The Kemppi PSS 5000 is a modular welding system for a 400 V supply, three phase, with liquid cooling. The maximum welding current is 500 A, and one power source handles three processes: MIG with pulse, TIG AC/DC with HF ignition and a covered electrode in MMA. The set is made of the power source, the cooling module and the TIG unit.
What this machine is for
This is a power source for a plant that one day welds thick structural steel and the next an aluminium tank. A current of 500 A gives a margin for thick fillet welds, multi run joints, hard facing and work with a large diameter wire, and in MMA mode it lets you burn electrodes of large diameters that an ordinary workshop power source will not pull. The modular build means that the power source, the cooler, the wire feeder and the TIG unit stand together on one trolley and you change the station over by moving the equipment, without a rebuild of the whole installation.
MIG mode with pulse orders the transfer of metal through the arc. The drops come off one by one in the rhythm of the impulses, so there is much less spatter, and you control the amount of heat put into the part with a setting. This matters on high alloy steels and on aluminium, where too much heat bends the element and changes the structure in the heat affected zone. In work on thin sheet less heat means less straightening after welding and less grinding of the face.
The TIG AC/DC unit with HF ignition adds a second technology. On alternating current you weld aluminium and copper alloys, where the balance of the alternating current sets the proportion between cleaning the layer of oxides and the depth of penetration, and the frequency setting narrows or widens the arc. On direct current you work on acid resistant steel and on thin walled parts, where a focused, calm arc counts. HF ignition starts the arc without touching the material, so the tungsten electrode and the pool stay clean, without tungsten inclusions. Typical uses are the production of heavy machines and industrial assemblies, aluminium hulls and yachts, chemical apparatus and stainless steel tanks, pipeline shops, repair of castings and of thick parts of mining machines, and also work in shipyards and on large size structures.
Features and equipment
- Welding current up to 500 A on a 400 V three phase supply: a margin of power for thick structures and for large electrode diameters in MMA mode.
- Three processes in one system: MIG with pulse, TIG AC/DC with HF and MMA. A change of technology comes down to moving the equipment, without a rebuild of the station.
- Modular build: the power source, the liquid cooler, the TIG unit and the wire feeder are separate assemblies, so you replace a damaged module without touching the rest.
- MIG with pulse: an ordered transfer of drops cuts spatter almost to zero and lets you steer the amount of heat put into the part.
- TIG AC/DC: alternating current for aluminium and copper alloys, direct current for acid resistant steels and thin walls.
- HF ignition: the arc starts without contact, without dirt on the tungsten electrode and without tungsten inclusions in the weld.
- Adjustment of the balance of the alternating current: you set the proportion between oxide cleaning and penetration.
- Adjustment of the frequency of the alternating current: you narrow or widen the arc, depending on whether you weld a small part or a thick plate.
- Inverter control with a fast reaction to a change of the arc length: when the distance of the electrode from the material changes, the circuit corrects the parameters and holds an even penetration.
- MMA mode with a current up to 500 A: you take electrodes of large diameters in repairs and in hard facing.
- Liquid cooling with control of the circuit: the protection circuit watches the flow, and the cooler takes the heat from the torch on long welds.
- Mobile MIG wire feeders: you move the feeder away from the power source, so on a large element you walk with the torch instead of moving the machine.
- Multi shift work: the power circuit and the cooling are counted for continuous production, not for single runs in a workshop.
Technical data
| Brand | Kemppi |
|---|---|
| Model | PSS 5000 |
| Type | modular multiprocess system |
| Maximum welding current | 500 A |
| Welding current given on the card | up to 500 A |
| Supply voltage | 400 V, three phases |
| Processes | MIG with pulse, TIG AC/DC with HF, MMA |
| TIG ignition | HF, without contact |
| Type of cooling | liquid |
| Alternating current settings | balance and frequency |
| Materials | structural steel, high alloy steels, aluminium, copper alloys |
What you get
- Kemppi PSS 5000 power source
- liquid cooling module
- TIG AC/DC unit
- control cabling
What to watch out for
The supply is a 400 V mains in a three phase system, and the power circuit has to be matched to work at 500 A. At such a current the cross section of the supply cables, the state of the contacts in the switchboard and the quality of the earth connection mean more than the setting on the panel itself, so settle the installation with an electrician. The equipment also has to be matched to this current: a liquid cooled MIG torch with the right rating, interconnection cables with the right cross section, and for MMA mode a separate electrode holder rated for high currents. The card does not list torches or welding cables in the set, so confirm the set with us before you buy.
The cooler works in a closed circuit and needs fluid with frost protection and clear quick couplings. Before the first strike check the level, the flow and the tightness, because running dry destroys the pump and the torch. HF ignition sends high frequency impulses that can disturb electronics nearby, so keep controllers, scales and computers away from the station, and lead the earth short and firm. The system is modular, made of several assemblies, and the card does not give the weight or the dimensions, so plan the transport and the way onto the station in advance. For TIG mode add an argon cylinder with a regulator, and for MIG a mixture matched to the material, because the gas goes down fast in work at 500 A. On alternating current the tungsten electrode wears faster than on direct current, so keep a stock of electrodes and collets. Settle the scope of the set, the state of the control cables and of the TIG unit with us before collection.
This unit is sold
This machine has already gone to a customer. Similar units are listed below, and if you want the same model, leave your contact details in the form and we will let you know when the next one arrives.