Kemppi MXF 65 Operating Manual
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Operating manual • English
Käyttöohje • Suomi
Bruksanvisning • Svenska
Bruksanvisning • Norsk
Brugsanvisning • Dansk
Gebrauchsanweisung • Deutsch
Gebruiksaanwijzing • Nederlands
Manuel d’utilisation • Français
Manual de instrucciones • Español
Instrukcja obsługi • Polski
Инструкции по эксплуатации • По-русски
操作手册 • 中文
F
AST
M
IG™
MXF65
MXF67
EN
FI
ES
PL
NL
FR
RU
ZH
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DE
SV
NO
Operating Manual
english
EN
EN
I
COntents
1. preFaCe
.......................................................................................................................................................
3
1.1 General
.................................................................................................................................................................
3
1.2 About FastMig Pulse products
...........................................................................................................
3
1.3 General safety Instructions
...................................................................................................................
3
2. installatiOn
.....................................................................................................................................
6
2.1 Machine introduction, MXF 65, 67
...................................................................................................
6
2.2 Connection of system
...............................................................................................................................
7
2.3 Assembly of MIG/MAG system
...........................................................................................................
8
2.4 Accessories corresponding to wire diameter
..........................................................................
9
2.5 Welding gun selection
..............................................................................................................................
9
2.6 Mounting and locking of wire spool
..............................................................................................
9
2.7 Loading the filler wire and automatic feed
............................................................................
10
2.8 DuraTorque™ 400, 4 wheel wire feed mechanism
............................................................
10
2.9 Adjustment of pressure arms
...........................................................................................................
11
2.10 Adjustment of spool brake
.................................................................................................................
11
2.11 Burn back time
............................................................................................................................................
12
2.12 Earth return cable
.....................................................................................................................................
12
2.13 Shielding gas
................................................................................................................................................
12
2.14 Main switch I/O
...........................................................................................................................................
13
2.15 Operation of cooling unit, Fastcool 10
......................................................................................
13
2.16 MXF HANGING kit
.....................................................................................................................................
13
3. COntrOl panel OperatiOns
.................................................................................
14
4. Welding sOFtWare delivery prOFile
.................................................
15
5. pF65 panel ButtOn FunCtiOns
........................................................................
17
5.1 ON / OFF Button
.........................................................................................................................................
17
5.2 Dynamics Button
.......................................................................................................................................
17
5.3 Gas Test Button
...........................................................................................................................................
17
5.4 Wire Inch Button
........................................................................................................................................
18
5.5 Channel -
..........................................................................................................................................................
18
5.6 Channel +
........................................................................................................................................................
18
5.7 2T/4T Button
.................................................................................................................................................
18
5.8 Extra functions Button
...........................................................................................................................
18
5.9 Remote Selection Button
....................................................................................................................
19
5.10 Power encoder potentiometer
........................................................................................................
19
5.11 Arc length/voltage/adjustment potentiometer
.................................................................
19
5.12 PF65 panel overview
...............................................................................................................................
20
5.13 SF 54 panel overview for Fastmig Synergic
............................................................................
21
5.14 SF 53 panel overview for Fastmig Synergic
............................................................................
22
6. BasiC trOuBleshOOting
............................................................................................
23
7. MaintenanCe
................................................................................................................................
24
8. dispOsal OF the MaChine
........................................................................................
24
9. Ordering nuMBers
.............................................................................................................
24
10. teChniCal data
........................................................................................................................
27
11. Warranty pOliCy
..................................................................................................................
28
2
1.
1.1
1.2
1.3 preFaCe general
Congratulations on choosing the FastMig MXF equipment. Used correctly, Kemppi products can significantly increase the productivity of your welding, and provide years of economical service.
This operating manual contains important information on the use, maintenance and safety of your Kemppi product. The technical specifications of the equipment can be found at the end of the manual.
Please read the manual carefully before using the equipment for the first time. For your own safety and that of your working environment, pay particular attention to the safety instructions in the manual.
For more information on Kemppi products, contact Kemppi Oy, consult an authorised Kemppi dealer, or visit the Kemppi web site at www.kemppi.com.
The specifications presented in this manual are subject to change without prior notice.
important notes
Items in the manual that require particular attention in order to minimise damage and personal harm are indicated with the
’NOTE!’
notation. Read these sections carefully and follow their instructions.
aBOut FastMig pulse prOduCts
Kemppi FastMig™ MXF 65 and MXF 67 are wire feeders designed for demanding professional use and intended for 300-mm wire spools. They can be used with both Fastmig Pulse and
Fastmig Synergic power sources.
Alternative panels for MXF 65 & 67 depend on the used power source i.e. Fastmig Synergic becomes compatible by connecting SF 53 or SF 54 function panels with MXF wire feed unit, and in the case of PF 65 function panel Fastmig Pulse power source can be connected.
Operation of wire feed units are controlled and adjusted by microprocessor. By adding an optional synchronization unit (MXF Sync 65), SuperSnake sub-feeder device may be connected to MXF 65 & 67.
This manual provides instructions on the start-up and use of the MXF 65 & 67 MIG/MAG wire feeding units.
general saFety instruCtiOns
Kemppi welding equipments conform to international safety standards. Safety is an important issue in equipment design and manufacturing. Therefore, Kemppi welding solutions are unparalleled in safety. There are, however, always certain hazards involved in using welding equipment. Therefore, to ensure your personal safety and the safety of your working environment, carefully read the safety instructions below and respect them.
use of personal protective equipment
•
•
•
The arc and its reflecting radiation damage unprotected eyes. Shield your eyes and face appropriately before you start welding or observe welding. As the welding current increases, the welding face screen lens darkness should also increase.
Arc radiation and spatters burn unprotected skin. Always wear protective gloves, clothing and footwear when welding.
Always wear hearing protection if the ambient noise level exceeds the allowable limit
(e.g., 85 dB).
general operating safety
• Exercise caution when handling parts heated during welding. For example, the tip of the welding torch or gun, and the end of the welding rod and the work piece. The temperature of items burn unprotected skin.
EN
3
EN
I
4
•
•
•
•
Do not expose the machine to high temperatures, as this may cause damage.
Keep intermediate and earth return cables as close to each other as possible throughout their length. Straighten any loops in the cables as this limits inductive effects on welding performance. This also minimizes your exposure to harmful magnetic fields, which may, for example, interfere with a pacemaker.
Do not wrap the welding cables around your body.
In environments classified as dangerous, only use S-marked welding equipments with a safe idle voltage level. These work environments include, for example, humid, hot or small spaces, where the user may be directly exposed to the surrounding conductive materials.
spatter and fire safety
•
•
•
•
•
•
Welding is always classified as hot work, so pay particular attention to the fire safety regulations during welding and after it.
Remember that fire can break out from sparks, even several hours after the welding work is completed.
Protect the environment from welding spatter. Remove combustible materials, such as flammable liquid from the welding vicinity, and supply the welding site with adequate fire fighting equipment.
In special welding jobs, be prepared for hazards such as fire or explosion when welding inside enclosed work spaces, such as tanks and vessels. Ensure you have authority to work.
Never direct the sparks or cutting spray of a grinder toward the welding machine or flammable materials.
Beware of hot objects or spatter falling on the machine when working above. Welding in flammable or explosive sites is absolutely forbidden.
general electric safety
•
•
•
•
•
•
•
•
Only connect the welding machine to an earthed electric network. Note the recommended mains fuse size.
Do not take the welding machine inside a container, vehicle or similar work piece unless authorized to do so.
Do not place the welding machine on a wet surface and do not work on a wet surface.
Do not allow the mains cable to be directly exposed to water.
Ensure cables or welding torches are not squashed by heavy objects and that they are not exposed to sharp edges or a hot work piece.
Make sure that faulty and damaged welding torches are changed immediately as they may cause electrocution or fire.
Remember that the cable, plugs and other electric devices may be installed or replaced only by an electrical contractor or engineer authorized to perform such operations.
Turn off the welding machine when it is not in use.
Welding power circuit
•
•
•
Insulate yourself from the welding circuit by using dry and undamaged protective clothing.
Never touch the work piece and welding rod, welding wire, welding electrode or contact tip at the same time.
Do not put the welding torch or ground cable on the welding machine or other electric equipment.
Welding fumes
•
•
•
Ensure proper ventilation and avoid inhaling the fumes.
Ensure a sufficient supply of fresh air, particularly in closed spaces. You can also ensure an adequate supply of clean breathing air by using a filtered fresh-air mask.
Take extra precautions when working on metals or surface-treated materials containing, for example, lead, cadmium, zinc, mercury or beryllium.
transportation, lifting and suspension
•
•
Never pull or lift the machine by the welding torch or other cables. Always use the lifting points or handles designed for that purpose.
Only use a transport unit designed for the equipment. Try to transport the machine in an upright position, if possible.
•
•
•
Never lift a gas cylinder and the welding machine at the same time. There are separate provisions for gas cylinder transportation.
Never use a welding machine when suspended unless the suspension device has been designed and approved for that particular purpose.
Do not exceed the maximum allowable load of suspension beams or the transportation trolley of welding equipment. It is recommended that the wire coil be removed during lifting or transportation.
environment
•
•
•
•
•
Welding equipment is not recommended for use in rain or snow - see manual. Protect the equipment against rain and strong sunlight. Always store the machine in a dry and clean space.
Protect the machine from sand and dust during use and in storage. The recommended operating temperature range is -20 to +40 °C. The machine’s operation efficiency decreases and it becomes more prone to damage if used in temperatures in excess of 40 °C.
Place the machine so that it is not exposed to hot surfaces, sparks or spatter.
Make sure the airflow to and from the machine is unrestricted.
EMC classification of this product is class A in accordance with electromagnetic compatibility standards CISPR 11 and IEC 60974-10, and therefore the product is designed to be used in an industrial environment only.
WARNING: This class A equipment is not intended for use in residential locations where
• the electrical power is provided by a public low-voltage supply system. In those locations it may be difficult to ensure the electromagnetic compatibility due to conducted and radiated disturbances.
Arc welding equipments cause electromagnetic disturbance. To minimize the harmful effects, strictly use the equipment according to the operating manual and other recommendations.
gas bottles and pneumatic devices
•
•
•
•
•
•
Adhere to the instructions for handling pneumatic devices and gas bottles.
Make sure that gas bottles are used and stored in properly ventilated spaces.
A leaking gas bottle may replace the breathable air, causing suffocation.
Before use, make sure that the gas bottle contains gas suitable for the intended welding purpose.
Always fix the gas bottle securely in an upright position, against a bottle wall rack or purpose-made bottle cart.
Never move a gas bottle when the regulator or flow adjuster is in place. Replace the valve cover during transportation. Close the bottle valve after use.
disclaimer
While every effort has been made to ensure that the information contained in this guide is accurate and complete, no liability can be accepted for any errors or omissions. Kemppi reserves the right to change the specification of the product described at any time without prior notice. Do not copy, record, reproduce or transmit the contents of this guide without prior permission from Kemppi.
EN
5
2.
2.1 installatiOn
MaChine intrOduCtiOn, MXF 65, 67
WF #
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
Control function panel
Remote control connector
Sub feeder Sync connector (kit optional)
Gun water connections (cooling optional)
Euro gun connector
EN
I
6.
7.
8.
9.
6
6.
7.
8.
9.
Shielding gas connection
Connection for control cable
Welding current cable connector
Lead-in and clamping of cooling liquid hoses
2.2 COnneCtiOn OF systeM
2.2.1 Water cooled system: FastMig pulse + MXF + FastCool 10
4.
5.
6.
1.
7.
2.
8.
3.
9.
1. MXF wire feed unit
2. FastMig Pulse power source
3. FastCool water cooler and power connection
4. Gas supply
5. MMA electrode holder
6. Remote control device
7. Liquid cooled welding Gun
8. Power cable
9. Earth return lead and clamp
EN
7
2.2.2 gas cooled system: FastMig pulse + MXF
3.
4.
5.
1.
6.
2.
7.
EN
I
EN
2.3
8.
5.
6.
7.
8.
1.
2.
3.
4.
MXF wire feed unit
FastMig Pulse power source
Gas supply
MMA electrode holder
Remote control device
Air cooled welding Gun
Power cable
Earth return lead and clamp
asseMBly OF Mig/Mag systeM
Assemble the units in the order mentioned below. Follow the additional mounting and operation instructions delivered with each package.
1. installation of power source
Read paragraph: ”Installation” in the operation instructions for FastMig™ power sources, and complete the installation according to that advice.
2. Mounting of power sources to transport wagon
Read and follow the instructions given in the transport cart installation/assembly manual
3. Mounting the FastMig MXF wire feed unit to the power source
Remove the cover sticker on top of the power source. Screw the fastening pivot into the power source – hand tighten only. Place the supplied plastic spacers over the pivot. Lift the
MXF wire feeder into place, locating over the pivot.
4. Connecting cables
Connect the cables in accordance with the equipment notes provided in this manual.
The polarity of the welding wire (+ or -) can be selected by connecting the wire feed unit to either the positive or negative power source terminals.
Most Mig/Mag applications run the wire feed unit connected to the positive terminal of the power source.
5. Mounting FastMig wire feed units to boom and swing arms
When mounting wire feed units to boom and swing arms, the unit must be electrically isolated from both.
Suspension angle of wire feed unit can be changed by moving the fixing point in handle.
8
2.4
2.5
2.6 aCCessOries COrrespOnding tO Wire diaMeter
Colour coded wire feed rolls and guide tubes are available to suit a variety of filler wire types and sizes. Drive roll groove geometry and design, vary depending on the application. Further details are available in the spare parts tables.
MXF wire feed units are normally equipped with 1.2 mm V-groove orange coloured feed rolls from the factory. These best suit 1.2mm solid Ferrous wires. Silver colour wire guide tubes are also fitted, for welding filler wires of 0.6 - 1.6 mm diameter.
Please ensure you select the correct drive rolls and guide tubes from the table to suit your particular welding application.
Welding gun seleCtiOn
Please ensure that the welding gun selected is suitable for the target application. Check the gun manufacturers specification and ensure the gun meets the welding duty requirements.
Also consider the extra heating effects of Pulse Mig/Mag welding on the gun selected.
Kemppi gun products are designed to meet many different applications. Special wire liners and contact tips are available for different wire types and sizes.
Distance wire feeding is accommodated with WeldSnake and SuperSnake products in either
Gas or Water cooled models.
Thermal and load protection is also designed to some Kemppi Gun models and feed units, so carefully consider your requirements and consult your local Kemppi sales team to ensure you choose the correct alternative for your needs.
MOunting and lOCking OF Wire spOOl
EN
NOTE!
Check that in filler wire spool is correctly mounted and locked into position. Ensure the spool is not damaged or deformed in such a way that it can rub or chaff against the internal surface of the wire feed unit chassis or door. This may result in increased drag, impacting on weld quality.
This may also result in long term wire feed unit damage, rendering the unit unserviceable or unsafe to use.
9
EN
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2.7
2.8 lOading the Filler Wire and autOMatiC Feed
Automatic wire feed makes wire spool changes faster. When changing the wire spool, the pressure of feed rolls need not be released.
Simply ensure that the groove of the feed roll matches the diameter of filler wire used. Release the wire end from the spool and cut off any deformed section. Be careful the wire does not spill from the spool sides.
Straighten about 20cm of filler wire and ensure the tip has no sharp edges. File if necessary, as a sharp wire edge may damage the wire gun liner - particularly softer plastic liners.
Present the filler wire tip to the back of the wire feed rolls and press the wire inch switch on the wire feed panel. Feed the wire to the gun contact tip and prepare to weld.
NOTE!
Smaller diameter filler wires may need to be loaded manually - with the feed roll pressure arms released. This is because it is easy to over estimate the pressure required to feed these smaller filler wires. Too high feed roll pressures can easily deform filler wires and contribute to later feeding problems.
duratOrque™ 400, 4 Wheel Wire Feed MeChanisM
Wire guide tubes
Ss, Al, Fe,
Mc, Fc
ø 0.6 ... 1.6 mm
ø 1.6 ... 2.4 mm
Fe, Mc, Fc ø 0.6 ... 0.8 mm
ø 0.9 ... 1.6 mm
ø 1.6 ... 2.4 mm
ø 2.5/64 mm,
W000762, silver, plastic
ø 3.5/64 mm,
W001430, silver, plastic
ø 1.0/67 mm,
W001432, white, steel
ø 2.0/64 mm,
W001433, orange, steel
ø 4.0/63 mm,
W001434, blue, steel
ø 2.5/33 mm,
W000956, silver, plastic
ø 3.5/33 mm,
W001431, silver, plastic
ø 2.0/33 mm,
W001435, orange, steel
ø 4.0/33 mm,
W001436, blue, steel
ø 2.0 mm,
W000624, plastic
ø 3.5 mm,
W001389, plastic
ø 2.0 mm,
W000624, plastic
ø 3.5 mm,
W001389, plastic
ø 3.5 mm,
W001391, brass
10
24.8.2005 12:55
2.9
Wire feed rolls
Fe, Ss, Al,
V-groove
ø mm
0.6
0.8/0.9
Fe, Fc, Mc, knurled
Fe, Fc, Mc,
Ss, Al,
U-groove
1.4/1.6
2.0
2.4
1.0
1.2
1.6
2.0
2.4
1.0
1.2
1.0
1.2
1.4
1.6
grey black red orange yellow grey black red orange yellow colour pale grey white red orange brown yellow drawing pressing
W001045 W001046
W001047 W001048
W000675 W000676
W000960 W000961
W001049 W001050
W001051 W001052
W001053 W001054
W001055 W001056
W001057 W001058
W001059 W001060
W001061 W001062
W001063 W001064
W001065 W001066
W001067 W001068
W001069 W001070
W001071 W001072
adjustMent OF pressure arMs
Adjust the drive pressure to the filler wire with the thumb screws mounted over the pressure arms. Notice the graduated scales indicating load. The load applied should be sufficient to overcome a light braking force applied by hand to the filler wire, as it exits the welding gun contact tip.
For smaller diameter and soft filler wires, less feed pressure is required. It should be possible to apply a light breaking force to the filler wire by hand, as it exits the gun contact tip. But slightly more wire flow restriction should render the drives rolls to slip slightly over the filler wire without deforming the wire
NOTE!
Excessive pressure causes flattening of the filler wire and damage to coated or cored filler wires. It also causes undue wear of the feed rolls and increases gearbox load, so reducing service life.
2.10 adjustMent OF spOOl Brake
Brake force is adjusted through the hole behind the locking clip. Remove the locking clip by hand, and adjust the tension and pressure to the friction pads mounted inside with a screw driver. See diagram and location A.
EN
A
The load applied varies depending on the size and weight of the filler wire and spool, but also the filler wire feed speed set. The heavier the wire spool and the faster the feed speed, the greater the need to increase the braking load. Adjust the pressure, secure the locking clip, set the wire feed speed and check that the braking force is enough to ensure the filler wire does not spill from the spool on overrun.
NOTE!
system.
Too much or unnecessary loads can impact welding quality, load and wear to the wire feed
11
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2.11 Burn BaCk tiMe
FastMig electronics controls the burn back time. When welding stops an automatic sequence ensures that the filler wire does not stick to the work piece and that no ball is formed at the wire tip, ensuring reliable re-ignition. This system works regardless of the wire feed speed set.
2.12 earth return CaBle
Preferably the earth return cable and clamp should be connected directly to the welding material.
Always use a good quality, 70mm2 heavy copper cable, and if possible a screw type 600A clamp. Ensure that the surface contact to the work piece is clean of metal oxide and or paint.
Make sure the clamp is firmly secured.
2.13 shielding gas
NOTE!
Handle shielding gas bottle with care. Assess the risks associated with handling and using compressed gas. Always use a cylinder transport carriage and secure the cylinder safely.
There are many different suppliers of quality shielding gases for welding. Please ensure that you are selecting the correct gas for your application. FastMig Pulse uses welding curves for Synergic and Pulsed welding. These curves are created and recommend a particular gas mixture to be used. This information can be found in the basic curve information P65 panel.
Shielding gas effects welding performance and is a fundamental component to overall weld quality.
20
15
10
5 l/min
T 32
MM
NOTE!
Shielding gas flow rate from the welding gun is set according to the application, weld joint, gas type and gas nozzle shape and size. The flow rate should be measured at the welding gun nozzle before welding via a Rotameter, and normally measure's between 10 – 20 litres per minute for many welding applications.
12
2.13.1 installing gas bottle
Always fasten the gas bottle properly in the vertical position, in a special holder against the wall or on a cylinder carriage. Remember to close gas bottle valve after welding.
parts of gas flow regulator
1
6
3
7
2
5
4
2.14
2.15
5.
6.
7.
1.
2.
3.
4.
Gas bottle valve
Flow regulation screw
Connecting nut
Hose tail
Hose tail nut
Gas bottle pressure gauge
Shielding gas flow meter
Main sWitCh i/O
When you turn the main switch of the FastMig™ power source into I-position, the pilot lamp closest to this switch will illuminate, indicating the power source is ready for welding. The equipment will return to the operation state as before the main switch was turned to the zero position.
Always start and switch off the machine with the main switch, never use the mains plug as a switch.
OperatiOn OF COOling unit, FastCOOl 10
Operation of the cooling unit is automatic, starting when welding commences. When welding stops the pump will continue operation for approx. 5 min, so reducing the gun and the cooling liquid to ambient temperature. Read the operation instructions for the Fastcool 10 unit.
2.16 MXF hanging kit
The MXF 65/67 wire feed units can be hanged from a special hanging kit available as an accessory. This allows the wire feed unit to be suspended above the work area.
EN
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3.
3.1
COntrOl panel OperatiOns
MXF wire feeders can be connected to either Fastmig Pulse or Fastmig Synergic power sources.
PF65 function panel is compatible with Fastmig Pulse and SF53 and SF54 panels enable compatibility with Fastmig Synergic KMS power sources.
COnneCting and MOunting
EN
I
1.
1.
Fasten the ribbon cable connector from the MXF wire feed unit to the function panel.
14
2.
2.
Place the bottom edge of the panel behind the securing clips on the machine. Remove the fixing pin from the top edge with, for example, a screwdriver. Then gently push the upper part of the panel into place. Make sure that the cables do not get damaged, continue gently pushing the upper part of the panel until it clips into place.
4.
3.
3.
Finally secure the panel into place with the additional black plastic security clip provided.
Ensure that the clip is positioned correctly. You will notice that the clip does not seat snuggly if its positioned upside down.
Welding sOFtWare delivery prOFile
FastMig Pulse is designed to allow customer specified welding software choice. Following delivery and installation your machine will include welding software specified at the point of order. Detailed in the table below are typical welding curves available. If the delivery specification is focused to a specific project and you wish to up-date the machine in future, you can select additional welding software from the WISE & MATCH software menu. Order and load these software products to your machine with Kemppi DataGun field program device.
Wise and Match products provide optional welding application solutions. Wise and Match products menu includes special weld process for (1) root pass and (2) thin plate welding, (3) auto power regulation and (4) arc length recognition, (5) system lock function, plus additional base material curves and optional panel function. With Wise & Match you can turn something special into something unique.
1. WiseRoot
2. WiseThin
3. WisePenetration
4. WiseFusion
5. MatchLog
6265011
9991013
9991000
9991014
9991017
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WORK PACK. The welding table below details Work Pack delivery option. Additional welding software products can be purchased and added later if required.
Fe
Fe
SS
SS
SS
Fe
SS
Group
Alu
Alu
Alu
Fe
N:o
A01
A02
A12
F03
F04
S03
S04
S06
R04
M04
S84
Pulse
X
X
X
X
X
X
X
X
1-MIG
X
X
X
X
X
X
X
X
X
X
Wire ø mm
1.2
1.2
1.2
1.2
1
1.2
1
1
1.2
1.2
1
Material
AlMg5/AlMgMn
AlMg5/AlMgMn
AlSi5/AlSi12
Fe
Fe
Ss-316/308
Ss-316/308
Ss-316/308
FeFC_Rut
FeMC
FC-316
Gas
Ar
Ar
Ar
Ar+18–25%CO2
Ar+18–25%CO2
Ar+2%CO2
Ar+2%CO2
Ar+2%CO2
Ar+18–25%CO2
Ar+18–25%CO2
Ar+25%CO2
Additional welding curves available. Further welding curves are available upon request through Kemppi MATCH products system.
Group
Alu
Fe
Fe
Ss
N:o
A13
F01
F02
S73
Pulse
X
X
X
X
1-MIG Wire ø mm
X
X
X
1.6
0.8
0.9
1
Material
AlSi5/AlSi12
Fe
Fe
Inc625/SMO
Gas
Ar
Ar+18–25%CO2
Ar+18–25%CO2
Ar+He+CO2
Kemppi WISE products are welding process solutions. WiseRoot and WiseThin process group curves are listed below.
Ss
Ss
Fe
Ss
Ss
Ss
Fe
Fe
Cu
Fe
SS
Cu
Fe
SS
Group
Fe
Fe
Fe
F24
S01
S02
S12
S13
S14
C13
F21
F22
F23
F04
S03
S04
C03
N:o
F01
F02
F03
WiseRoot WiseThin Wire ø mm
X
X
X
X
X
0.8
0.9
1
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
1.2
0.8
0.9
0.9
1
1.2
1
0.8
0.9
1
1.2
1
1.2
1
Material
Fe
Fe
Fe
Fe
Fe
CuAl8
Fe
Fe
Ss-316/308
Ss-316/308
CuSi3
Fe
Ss-316/308
Ss-316/308
Ss-316/308
Ss-316/308
Ss-316/308
Gas
Ar+18–25%CO2
Ar+18–25%CO2
Ar+18–25%CO2
Ar
CO2
CO2
CO2
Ar+18–25%CO2
Ar+2%CO2
Ar+2%CO2
Ar
CO2
Ar+2%CO2
Ar+2%CO2
Ar+He+CO2
Ar+He+CO2
Ar+He+CO2
16
5. pF65 panel ButtOn FunCtiOns
1.
2.
3.
4.
10.
11.
5.1
5. 6.
On / OFF ButtOn
7.
8.
9.
5.2
1.
Short Press: Panel returns to default display.
Long Press: When Welding panel (PF65) is ON => Welding panel is turned OFF. When Welding panel (PF65) OFF => welding panel is turned ON and Setup Panel (P65) turns ON and selects automatically that Welding Panel (WF#).
dynaMiCs ButtOn
5.3
2.
Short Press: Dynamics setting if welding process is MIG/Synergic MIG. ArcForce setting if welding process is MMA. Forming Pulse setting if welding process is Wise-Root/WiseThin.
Long Press: Wire Feeder number selection (WF#). If more than one Wire Feeder is connected to system WF number selection must be made. Every Wire Feeer must be different WF number.
gas test ButtOn
3.
Gas Test function.
Pressing the button will show the gas test time. Gas test time can be adjusted by using the pulse encoder.
Gas test will proceed after time adjustment is complete (short delay).
Gas test can be stopped by pressing any button.
EN
17
5.4 Wire inCh ButtOn
5.5
4.
Wire Feeder will start immediately when the button is pressed.
The default wire inch speed is 5.0m/min.
Wire Inch speed can be adjusted (+/-) using the pulse encoder.
When the button is released the Wire Feeder will stop. If the button is pressed again, the wire feeder starts again and slopes to selected wire feed speed (if higher speed is adjusted).
Channel -
5.6
5.
Memory channel down selection.
Panel jumps directly to the previous memory channel that can be found from memory.
Channel +
5.7
6.
Short Press: Memory channel up selection.
Panel jumps directly to next memory channel that can be found from memory.
Long Press: Selected memory channel is locked / unlocked. No panel parameter changes allowed to that memory channel (panel lock).
2t/4t ButtOn
EN
I
5.8
7.
Gun trigger logic selection.
Short Press: 2T / 4T selection.
Long Press: MatchLog ON/OFF selection if license found.
eXtra FunCtiOns ButtOn
8.
Short Press: Crater Filling selection / Hot Start Selection.
Long Press: MMA ON/OFF selection if license found.
18
5.9 reMOte seleCtiOn ButtOn
9.
Short Press: Panel /Gun Remote / Hand remote selection. If remote auto recognition is selected ON (see P65 panel menu) only those remote controls which can be found are selected.
Long Press: CH remote function ON/OFF. Gun remote or Hand remote control must be first selected before CH remote function can be selected ON/OFF. When active, memory channels are selectable from the remote control device.
5.10 pOWer enCOder pOtentiOMeter
10.
The power encoder knob allows adjustment of the wire feed speed or power in either Basic,
Synergic and Pulse Mig/Mag process. MMA current level is also adjusted here if the process licence is active. Adjustments can be made before or during the arc process. This control also adjusts additional parameter values when selected.
5.11 arC length/vOltage/adjustMent pOtentiOMeter
11.
Arc length, voltage and parameter adjustments can be made using this knob. Adjustments can be made before or during welding.
EN
19
5.12 pF65 panel OvervieW
1.
2.
3.
4.
5.
6.
8.
EN
I
11.
10.
7.
9.
12.
13.
4.
5.
6.
7.
8.
9.
1.
2.
3.
10.
11.
12.
13.
Main switch (long press) a) Wire feed speed/welding current display b) Display of selected adjustable parameter a) Activation of MIG welding dynamics / Arc Force adjustment b) Selection of Wire Feeder (= paralleled wire feeders)
Gas purge
Wire inch a) Display of welding voltage /plate thickness /timer settings b) Display of selected adjustable parameter
Selection of MIG gun trigger function: 2T/4T/MATCHLOG long press *)
Display of welding process: MIG, 1-MIG, PULSE, DOUBLE PULSE, WISE *) a) Selection of additional MIG functions b) Activation of MMA welding process (long press*) a) Adjustment of wire feed speed b) Adjustment of welding power (Synergic 1-MIG and PULSE) c) Adjustment of electrode welding (MMA) current *) d) Adjustment of additional parameters when selected (ie Wire inch, Gas Test)
Memory channels 0-9, programming through P65 panel on the power source, panel lock
(long press on +) a) Adjustment of welding voltage b) Adjustment of length of welding arc (Synergic 1-MIG and PULSE) c) Adjustment of additional parameters when selected (ie MIG Dynamics)
Panel control/remote control unit selection, channel remote control (long press)
*) Not included on standard delivery, see chapter 6: Ordering numbers
automatic Weld data display:
Last recorded welding values are displayed post welding. See power source panel P65.Select
MENU and then Weld Data.
20
5.13 sF 54 panel OvervieW FOr FastMig synergiC
1.
2.
3.
4.
5.
6.
7.
8.
SETUP
4T
2T
MMA
MMA
MIG
ARC FORCE
DYNAMICS
GAS TEST m/min weld data
WIRE INCH
A V
U
PANEL
5.
6.
7.
8.
1.
2.
3.
4.
9.
10.
11.
12.
13.
W001322
9.
10.
11.
SF 54 MLS™
12.
Main switch
Display of wire feed speed/welding current
Selection of MIG dynamics for adjustments
Selection of gas/water cooled MIG gun
Gas purge
Weld data: Last used welding parameters shown in displays
Wire inch
Display of set value of welding voltage/voltage during welding
Selection of MIG/MMA process a) Selection of gun switch function b) Changing of basic parameters of the unit, SETUP (long pressing) a) Adjustment of wire feed speed b) Selection of SETUP parameters a) Adjustment of welding voltage b) Adjustment of MIG dynamics c) Adjustment of SETUP parameters
Manual control/remote control unit selection
13.
EN
21
EN
I
5.14 sF 53 panel OvervieW FOr FastMig synergiC
1.
2.
3.
4.
5.
6.
7.
8.
ARC FORCE
DYNAMICS
GAS TEST m/min weld data
WIRE INCH
A
POWER
V
U
SETUP
4T
2T
MMA
MEMORY
SET
ON
SET
SAVE
MMA
MIG
SELECT
SYNERGIC
PROGRAM
CH
W001257
quick setup
15.
ch clear ch remote
SF 53 MLS™
16.
17.
9.
10.
11.
12.
13.
14.
3.
4.
5.
6.
7.
8.
1.
2.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Main switch a) Wire feed speed/welding current/sheet thickness display b) Display of selected adjustable parameter
Activation of welding dynamics adjustment
Selection of gas/water cooled MIG gun
Gas purge
Weld data: Last used welding parameters shown in displays
Wire inch a) Welding voltage display b) Display of value of selected adjustable parameter
1-MIG selection check/1-MIG welding arc selection activation a) Selection of MIG process: 2T/4T b) Changing of basic parameters of the unit, SETUP (long pressing)
Selection of welding process MIG,1-MIG, MMA, FR-MIG *)
Activation of additional MIG function parameter adjustment
Selection of additional MIG functions a) Adjustment of wire feed speed b) Adjustment of welding power setting (1-MIG) c) Adjustment of MMA welding current d) Selection of SETUP parameter e) Selection of 1-MIG arc (material)
Memory channels, storage of MIG parameters a) Welding voltage display b) Adjustment of length of welding arc (1-MIG) c) Adjustment of MIG dynamics d) Adjustment of SETUP parameter e) Selection of 1-MIG arc
Manual control/remote control unit selection
*) FR-MIG for root pass welding is not included in standard delivery.
22
6. BasiC trOuBleshOOting
NOTE!
The problems listed and the possible causes are not definitive, but serve to suggest some standard and typical situations that may present during normal environmental use when using the Mig/Mag process with FastMig Pulse.
Problem
Machine won’t work?
Dirty, poor quality weld?
Variable welding performance?
Check the following
•
•
•
•
•
•
•
Check mains plug is connected
Check mains power distribution is switched on
Check the mains fuse and or circuit breaker
Check power source 0/I switch is ON
Check interconnection cable set and connectors between the power source and wire feed unit are correctly fastened. See the manual schematic
Check earth return lead is connected
Check function panels are switched on – Orange buttons top left, long press.
•
•
•
•
•
•
•
Check shielding gas supply
Check and set gas flow rate
Check gas type for application
Check gun/electrode polarity. Example: Fe solid filler wire: Earth return should be connected to the – pole, wire feed unit to the + pole connector
Check correct welding curve selected
Check correct Channel (job) number selected on PF65 function panel
Check power supply – Phase down?
•
•
•
•
•
•
•
•
•
Check wire feed mechanism is correctly adjusted
Check correct drive rolls are fitted
Check wire spool overrun tension is correctly adjusted
Check gun liner is not blocked. Replace if necessary
Check correct gun liner is fitted for the filler wire size and type
Check contact tip for size, type and wear
Check gun is not over heating in application
Check cable connections and earth return clamp
Check welding parameter settings.
Filler wire won’t feed?
High spatter volume?
•
•
•
•
•
•
Check wire feed mechanism. Pressure arms are closed? Close and adjust
Check welding gun switch function.
Check euro gun collar is correctly fastened to euro block
Check gun liner is not blocked
Check contact tip, size, type, wear
Check and try alternative gun.
•
•
•
•
•
•
•
•
•
•
Check welding parameter values
Check inductance/Dynamics values
•Check cable compensation value if long cables are fitted
Check gas type and flow
Check welding polarity – cable connections
Check filler material selection
Check correct welding curve selected
Check correct Channel (job) number selection
Check filler wire delivery system
Check power supply – 3 x phase present?
NOTE!
Many of these checks may be carried out by the operator. However certain checks relating to mains power must be completed by an authorised trained electrician.
EN
23
EN
I
7.
7.1
7.2
8.
9.
MaintenanCe
When considering and planning routine maintenance, please consider the the frequency of machine use and the working environment.
Correct operation of the machine and regular maintenance will help you avoid unnecessary downtime and equipment failure.
NOTE!
Disconnect the machine from the mains before handling the electrical cables.
daily MaintenanCe
•
•
•
Check the overall condition of the welding gun. Remove welding spatter from the contact tip and clean the gas nozzle. Replace worn or damaged parts. Only use original Kemppi spare parts.
Check the condition and connection of the welding circuit components: welding gun, earth return cable and clamp, sockets and connectors.
Check the condition of the feed rolls, needle bearings and shafts. Clean and lubricate bearings and shafts with a small quantity of light machine oil if necessary. Assemble, adjust and test function.
serviCe shOp MaintenanCe
Kemppi Service Workshops complete maintenance according to their Kemppi service agreement. Recommended termed service and cleaning is listed in the FastMig Pulse Power source manual.
Regular preventative maintenance by trained technicians will increase equipment life and ensure reliable operation.
dispOsal OF the MaChine
Do not dispose of electrical equipment with normal waste!
In observance of European Directive 2002/96/EC on waste electrical and electronic equipment, and its implementation in accordance with national law, electrical equipment that has reached the end of its life must be collected separately and taken to an appropriate environmentally responsible recycling facility.
The owner of the equipment is obliged to deliver a decommissioned unit to a regional collection centre, per the instructions of local authorities or a Kemppi representative. By applying this European Directive you will improve the environment and human health.
Ordering nuMBers
PF 65 panel
FastMig Pulse 350, 3 ~ 400V
FastMig Pulse 450, 3 ~ 400V
MXF65 wire feeder
MXF67 wire feeder
MXF65 wire feeder
MXF67 wire feeder
Work pack profile
Work pack profile
Project pack custom
Project pack custom
6155100
6150400
6150500
6152100EL
6152200EL
6152100
6152200
SF 53 panel, 300 mm
SF 54 panel, 300 mm
FastMig KMS 300, 3 ~ 400V
FastMig KMS 400, 3 ~ 400V
FastMig KMS 500, 3 ~ 400V
6085300
6085400
6053000
6054000
6055000
24
Cooling unit Fastcool 10
Sub feeder synchronisation unit
MXF Sync 65
SuperSnake GT02S sub feeder
SuperSnake GT02S sub feeder
SuperSnake GT02S sub feeder
SuperSnake GT02S sub feeder
SuperSnake GT02S W sub feeder
SuperSnake GT02S W sub feeder
SuperSnake GT02S W sub feeder
SuperSnake GT02S W sub feeder
Transport unit PM500
Transport unit P 501
Transport unit PM 501
Transport unit PM 502
MSF 55 & MXF 65 hanging kit
KFH 1000 hanging device
Remote control units
R20
R30 DataRemote
R30 DataRemote
RMT 10 (for PMT MIG gun)
MIG guns
PMT 35
PMT 35
PMT 42
PMT 42
PMT 50
PMT 50
PMT 30W
PMT 30W
PMT 42W
PMT 42W
PMT 52W
PMT 52W
10m
15m
20m
25m
10m
15m
20m
25m
5 m
5 m
10 m
4,5 m
3 m
4,5 m
3 m
4,5 m
3 m
4,5 m
3 m
4,5 m
3 m
4,5 m
3 m
6185419
6185420
618542001
6185475
6253513
6263514
6254213
6254214
6255013
6255014
6253043
6253044
6254203
6254204
6255203
6255204
6068100
W004030
6185291
6185269
6185292
6185293
W001694
6185100
6153100
6153150
6153200
6153250
6154100
6154150
6154200
6154250
EN
25
EN
I
SS
SS
SS
SS
SS
SS
SS
WS 35
WS 30 W
WS 30 W
WS 42 W
WS 42 W
SS
SS
Interconnection cable
Interconnection cable
Interconnection cable
Interconnection cable
Interconnection cable
Interconnection cable
Interconnection cable, water cooled
Interconnection cable, water cooled
Interconnection cable, water cooled
Interconnection cable, water cooled
Interconnection cable, water cooled
Interconnection cable, water cooled
Other lengths available
WiseFusion welding function
WisePenetration welding function
WiseRoot welding process
WiseThin welding process
MatchLog
MMA welding process
AL 1.2 mm 6 m
AL 1.2-1.6 mm 6 m
AL 1.2 - 1.6 mm 8 m
AL 1.2 - 1.6 mm 6 m
AL 1.2 - 1.6 mm 8 m
1.0 mm 6 m
1.0 mm
1.2 mm
1.0 mm
1.2 mm
1.0 mm
8 m
6 m
6 m
6 m
8 m
1.2 mm
1.0 mm
1.2 mm
6 m
8 m
8 m
1.8 m
5 m
10 m
15 m
20 m
30 m
1.8 m
5 m
10 m
15 m
20 m
30 m
6260401
6260405
6260326
6260325
6260327
6260330
6260330
6260407
6260334
6260335
6260337
6260340
6260339
9991014
9991000
6265011
9991013
9991017
9991016
6253516A12
6253516S10
6253048A12
6254206A12
6254208A12
6253516S10
6253046S10
6253046S12
6253048S10
6253048S12
6254206S10
6254206S12
6254208S10
6254208S12
26
10. teChniCal data
Operating voltage
(safety voltage)
Rated power
Load capacity 40° C
Wire feed speed
Wire feed mechanism
Diameter of feed rolls
Filler wires
Wire spool
Gun connection
Operation temperature range
Storage temperature range
EMC class
Degree of protection
External dimensions
Weight
MXF 65
50 V DC
60 % ED
100 % ED
100 W
520 A
440 A
0 ... 25 m/min
4-roll
32 mm
ø Fe, Ss 0.6 ... 1.6 mm
ø Cored wire 0.8 ... 1.6 mm
ø Al 1.0 ... 1.6 mm max. weight 20 kg max. ø 300 mm
Euro
-20 ... +40 °C
-40 ... +60 °C
L x W x H
A
IP23S
510 x 200 x 310 mm
11 kg
The products meet conformity requirements for CE marking.
MXF 67
50 V DC
100 W
520 A
440 A
0 ... 25 m/min
4-roll
32 mm
0.6 ... 1.6 mm
0.8 ... 2.0 mm
1.0 ... 2.4 mm
20 kg
300 mm
Euro
-20 ... +40 °C
-40 ... +60 °C
A
IP23S
620 x 210 x 445 mm
14 kg
EN
27
EN
I
11. Warranty pOliCy
Kemppi Oy provides a warranty for products manufactured and sold by the company if defects in materials or workmanship occur. Warranty repairs are to be carried out only by an authorised Kemppi Service Agent. Packing, shipping, and insurance are at the orderer’s expense.
The warranty starts on the date of purchase. Spoken promises not included in the terms of warranty are not binding on the warrantor.
limitations of the warranty
The following conditions are not covered under the terms of warranty: defects arising from normal wear and tear, non-compliance with operation and maintenance instructions, overloading, negligence, connection to incorrect or faulty supply voltage (including voltage surges outside equipment specifications), incorrect gas pressure, anomalies or failures in the electric network, transport or storage damage, and fire or damage due to forces of nature. This warranty does not cover direct or indirect travel costs, daily allowances, or accommodation related to warranty service.
The warranty does not cover welding torches and their consumables, feeder drive rolls, and feeder guide tubes.
Direct or indirect damage caused by a defective product is not covered under the warranty.
The warranty becomes void if modifications are made to the machine that are not approved by the manufacturer or if non-original spare parts are used in repairs.
The warranty is voided if repairs are carried out by a repair agent not authorised by Kemppi.
undertaking warranty repairs
Warranty defects must be reported to Kemppi or an authorised Kemppi Service Agent without delay.
Before a warranty repair is undertaken, the customer must present proof of warranty or otherwise prove the validity of the warranty in writing. The proof must indicate the date of purchase and the manufacturing number of the unit to be repaired. The parts replaced under the terms of this warranty remain the property of Kemppi and must be returned to Kemppi if requested.
After a warranty repair, the warranty of the machine or equipment, repaired or replaced, shall be continued to the end of the original warranty period.
28
KEMPPI OY
PL 13
FIN-15801 LAHTI
FINLAND
Tel +358 3 899 11
Telefax +358 3 899 428 www.kemppi.com
KEMPPIKONEET OY
PL 13
FIN-15801 LAHTI
FINLAND
Tel +358 3 899 11
Telefax +358 3 734 8398 e-mail: myynti.fi @kemppi.com
KEMPPI SVERIGE AB
Box 717
S-194 27 UPPLANDS VÄSBY
SVERIGE
Tel +46 8 590 783 00
Telefax +46 8 590 823 94 e-mail: [email protected]
KEMPPI NORGE A/S
Postboks 2151, Postterminalen
N-3103 TØNSBERG
NORGE
Tel +47 33 346000
Telefax +47 33 346010 e-mail: [email protected]
KEMPPI DANMARK A/S
Literbuen 11
DK-2740 SKOVLUNDE
DANMARK
Tel +45 4494 1677
Telefax +45 4494 1536 e-mail:[email protected]
KEMPPI BENELUX B.V.
Postbus 5603
NL-4801 EA BREDA
NEDERLAND
Tel +31 765717750
Telefax +31 765716345 e-mail: [email protected]
KEMPPI (UK) Ltd
Martti Kemppi Building
Fraser Road
Priory Business Park
BEDFORD, MK443WH
ENGLAND
Tel +44 (0)845 6444201
Fax +44 (0)845 6444202 e-mail: [email protected]
KEMPPI FRANCE S.A.S.
65 Avenue de la Couronne des Prés
78681 EPONE CEDEX
FRANCE
Tel +33 1 30 90 04 40
Telefax +33 1 30 90 04 45 e-mail: [email protected]
KEMPPI GmbH
Otto-Hahn-Straße 14
D-35510 BUTZBACH
DEUTSCHLAND
Tel +49 6033 88 020
Telefax +49 6033 72 528 e-mail:[email protected]
KEMPPI SPÓŁKA Z O.O.
Ul. Borzymowska 32
02-565 WARSZAWA
POLAND
Tel +48 22 7816162
Telefax +48 22 7816505 e-mail: [email protected]
KEMPPI AUSTRALIA PTY LTD.
25A, Stennett Road
INGLEBURN NSW 2565
AUSTRALIA
Tel. +61 2 9605 9500
Telefax +61 2 9605 5999 e-mail: [email protected]
KEMPPI OY LIMITADA
Av. Pdte. Edo. Frei Montalva 6001-81
Conchalí, SANTIAGO,
CHILE
Tel +56-2-949 1990
Telefax +56-2-949 1991 e-mail: [email protected]
OOO KEMPPI
Polkovaya str. 1, Building 6
127018 MOSCOW
RUSSIA
Tel +7 495 739 4304
Telefax +7 495 739 4305 e-mail: [email protected]
ОOО КЕМППИ
ул. Полковая 1, строение 6
127018 Москва
Tel +7 495 739 4304
Telefax +7 495 739 4305 e-mail: [email protected]
KEMPPI, TRADING (Beijing)
COMPANY, LIMITED
Room 420, 3 Zone, Building B,
No.12 Hongda North Street,
Beijing Economic Development Zone,
100176 Beijing
CHINA
Telefon: +86-10-6787 6064
+86-10-6787 1282
Telefax: +86-10-6787 5259
E-mail: [email protected]
肯倍贸易（北京）有限公司
中国北京经济技术开发区宏达北路
12号
创新大厦B座三区
420室 （100176）
电话：
+86-10-6787 6064
+86-10-6787 1282
传真：
+86-10-6787 5259 e-mail: [email protected]
www.kemppi.com
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