Kemppi fastmig MF 29 Operating Manual

FastMig

MF 29

Operating manual

Käyttöohje

Bruksanvisning

Bruksanvisning

Brugsanvisning

Gebrauchsanweisung

Gebruiksaanwijzing

Manuel d’utilisation

Manual de instrucciones

Instrukcja obsługi

Инструкции по эксплуатации

Manual de utilização

Manuale d’uso

PT

IT

NL

FR

DA

DE

EN

FI

SV

NO

ES

PL

RU

© Kemppi Oy / 1152

OPERATING MANUAL

English

EN

EN

CONTENTS

1. Preface

..........................................................................................

3

1.1 General

.......................................................................................................................................

3

2. Product introduction

...................................................................

4

2.1 Operation control and connectors

..................................................................................

4

2.2 Connection of system

...........................................................................................................

5

2.3 DuraTorque™ 400, 4 wheel wire feed mechanism

.....................................................

6

3. Installation

...................................................................................

7

3.1 Assembly of mig system

......................................................................................................

7

3.2 Mounting of MIG welding gun

..........................................................................................

7

3.3 Mounting and locking of wire spool

...............................................................................

7

3.4 Automatic wire feed to gun

................................................................................................

7

3.5 Adjustment of pressure

........................................................................................................

8

3.6 Adjustment of tightness of spool brake

........................................................................

8

3.7 Burn back time

........................................................................................................................

8

3.8 Ground cable

............................................................................................................................

8

3.9 Shielding gas

............................................................................................................................

8

3.9.1 Installing gas cylinder ......................................................................................................

9

3.10 Main switch I/O

.......................................................................................................................

9

3.11 Operation of cooling unit, FastCool 10

........................................................................

10

3.12 Hanging

....................................................................................................................................

10

4. Service, operation disturbances

..............................................

10

5. Maintenance

..............................................................................

11

5.1 Daily maintenance

...............................................................................................................

11

5.2 Service shop maintenance

...............................................................................................

11

5.2.1 disposal of the machine ................................................................................................

11

6. Ordering numbers

.....................................................................

12

7. Technical data

............................................................................

13

2

FastMig MF 29

1. PREFACE

1.1 General

Congratulations on choosing the FastMig 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.

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

© Kemppi Oy / 1152

3

EN

2. PRODUCT INTRODUCTION

FastMig MF is basic wire feeder designed for demanding enviroment. It can be used with

Kemppi's basic FastMig power sources KM 300, KM 400, and KM 500.

2.1 Operation control and connectors

1. Control panel

2. Welding gun EURO connector

1.

2.

3.

4.

5.

6.

3. Connection for control cable

4. Shielding gas connection

5. Welding current cable connector

6. Lead-in of cooling liquid hoses

4T

2T

2

1

0

MIN

3

4

5

6

7

8

10

9

MAX

2

1

0

MIN

3

4

5

6

7

8

10

9

MAX

1.

2.

3.

1. Selection of gun operating mode

2. Adjustment of wire feed speed

3. Adjustment of welding voltage

4

FastMig MF 29

2.2 Connection of system

EN

© Kemppi Oy / 1152

5

EN

2.3 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

2.

1.

6

Wire feed rolls

ø mm

Fe, Ss, Al,

V-groove

Fe, Fc, Mc, knurled

Fe, Fc, Mc,

Ss, Al,

U-groove

1.0

1.2

1.6

1.6

2.0

2.4

1.0

1.2

1.4/1.6

2.0

2.4

0.6

0.8/0.9

1.0

1.2

1.4

FastMig MF 29 orange yellow grey black red orange yellow colour pale grey white red orange brown yellow grey black red 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

24.8.2005 12:55

3. INSTALLATION

3.1 Assembly of mig system

Assemble the units in order mentioned below and follow mounting and operation instructions which are delivered in packages.

Installation of power source

Read paragraph: ”Installation” in operation instructions for FastMig power sources and carry out the installation according to that.

Mounting of KM power sources to transport wagon

Read and follow the instructions given in the transport cart installation/assembly manual

Connecting cables

Connect the cables in accordance with the equipment notes provided.

The polarity of the welding wire (+ or -) can be changed by replacing the MF welding current cable and return current cable with the FastMig™ power source welding cable connector.

Mounting of FastMig wire feed units to boom

NOTE! Wire feed unit must be mounted to boom in such a way that its chassis is galvanic separated both from swing arm and boom.

Suspension angle of wire feed unit can be changed by moving fixing point in handle.

3.2 Mounting of MIG welding gun

In order to ensure trouble-free welding check in operation instructions of gun used by you that wire guide tube and contact tip of gun are according to manufacturer’s recommendation suitable to be used for wire feed diameter and type in question. To tight a wire guide tube might cause for wire feed unit a bigger stress than normally as well as disturbances in wire feed.

Screw snap connector of gun tight that there won’t come any voltage losses on connecting surface. A loose connection will heat gun and wire feed unit and feeder.

3.3 Mounting and locking of wire spool

A

EN

B

• Release the locking nut (A)!

• Mount the spool at its place. Note rotating direction of spool

• Lock the spool with locking nut..

NOTE! Check that in filler wire spool there are no parts sticking out, which could e.g. chafe against chassis or door of wire feed unit. Dragging parts might expose chassis of wire feed unit under voltage.

3.4 Automatic wire feed to gun

Automatic wire feed makes change of wire spool more rapid. In spool change the pressure of feed rolls need not to be released and filler wire goes automatically to correct wire line.

• Make sure that groove of feed roll matches the diameter of welding wire used.

• Release the wire end from spool and cut off the bent length. Be careful that the wire does not spill from the spool to sides!

• Straighten about 20 cm of the wire and see that the end of it has no sharp edges (file off if necessary). A sharp edge may damage the wire guide tube and contact tip of the welding gun.

© Kemppi Oy / 1152

7

EN

• Draw a bit of loose wire from wire spool. Feed wire through back liner to feed rolls. Do not release pressure of feed rolls!

• Press the gun switch and feed wire until wire goes through feed rolls to gun. See that wire is in grooves of both feed roll pairs!

• Press still the gun switch until wire has come through contact tip.

Automatic feed may sometimes fail with thin wires (Fe, Fc, Ss: 0,6 – 0,8 mm, Al: 0,8 – 1,0 mm).

In that case you might have to open feed rolls and feed wire manually through feed rolls.

3.5 Adjustment of pressure

Adjust the pressure of feed rolls with the control screw (20) so that the wire is fed into the wire guide tube evenly and allows a little braking when coming out from the contact tip without slipping at the feed rolls.

NOTE! Excessive pressure causes flattening of the filler wire and damage to the coating. It also causes undue wear of the feed rolls as well as friction.

3.6 Adjustment of tightness of spool brake

A

B

Brake force is adjusted by screwing the adjusting nut (B), tightening clockwise direction.

Adjust brake force as so big that the wire is not allowed to become too loose on the spool so that it would spill from the spool when the rotation of the spool stops. Need for brake force is increased with increase of wire feed speed.

Since the brake loads for its part the motor, you shouldn’t keep it unnecessarily tight.

3.7 Burn back time

Electronics of feed unit controls stopping of welding automatically so that the wire end doesn’t melt fastened to the contact tip or the work piece. Automatics work regardless of the wire feed speed. Can be adjusted also from power source SETUP-menu ('PoC').

3.8 Ground cable

Connecting of earth cable should be preferably connected directly to the welding material.

Contact surface of press always should be as large as possible.

Clean the fastening surface from paint and rust!

Use in your MIG equipment at least 70 mm². Thinner cross-sectional areas might cause overheating of connectors and insulations.

Make sure that the welding gun in your use is designed for max. welding current needed by you!

NOTE! Never use a damaged welding gun!

3.9 Shielding gas

NOTE! Handle gas cylinder with care. There is a risk for injury if the cylinder or its valve is damaged!

For welding stainless steels, mixed gases are normally used. Check that the gas cylinder valve is suitable for the gas. The flow rate is set according to the welding power used in the job. A suitable flow rate is normally 8 – 10 l/min. If the gas flow is not suitable, the welded joint will be sporous. Contact your local Kemppi-dealer for choosing gas and equipment.

8

FastMig MF 29

3.9.1 Installing gas cylinder

NOTE! Always fasten gas cylinder properly in vertical position in a special holder on the wall or on a carriage. Remember to close gas cylinder valve after having finished welding.

Parts of gas flow regulator

A F

C

G

B

E

D

A. Gas cylinder valve

B. Press regulation screw

C. Connecting nut

D. Hose spindle

E. Jacket nut

F. Gas cylinder pressure meter

G. Gas hose pressure meter

The following installing instructions are valid for most of the gas flow regulator types:

1. Step aside and open the cylinder valve (A) for a while to blow out possible impurities from the cylinder valve.

2. Turn the press regulation screw (B) of the regulator until no spring pressure can be felt.

3. Close needle valve, if there is one in the regulator.

4. Install the regulator on cylinder valve and tighten connecting nut (C) with a wrench.

5. Install hose spindle (D) and jacket nut (E) into gas hose and tighten with hose clamp.

6. Connect the hose with the regulator and the other end with the wire feed unit. Tighten the jacket nut.

7. Open cylinder valve slowly. Gas cylinder pressure meter (F) shows the cylinder pressure.

Note! Do not use the whole contents of the cylinder. The cylinder should be filled when the cylinder pressure is 2 bar.

8. Open needle valve if there is one in the regulator.

9. Turn regulation screw (B) until hose pressure meter (G) shows the required flow (or pressure). When regulating flow amount, the power source should be in switched on and the gun switch pressed simultaneously.

Close cylinder valve after having finished welding. If the machine will be out of use for a long time, unscrew the pressure regulation screw.

3.10 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 light up, indicating the power source is ready for welding.

NOTE! Always start and switch off the machine with the main switch, never use the mains plug as a switch.

EN

© Kemppi Oy / 1152

9

3.11 Operation of cooling unit, FastCool 10

Operation of cooling unit is controlled in such a way that pump is started when welding is started. After welding stop pump is rotating for approx. 5 min cooling the gun and the cooling liquid to ambient temperature.

Read in operation instructions for the FastCool 10 unit the trouble situations of the liquid circulation system and protection against torch etc. damage.

3.12 Hanging

MF 29 can be hanged to the barrier with an optional hanging frame (6185285). The machine is not supposed to be hanged from its handle.

EN

4. SERVICE, OPERATION DISTURBANCES

The amount of use and the working environment should be taken into consideration when planning the frequency of maintenance of MF. Careful use and preventive maintenance will help to ensure trouble-free operation.

The following maintenance operations should be carried out at least every six months:

Check:

• The wear of the grooves of the feed rolls. Excessive wear of grooves causes problems in wire feed.

• The wear of the wire guide tubes of wire feed. Badly worn feed rolls and wire guide tubes should be discarded.

• The wire guide tube in the gun should be set as near the feed rolls as possible, but not touching them and the wire must follow a straight line from the end of the tube to the groove of the feed roll.

• Spool brake adjustment.

• Electric connections

- Oxidised couplings must be cleaned

- Loose couplings must be tightened

Clean dust and dirt from the equipment.

NOTE! When using compressed air, always protect your eyes with proper eye protection.

In case of problems contact your KEMPPI dealer.

Lubricate the feed rolls twice a year.

10

FastMig MF 29

5. 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.

5.1 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.

5.2 Service shop maintenance

Kemppi Service Workshops complete maintenance according to their Kemppi service agreement. Recommended termed service and cleaning is listed in the FastMig KM power source manual.

Regular preventative maintenance by trained technicians will increase equipment life and ensure reliable operation.

5.2.1 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.

EN

© Kemppi Oy / 1152

11

EN

6. ORDERING NUMBERS

MF 29

KM 300

KM 400

KM 500

Cooling unit FastCool 10

Transport unit PM500

Accessories

KWF 200 protection slides

KWF gas flow regulator (mounting set)

MIG-guns

MMT 35

MMT 42

MMT 42

MMT 30W

MMT 30W

MMT 42W

MMT 42W

MMT 52W

MMT 25

MMT 25

MMT 27

MMT 27

MMT 32

MMT32

MMT 35

MMT 52W

Interconnecting cables

KM 70-1.8-WH

KM 70-15-WH

KM 70-1.8-GH

KM 70-15-GH

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

4,5 m

3 m

4,5 m

3 m

3-ph 400V

3-ph 400V

3-ph 400V

6063200

6033000

6034000

6035000

6068100

6185291

6185286

W000364

6252513MMT

6252514MMT

6252713MMT

6252714MMT

6253213MMT

6253214MMT

6253513MMT

6253514MMT

6254213MMT

6254214MMT

6253043MMT

6253044MMT

6254203MMT

6254204MMT

6255203MMT

6255204MMT

6260411

6260412

6260413

6260414

12

FastMig MF 29

7. TECHNICAL DATA

MF 29

Operating voltage (safety voltage)

Connection capacity

Output 40 °C

Wire feed mechanism

Diameter of feed roll

Wire feed speed

Filler wires

Wire spool

Gun connection

Operating temperature range

Storage temperature range

EMC class

Degree of protection

External dimensions

Weight

60 % ED

100 % ED

ø Fe, Ss

ø Cored wire

ø Al max. weight max. ø

LxWxH

24 VDC

100 W

520 A

440 A

4-roll feed

32 mm

0 – 25 m/min

0.6 – 1.6 mm

0.8 – 1.6 mm

1.0 – 1.6 mm

5 kg

200 mm

Euro

-20 ... +40 °C

-40 ... +60 °C

A

IP23S

510 x 200 x 310 mm

8.0 kg

EN

© Kemppi Oy / 1152

13

KEMPPI OY

Kempinkatu 1

PL 13

FIN-15801 LAHTI

FINLAND

Tel +358 3 899 11

Telefax +358 3 899 428 [email protected]

www.kemppi.com

Kotimaan myynti:

Tel +358 3 899 11

Telefax +358 3 734 8398 [email protected]

KEMPPI SVERIGE AB

Box 717

S-194 27 UPPLANDS VÄSBY

SVERIGE

Tel +46 8 590 783 00

Telefax +46 8 590 823 94 [email protected]

KEMPPI NORGE A/S

Postboks 2151, Postterminalen

N-3103 TØNSBERG

NORGE

Tel +47 33 346000

Telefax +47 33 346010 [email protected]

KEMPPI DANMARK A/S

Literbuen 11

DK-2740 SKOVLUNDE

DANMARK

Tel +45 4494 1677

Telefax +45 4494 1536 [email protected]

KEMPPI BENELUX B.V.

Postbus 5603

NL-4801 EA BREDA

NEDERLAND

Tel +31 765717750

Telefax +31 765716345 [email protected]

KEMPPI (UK) Ltd

Martti Kemppi Building

Fraser Road

Priory Business Park

BEDFORD, MK44 3WH

UNITED KINGDOM

Tel +44 (0)845 6444201

Telefax +44 (0)845 6444202 [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 [email protected]

KEMPPI GmbH

Otto-Hahn-Straße 14

D-35510 BUTZBACH

DEUTSCHLAND

Tel +49 6033 88 020

Telefax +49 6033 72 528 [email protected]

KEMPPI SPÓŁKA Z O.O.

Ul. Borzymowska 32

03-565 WARSZAWA

POLAND

Tel +48 22 7816162

Telefax +48 22 7816505 [email protected]

KEMPPI AUSTRALIA PTY LTD.

13 Cullen Place

P.O. Box 5256, Greystanes NSW 2145

SMITHFIELD NSW 2164

AUSTRALIA

Tel. +61 2 9605 9500

Telefax +61 2 9605 5999 [email protected]

OOO KEMPPI

Polkovaya str. 1, Building 6

127018 MOSCOW

RUSSIA

Tel +7 495 739 4304

Telefax +7 495 739 4305 [email protected]

ООО КЕМППИ ул. Полковая 1, строение 6

127018 Москва

Tel +7 495 739 4304

Telefax +7 495 739 4305 [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

Tel +86-10-6787 6064

+86-10-6787 1282

Telefax +86-10-6787 5259 [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 [email protected]

KEMPPI INDIA PVT LTD

LAKSHMI TOWERS

New No. 2/770,

First Main Road,

KAZURA Gardens,

Neelangarai,

CHENNAI - 600 041

TAMIL NADU

Tel +91-44-4567 1200

Telefax +91-44-4567 1234 [email protected]

www.kemppi.com