 mm, cable connection with hexa-conal screw, body of brass
9871560
Electrode holders A 60/35 % ED, Current rating Weight (g) / Cable size (mm²) Order number
KEMPPI 300 150 / 200 , 300A 321 / 16…25 9871021
KEMPPI 400 200/250, 400A 421 / 16…25 9871031
KEMPPI 500 250/300, 500A 500 / 35…50 9871041
KEMPPI 600 300/400, 600A 855 / 50…70 9871051
MYKING 200 200 A 285 / 10…25 9871060
MYKING 450 450 A 85 / 35…70 9871070
In all electrode holders: body of brass, cable fastening with hexaconal screw
MYKING 600 600 A 535 / 50…70 9871080
74 75Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
Gun Holders Model Order number
GH 10 The holders are primarily meant to be mounted on the welding machines, but also 6256010
GH 20 on transport units or on welding tables, to all Kemppi MIG / TIG welding machines 6256020
GH 30 6256030
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 4301820
for 1.2 mm wire ball bearings, press spring, press divider, improve wire feeding in Al-welding if 4301830
for 1.6 mm wire spring bushing, necessary accessories you have an old Kemppi feeder: Promig, 4301840
Wire, Feed or Kempomat (3200/4000)
Cable connectors Current durability A Cable mm² Order number, maleOrder number,
female
200 10…25 9771650 9771626
250 35 9771671 9771628
315 50 9771670 9771627
400 70 9771680 9771629
500 95 - 9771630
600 95 9771681 -
BRANCH CONNECTORS 70/90 1 male, 2 female 9771637
Contact plugs Connecting machines to the mains supply Order number
Contact plug 16 A, 5 poles, 380 V 9770812
Contact plug 32 A, 5 poles, 380 V 9770813
Contact plug 64 A, 5 poles, 380 V 9770814
Gas guard Order number
GG 400, is an accessory to be used with wire feeders to control the gas flow and to 6237405
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 diametermax. mm
Nominal voltagemax. Uo/U V Order number
4 X 1.5 mm² 11.0 300/500 9722122
4 X 2.5 mm² 13.0 300/500 9722138
4 X 6 mm² 19.5 450/750 9722142
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.
76 77
T 100 T 110 T 120 T 130
P 20 P 40/P 40 L P 30W P 500
6185250 6185251 6185252 6185222
6185261 6185264 (L) 6185262 6185265
MASTER MLS™1600, 2500, 3500
MASTERTIG MLS™
20002500, 35002500W, 3500W
MASTERTIG15002200
MASTERTIG AC/DC
20002500, 2500W, 3500W
KEMPPI PRO EVOLUTION3200, 4200, 52003200, 4200, 5200 + Promig / Protig (P 40)3200, 4200, 5200 + Promig / Protig +Procool 30 (PSL 55)3200, 4200, 5200 + Promig / Protig +Procool 10
PROMIG200, 300, 501
KEMPOWELD / WIRE
KEMPOMIG / FEED
Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
TRANSPORT UNITS
76 77
T 10 T 22 ST 6 T 200
T 120 ST 5 KV 400
MASTERTIG MLS™20002500, 35002500W, 3500W
MASTERTIG15002200
MASTERTIG AC/DC20002500, 2500W, 3500W
KEMPPI PRO EVOLUTION3200, 4200, 52003200, 4200, 5200 + Promig / Protig3200, 4200, 5200 + Promig / Protig +Procool 303200, 4200, 5200 + Promig / Protig +Procool 10
MASTER 5001
KEMPPI PRO EVOLUTION3200, 4200, 52003200, 4200, 5200 + Promig / Protig3200, 4200, 5200 + Promig / Protig +Procool 303200, 4200, 5200 + Promig / Protig +Procool 10
MASTER 5001
KEMPOWELD / WIRE
KEMPOMIG / FEED
MIGGER
6185231 6185256 6185221 6185258
6185252 6185219 6185247
Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
78 79Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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 9873010
Welding filter lens 60 x 110 mm EN 8 9873161 Welding filter lens 90 x 110 mm EN 8 9873241
Welding filter lens 60 x 110 mm EN 9 9873171 Welding filter lens 90 x 110 mm EN 9 9873242
Welding filter lens 60 x 110 mm EN 10 9873181 Welding filter lens 90 x 110 mm EN 10 9873243
Welding filter lens 60 x 110 mm EN 11 9873191 Welding filter lens 90 x 110 mm EN 11 9873244
Welding filter lens 60 x 110 mm EN 12 9873202 Welding filter lens 90 x 110 mm EN 12 9873245
Welding filter lens 60 x 110 mm EN 13 9873211 Welding filter lens 90 x 110 mm EN 13 9872146
Welding filter lens 60 x 110 mm EN 14 9873212 Welding filter lens 90 x 110 mm EN 14 9873247
Protection glass 60 x 110 mm 9873149 Glass retaining spring 9873014
Protection glass, polykarb. 60 x 110 mm 9873155 Headband 9873012
Viewing lens 9873157 Sweatband 9873018
78 79Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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.
*) Beta 60/90 filter shade EN 10 in the delivery
Protection glas and magnifying glases for Beta
Magnifying glas 1,0 51 x 108 mm 9873260 Magnifying glas 1,5 51 x 108 mm 9873261Magnifying glas 2,0 51 x 108 mm 9873262Magnifying glas 2,5 51 x 108 mm 9873263Colourful Protection glas 90 x 110 x 1,0 Polycarb. DIN 3 9873255
Magnifying glas can be fixed easily with double-sided sticker.The protection plate complies the test requirements of UV radiation and filtratesalso 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 110 90 x 110 90 x 110 90 x 110
Viewing area 90 x 110 90 x 110 46.5 x 95 46.5 x 95
Filter shade range EN 8 - 14 * EN 8 - 14 * EN 3 / 11 EN 4 / 9 -13
Sensitivity - - Fixed Adjustable
Switching time - - 0.0005 s 0.00015 s
Delay (dark ->bright) - - 0.2 s 0.4 s
Order number 9873040 9873045 9873046 9873047
80 81Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
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
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 140 - 210 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
Betafresh 90 AF802200 Motor unit + airhose Basic 2000 Flow Control AF820000
incl.: welding helmet, blower unit, battery, hose, support belt, charger P-3 dustfilter Basic 2000 AF800010
Betafresh 90X AF822300 Prefilter 10 pack Basic 2000 AF800015
incl.: welding helmet, blower unit, battery, hose, support belt, charger Dust/odour filter 10 pack Basic 2000 AF800020
Spare parts Battery NiMH Basic 2000 AF800013
Beta 90 helmet BETAFRESH 90 AF702200 Battery NiMH Basic 2000 Flow Control AF800017
Beta 90X helmet BETAFRESH 90X AF702300 Heavy duty belt AF700091
Motor unit + airhose Basic 2000 AF800000 Protective hose for Plastic tube AF0080800SPP
Order information
80 81Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
82 83Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
82 83Kemppi Product Catalogue 2004 2004 Kemppi Product Catalogue
A10200EN