Kemppi fastmig MF 29 Operation Instructions Manual

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Operation instructions • english Gebrauchsanweisung • deutsch Gebruiksaanwijzing • nederlands Manuel d’utilisation • français
1906320E
0603
FASTMIG™
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CONTENTS
1. PREFACE ...................................................................................................................... 3
1.1. INTRODUCTION ......................................................................................................... 3
1.2. PRODUCT INTRODUCTION ...................................................................................... 3
1.2.1. OPERATION CONTROL AND CONNECTORS ............................................. 4
1.2.2. CONNECTION OF SYSTEM ......................................................................... 5
1.2.3. PARTS OF WIRE FEED MECHANISM, MF 29 ............................................. 6
1.3. OPERATION SAFETY ................................................................................................. 7
2. INSTALLATION .............................................................................................................. 8
2.1. ASSEMBLY OF MIG SYSTEM .................................................................................... 8
2.2. MOUNTING OF MIG WELDING GUN ........................................................................ 8
2.3. MOUNTING AND LOCKING OF WIRE REEL ............................................................. 8
2.4. AUTOMATIC WIRE FEED TO GUN ............................................................................ 9
2.5. ADJUSTMENT OF PRESSURE .................................................................................. 9
2.6. ADJUSTMENT OF TIGHTNESS OF REEL BRAKE .................................................... 9
2.7. BURN BACK TIME ...................................................................................................... 9
2.8. GROUND CABLE ...................................................................................................... 10
2.9. SHIELD GAS ............................................................................................................. 10
2.9.1. INSTALLING GAS BOTTLE ......................................................................... 10
2.10. MAIN SWITCH I/O ....................................................................................................11
2.11. OPERATION OF COOLING UNIT, FASTCOOL 10 ..................................................11
2.12. HANGING .................................................................................................................11
3. SERVICE, OPERATION DISTURBANCES ..................................................................11
4. DISPOSAL OF THE MACHINE ................................................................................... 12
5. ORDERING NUMBERS ............................................................................................... 12
6. TECHNICAL DATA ...................................................................................................... 13
7. TERMS OF GUARANTEE ........................................................................................... 14
2 – FASTMIG™ MF 29 / 0603 © KEMPPI OY
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1. PREFACE

1.1. INTRODUCTION

Congratulations on having purchased this product. Properly installed Kemppi products should prove to be productive machines requiring maintenance at only regular intervals. This manual is arranged to give you a good understanding of the equipment and its safe operation. It also contains maintenance information and technical specifications. Read this manual from front to back before installing, operating or maintaining the equipment for the first time. For further information on Kemppi products please contact us or your nearest Kemppi distributor.
The specifications and designs presented in this manual are subject to change without prior notice.
In this document, for danger to life or injury the following symbol is used: Read the warning texts carefully and follow the instructions. Please also study the Operation safety
instructions and respect them when installing, operating and servicing the machine.

1.2. PRODUCT INTRODUCTION

FastMig™ MF is basic wire feeder designed for demanding enviroment.
This equipment’s electromagnetic compatibility (EMC) is designed for use in an industrial environment. Class A equipment is not intended for use in residential location where the electrical power is provided by the public low-voltage supply system.
FASTMIG™ MF 29 / 0603 – 3© KEMPPI OY
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1.2.1. Operation control and connectors

MF 29
Operation panel
Connection of welding gun EURO
Lead-in of cooling liquid hoses
Connection for control cable
Shielding gas connection
Welding current cable connector
Selection of gun switch function
Adjustment of wire feed speed
Adjustment of welding voltage
4 – FASTMIG™ MF 29 / 0603 © KEMPPI OY
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1.2.2. Connection of system

FASTMIG™ MF 29 / 0603 – 5© KEMPPI OY
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1.2.3. Parts of wire feed mechanism, MF 29

6 – FASTMIG™ MF 29 / 0603 © KEMPPI OY
1.
2. 2.
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1.3. OPERATION SAFETY

Please study these Operation safety instructions and respect them when installing, operating and servicing the machine.
Welding arc and spatters
Welding arc will hurt unprotected eyes, also be very careful with reflecting arc flash. Welding arc and spatter will burn unprotected skin. Therefore it is highly recommended to always use safety gloves and protective clothing.
Danger for fire or explosion
Pay attention to fire safety regulations. Remove flammable or explosive materials from welding area. Always reserve sufficient fire-fighting equipment on welding area. Be prepared for hazards in special welding jobs, eg. for the danger of fire or explosion when welding container type work area. Note! Fire can break out from sparks even several hours after the welding work has been finished!
Mains voltage
Never take welding machine inside a work area (eg. container or truck). Do not place welding machine on a wet surface. Always check cables before operating the machine. Change defect cables without delay. Defect cables may cause an injury or set out a fire. Connection cable must not be compressed, it must not touch sharp edges or hot work pieces.
Welding power circuit
Isolate yourself by using proper protective clothing, do not wear wet clothing. Never work on a wet surface or use defect cables. Do not put MIG-gun or welding cables on welding machine or on other electric equipment. Do not press MIG-gun switch, if the gun is not directed towards a work piece.
Welding fumes
Take care that there is sufficient ventilation during welding. Take special safety precautions when welding metals, which contain lead, cadmium, zinc, mercury or beryllium.
FASTMIG™ MF 29 / 0603 – 7© KEMPPI OY
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2. INSTALLATION

2.1. ASSEMBLY OF MIG SYSTEM

Assemble the units in order mentioned below and follow mounting and operation instructions which are delivered in packages.
1. Installation of power source
Read paragraph: ”Installation” in operation instructions for FastMig™ power sources and carry out the installation according to that.
2. Mounting of KM power sources to transport wagon
Read and follow the instructions given in the transport cart installation/assembly manual
3. 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.
4. Mounting of FastMig™ wire feed units to boom
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.

2.2. 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.

2.3. MOUNTING AND LOCKING OF WIRE REEL

– Release the locking nut (A)! – Mount the reel at its place. Note rotating direction of reel – Lock the reel with locking nut..
Check that in filler wire reel 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.
8 – FASTMIG™ MF 29 / 0603 © KEMPPI OY
A
B
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2.4. AUTOMATIC WIRE FEED TO GUN

Automatic wire feed makes change of wire reel more rapid. In reel 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 reel and cut off the bent length. Be careful that the wire does not
spill from the reel 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.
FastMig™ MF 29 wire feed unit:
– Draw a bit of loose wire from wire reel. 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.

2.5. 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.
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.

2.6. ADJUSTMENT OF TIGHTNESS OF REEL BRAKE

Adjust brake force as so big that the wire is not allowed to become too loose on the reel so that it would spill from the reel when the rotation of the reel 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.

2.7. 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').
Brake force is adjusted by screwing the adjusting nut (B), tightening clockwise direction.
FASTMIG™ MF 29 / 0603 – 9© KEMPPI OY
A
B
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2.8. 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! Never use a damaged welding gun!

2.9. SHIELD GAS

Handle gas bottle with care. There is a risk for injury if gas bottle or bottle valve is damaged!
For welding stainless steels, mixed gases are normally used. Check that the gas bottle 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.

2.9.1. Installing gas bottle

Always fasten gas bottle properly in vertical position in a special holder on the wall or on a carriage. Remember to close gas bottle valve after having finished welding.
Parts of gas flow regulator
A Gas bottle valve B Press regulation screw C Connecting nut D Hose spindle E Jacket nut F Gas bottle 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 bottle valve (A) for a while to blow out possible impurities from the bottle 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 bottle 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 bottle valve slowly. Gas bottle pressure meter (F) shows the bottle pressure. Note! Do not use the whole contents of the bottle. The bottle should be filled when the bottle 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 bottle valve after having finished welding. If the machine will be out of use for a long time, unscrew the pressure regulation screw.
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E
B
D
G
A
F
C
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2.10. 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.
Always start and switch off the machine with the main switch, never use the mains plug as a switch.

2.11. 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.

2.12. 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.

3. 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. – Reel brake adjustment. – Electric connections * Oxidised couplings must be cleaned * Loose couplings must be tightened
Clean dust and dirt from the equipment.
When using compressed air, always protect your eyes with proper eye protection.
In case of problems contact your KEMPPI dealer.
twice a year
FASTMIG™ MF 29 / 0603 – 11© KEMPPI OY
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4. DISPOSAL OF THE MACHINE

Do not dispose of electrical equipment together 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 returned to an environmentally compatible recycling facility. As the owner of the equipment, you should get information on approved collection systems from our local representative.
By applying this European Directive you will improve the environment and human health!

5. ORDERING NUMBERS

MF 29 6063200 KM 300 3-ph 400V 6033000 KM 400 3-ph 400V 6034000 KM 500 3-ph 400V 6035000 Cooling unit Fastcool 10 6068100 Transport unit PM500 6185291
Accessories
KWF 300 protection slides 6185286 KWF gas flow regulator (mounting set) W000364
MIG-guns
MMT 25 3 m 6252513MMT
MMT 25 4,5 m 6252514MMT MMT 27 3 m 6252713MMT MMT 27 4,5 m 6252714MMT MMT 32 3 m 6253213MMT MMT32 4,5 m 6253214MMT MMT 35 3 m 6253513MMT MMT 35 4,5 m 6253514MMT MMT 42 3 m 6254213MMT MMT 42 4,5 m 6254214MMT MMT 30W 3 m 6253043MMT MMT 30W 4,5 m 6253044MMT MMT 42W 3 m 6254203MMT MMT 42W 4,5 m 6254204MMT MMT 52W 3 m 6255203MMT MMT 52W 4,5 m 6255204MMT
Interconnecting cables
KM 70-1.8-WH 6260411
KM 70-15-WH 6260412 KM 70-1.8-GH 6260413 KM 70-15-GH 6260414
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6. TECHNICAL DATA

The products meet conformity requirements for CE marking.
MF 29
Working voltage (safety voltage) 50 VDC
Rated power 100 W
Max. load (nominal values)
60 % ED 520 A
100 % ED 440 A
Operation principle 4-roll feed
Diameter of feed roll 32 mm
Wire feed speed 0...25 m/min
Filler wires
ø Fe, Ss 0,6...1.6
ø Cored wire 0,8...1.6
ø Al 1,0...1.6
Wire reel
max. weight 5 kg
max. size ø 200 mm
Gun connector Euro
Operation temperature range -20...+40 °C
Storage temperature range -40...+60 °C
Degree of protection IP 23 C
Dimensions
length 510 mm
width 200 mm
height 310 mm
Weight 9.4 kg
FASTMIG™ MF 29 / 0603 – 13© KEMPPI OY
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7. TERMS OF GUARANTEE

Kemppi Oy provides a guarantee for products manufactured and sold by them if defects in manufacture and materials occur. Guarantee repairs must be carried out only by an Authorised Kemppi Service Agent. Packing, freight and insurance costs to be paid by orderer. The guarantee is effected on the date of purchase. Verbal promises which do not comply with the terms of guarantee are not binding on guarantor.
Limitations on guarantee
The following conditions are not covered under the terms of guarantee: defects due to natural wear and tear, non-compliance with operating and maintenance instructions, connection to incorrect or faulty supply voltage (including voltage surges outside equipment spec.), incorrect gas pressure, overloading, transport or storage damage, fire of damage due to natural causes i.e. lightning or flooding.
This guarantee does not cover direct or indirect travelling costs, daily allowances or accommodation. Note: Under the terms of guarantee, welding torches and their consumables, feeder drive rolls and feeder guide tubes are not covered. Direct or indirect damage due to a defective product is not covered under the guarantee. The guarantee is void if changes are made to the product without approval of the manufacturer, or if repairs are carried out using non-approved spare parts.
The guarantee is also void if repairs are carried out by non-authorised agents.
Undertaking guarantee repairs
Guarantee defects must be informed to Kemppi or authorised Kemppi Service Agents within the guarantee period. Before any guarantee work is undertaken, the customer must provide proof of guarantee or proof of purchase, and serial number of the equipment in order to validate the guarantee. The parts replaced under the terns of guarantee remain the property of Kemppi.
Following the guarantee repair, the guarantee of the machine or equipment, repaired or replaced, will be continued to the end of the original guarantee period.
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KEMPPI OY PL 13 FIN – 15801 LAHTI FINLAND Tel (03) 899 11 Telefax (03) 899 428 www.kemppi.com
KEMPPIKONEET OY PL 13 FIN – 15801 LAHTI FINLAND Tel (03) 899 11 Telefax (03) 7348 398 e-mail: myynti.fi @kemppi.com
KEMPPI SVERIGE AB Box 717 S – 194 27 UPPLANDS VÄSBY SVERIGE Tel (08) 590 783 00 Telefax (08) 590 823 94 e-mail: sales.se@kemppi.com
KEMPPI NORGE A/S Postboks 2151, Postterminalen N – 3103 TØNSBERG NORGE Tel 33 34 60 00 Telefax 33 34 60 10 e-mail: sales.no@kemppi.com
KEMPPI DANMARK A/S Literbuen 11 DK – 2740 SKOVLUNDE DANMARK Tel 44 941 677 Telefax 44 941 536 e-mail:sales.dk@kemppi.com
KEMPPI BENELUX B.V. Postbus 5603 NL – 4801 EA BREDA NEDERLAND Tel +31 (0)76-5717750 Telefax +31 (0)76-5716345 e-mail: sales.nl@kemppi.com
KEMPPI (UK) Ltd Martti Kemppi Building Fraser Road Priory Business Park BEDFORD, MK443WH ENGLAND Tel 0845 6444201 Fax 0845 6444202 e-mail: sales.uk@kemppi.com
KEMPPI FRANCE S.A. 65 Avenue de la Couronne des Prés 78681 EPONE CEDEX FRANCE Tel (01) 30 90 04 40 Telefax (01) 30 90 04 45 e-mail: sales.fr@kemppi.com
KEMPPI GmbH Otto – Hahn – Straße 14 D – 35510 BUTZBACH DEUTSCHLAND Tel (06033) 88 020 Telefax (06033) 72 528 e-mail:sales.de@kemppi.com
KEMPPI SP. z o.o. Ul. Piłsudskiego 2 05-091 ZA¸BKI Poland Tel +48 22 781 6162 Telefax +48 22 781 6505 e-mail: info.pl@kemppi.com
KEMPPI WELDING MACHINES AUSTRALIA PTY LTD P.O. Box 404 (2/58 Lancaster Street) Ingleburn NSW 2565, Australia Tel. +61-2-9605 9500 Telefax +61-2-9605 5999 e-mail: info.au@kemppi.com
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www.kemppi.com
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