The Kemppi Pro 5000 Puls is an industrial MIG/MAG power source with pulse, with a welding current up to 500 A, supplied from a 400 V mains. The set has an ML panel, a Procool 10 liquid cooling unit, a Promig 500 wire feeder and a Kemppi trolley. The set weighs 100 kg.
What this machine is for
The 500 A covers thick steel plate, hard facing and structures that carry load: hulls, tanks, pipelines of large diameter and thick wall. The arc characteristic gives deep fusion, and the parameters hold under a long load, so the power source goes to stations with a heavy production load and into automated cells.
Pulse limits the heat put into the material and orders the droplet transfer. The cap comes out smooth, there is much less spatter, and you keep the pool under control also on stainless steel and on aluminium alloys, where porosity comes easily. On thick materials pulse raises the welding speed without a loss of fusion.
The ML panel, that is MIG Logic, has synergic programs for different metals, including aluminium and stainless steel. The aluminium programs match the parameters to the wire diameter and the type of alloy, and the right current characteristic together with pulse breaks the oxide layer on the surface, so the weld binds cleanly on thin sheet and on a heavy structural part.
The digital control links the wire feed speed with the welding voltage. Once you choose a program you set one value in practice, and the system looks after the rest and corrects the characteristic when the distance from the torch to the material changes. The result is even fusion and fewer corrections, also when several welders work on one part.
The system is modular: the power source, the Procool 10 cooling unit and the Promig 500 wire feeder are separate units. You move the feeder away from the power source, so you work further from the gas cylinder and get into tight spots in the structure, and service and extension go by module. Extension here also means adding another control panel or equipment, without replacing the power source.
Typical uses are heavy industry and shipbuilding, that is hulls and tanks, production of aluminium and stainless structures, a heavy mechanical workshop with repairs of construction machines, welding of pipelines with thick walls and large diameters, and automated cells where the power source runs under the constant watch of a controller. Steel structure works with a heavy production load took this set.
The energy efficiency of an inverter power source is higher than that of a transformer of a similar current, which you see in the draw during continuous work. On top of that comes hard facing, because at 500 A you lay build up layers on worn surfaces without changing the station. Pulse shortens the welding time, because you move the arc faster while you keep the fusion in thick material.
The modular layout has one more effect on the work: you move the feeder to where you stand, so the torch does not have to run in an arc around the part and it bends less. In tight spaces, between the ribs of a structure or inside a tank, this is the difference between comfortable welding and welding after which the liner goes for replacement every few weeks.
The digital readout of current and voltage is useful away from the station too. Quality control can compare the values with the WPS welding procedure, and the supervisor has confirmation that the part was welded within the parameter window. In batch production and on load carrying joints this shortens the discussion at handover.
Features and equipment
- Pulse welding. Control of the heat and of the metal transfer gives a smooth cap, less spatter and fewer defects such as porosity on stainless steel and aluminium.
- Programs for welding aluminium. The parameters match the wire diameter and the type of alloy, so setting the machine up is short and the result is repeatable on thin sheet and on a heavy part.
- The ML control panel (MIG Logic). A choice of synergic programs, adjustment of the pulse parameters and digital displays with the current and the voltage.
- Memory for your own parameter sets. You save and call up the settings for repeat joints, which shortens the changeover in batch production and when you change metal.
- Synergic mode and digital arc stabilisation. The system watches the parameters and corrects the current characteristic when the distance from the torch to the material changes, so the penetration is even.
- The Promig 500 wire feeder. An external unit with a solid drive and clear indicators for correcting the settings without walking up to the power source. It guides steel and aluminium wires without deforming them in the guides, which in pulse welding decides the stability of the arc.
- The Procool 10 liquid cooling unit. The heat exchanger and the pump keep the torch temperature at a safe level in continuous work at a high current, so the consumable torch parts do not wear out early. The unit is tied into the logic of the power source and blocks welding when there is no coolant flow.
- The Kemppi trolley. Solid wheels and handles let you move the set together with the gas cylinder across the shop floor, and the frame protects the power source and the feeder against knocks. Moving the system quickly to a given part shortens the downtime between jobs.
- A modular build. You place the power source, the cooling unit and the feeder around the station and service them separately, and you extend the set with an extra panel or equipment.
Technical data
| Brand | Kemppi |
|---|---|
| Maximum welding current | 500 A |
| Supply | 400 V |
| Welding mode | pulse, MIG/MAG |
| Cooling system | Procool 10, liquid |
| Wire feeder | Promig 500 |
| Control panel | ML, MIG Logic |
| Set weight | 100 kg |
What you get
- used Kemppi Pro 5000 power source with an ML panel
- Procool 10 liquid cooling unit
- Promig 500 wire feeder
- Kemppi trolley
What to watch out for
The supply is 400 V, three phase, so you need a three phase socket and a fuse matched to the draw at currents close to 500 A. Liquid cooling needs attention: before you start, check the fluid level in the tank, the work of the pump, the flow and the tightness of the quick couplings, and change the fluid as the manufacturer advises. The set weighs 100 kg, so plan unloading with a pallet truck and leave room in the hall for the trolley together with the cylinder.
The record gives no duty cycle at the separate currents, so if you plan continuous welding at the top settings, confirm those values before you buy. It does not give the length of the interconnection cable either, and it decides how far you can move the feeder from the power source. The record does not list a welding torch or an earth cable, you choose that equipment separately to suit the current and the length of the package, and for aluminium you add rollers for soft wire and a liner.
How we sell used machines
This unit was checked in our service workshop in Krotoszyn with measurements to PN-EN 60974-4 and a load test. The price includes the first year of the basic service package: an inspection with cleaning of the machine and a validation measurement. Further years can be added. We ship across the European Union, collection in person by appointment.
