Kemppi Feed 420R User Manual

Operation instructions  english
Gebrauchsanweisung  deutsch
Gebruiksaanwijzing  nederlands
Manuel dutilisation  français

1922420E

CONTENTS

1. PREFACE........................................................................................................................3

1.1. Introduction .......................................................................................................................3

1.2. Product introduction..........................................................................................................3

1.3. Operation safety................................................................................................................4

2. INSTALLATION...............................................................................................................5

2.1. Operation control and connectors.....................................................................................5

2.1.1. Feed 420R wire feeding control unit................................................................5

2.1.2. Feed 120R wire feeder ....................................................................................6

2.2. Units, accessories, cables.................................................................................................7

2.3. Parts of wire feed mechanism...........................................................................................8

2.4. Assembly of MIG system ..................................................................................................9

2.5. Installation.......................................................................................................................10

2.5.1. Wire feed mechanism (Feed 120R)......................................................................10

2.6. Mounting of MIG welding gun .........................................................................................10

2.7. Mounting and locking of wire reel (accessory)................................................................10

2.8. Automatic wire feed to gun (Feed 120R) ........................................................................ 11

2.9. Adjustment of pressure...................................................................................................11

2.10. Adjustment of tightness of wire reel brake (accessory)................................................... 11

2.11. Ground cable...................................................................................................................12

2.12. Shield gas .......................................................................................................................12

2.12.1. Installing gas bottle........................................................................................12

3. FEED 420R FUNCTIONS.............................................................................................. 13

3.1. Function panel.................................................................................................................13

3.2. Selection of welding process...........................................................................................13

3.3. Basic adjustments, basic displays...................................................................................13

3.4. MIG welding dynamics adjustment .................................................................................14

3.5. Selecting switch of main controls....................................................................................14

3.6. Display of selected 1-knob MIG synergetic program ......................................................14

3.7. 1-knob MIG synergy panel..............................................................................................14

3.8. Burn back time adjustment..............................................................................................14

3.9. Selection of 1-knob MIG synergetic curve ......................................................................15

3.10. Wire inch switch..............................................................................................................16

3.11. Gas purge switch ............................................................................................................16

3.12. Feed 420R error codes...................................................................................................16

4. ACCESSORIES............................................................................................................. 16

4.1. Synchronizing unit Sync 400...........................................................................................16

4.2. Gas guard GG 400..........................................................................................................16

4.3. Hanging onto boom.........................................................................................................16

5. SERVICE AND OPERATION DISTURBANCES...........................................................17

6. ORDERING NUMBERS ................................................................................................18

7. TECHNICAL DATA........................................................................................................19

2 – Kempomig Feed 420R, 120R / 0429

© COPYRIGHT KEMPPI OY

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 specifi cations. Read this manual from front
to back before installing, operating or maintaining the equipment for the fi rst time. For further
information on Kemppi products please contact us or your nearest Kemppi distributor.

Specifi cations 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

Kempomig Feed 420R together with Feed 120R is a welding system designed for robotic
and automated welding. It consists of Feed 420R with inbuilt robot interface and a robot arm
mounted feed unit Feed 120R. These two units are connected with an intermediate cable
assembly.

Manual control is possible by using an interchangeable control panel with basic controls and
displays for MIG welding and synergetic MIG.

Welding operation is controlled by microprocessor. The wire feed motor includes an amplifi ed
tachometer feedback system to ensure accurate wire feed speed.

The interface stage handles all major I/O signals for automated requirements.

© COPYRIGHT KEMPPI OY

Kempomig Feed 420R, 120R / 0429 – 3

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 hurts unprotected eyes. Be careful also with refl ecting arc fl ash. Welding arc and
spatter burn unprotected skin. Use safety gloves and protective clothing.

Danger for fi re or explosion

Pay attention to fi re safety regulations. Remove fl ammable or explosive materials from
welding place. Always reserve suffi cient fi re-fi ghting equipment on welding place. Be prepared
for hazards in special welding jobs, e.g. for the danger of fi re or explosion when welding
container type work pieces. Note! Fire can break out from sparks even several hours after the
welding work has been fi nished!

Mains voltage

Never take welding machine inside a work piece (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 fi re. 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’s switch, if the gun is not directed towards a
work piece.

Welding fumes

Take care that there is suffi cient ventilation during welding. Take special safety precautions
when welding metals which contain lead, cadmium, zinc, mercury or beryllium.

4 – Kempomig Feed 420R, 120R / 0429

© COPYRIGHT KEMPPI OY

2. INSTALLATION

2.1 OPERATION CONTROL AND CONNECTORS

2.1.1. Feed 420R wire feeding control unit

Control panel

Wire inch

Gas purge

Robot controller

connector

Control cable connector to Feed 120R

Welding current output connector (+)

Hole for wire outlet connector

Fixed welding cable to power source

Control cable connector (Kempomig)

Gas snap connectors

© COPYRIGHT KEMPPI OY

Gas fl ow meter (accessory)

Voltage monitoring connector (–)

Kempomig Feed 420R, 120R / 0429 – 5

2.1.2. Feed 120R wire feeder

Gas purge

Wire inch

Snap connector for air blast

Euro connector for robot gun

Snap connectors for

cooling liquid

Connector for motorised gun

Control cable connector (Feed 420R)

Snap connector for gas

Wire liner inlet

Welding current cable connector

6 – Kempomig Feed 420R, 120R / 0429

© COPYRIGHT KEMPPI OY