COMMANDES A DISTANCE................................ 40
ANOMALIES DE FONCTIONNEMENT ............... 41
9907 / 1923590 / 3
Käyttösäätimet ja liittimet
Funktionsreglage och anslutningar
Operation control and connectors
Bedienungselemente und Anschlusse
Suomi
Bedieningelementen en aansluitingen
Commandes et connecteurs
Langansyöttönopeuden lähisäätö
Panelreglage för trådmatningshastighet
Local control for wire feed speed
Nahreglung für Drahtvorschubgeschwindigkeit
Paneelregeling voor draadaanvoersnelheid
Commande locale de la vitesse de dévidage
Säätötavan valintakytkin (lähi-/kaukosäätö)
Väljare för reglagemetod (panel-/fjärreglering)
Control mode selecting switch (local/remote
control)
Wahlschalter für Regelungsmethode (Nah-/
Fernregelung)
EnglishDeutschFrançaisNederlandsSvenska
Keuzeschakelaar voor bediening (paneel-/
afstandsbediening)
Sélecteur du mode de commande (commande
locale/à distance)
Hitsauspistoolin liitäntä EURO
Svetspistolens anslutning EURO
Connection of welding gun EURO
Anschluß der Schweißpistole EURO
Aansluiting voor laspistool EURO
Connecteur torche EURO
Jälkivirta-ajan säätö
Inställning av efterbrinntid
Burn back time adjustment
Einstellung für Rückbrandzeit
Instelling voor afbrandvertraging
Réglage de la durée du retard d´arc
Hitsausjännitteen lähisäätö
Panelreglage för svetsspänning
Local control for welding voltage
Nahreglung für Schweißspannung
Paneelregeling voor lasspanning
Commande locale de la tension de
soudage
Käynnistystavan valintakytkin
Valbrytare för startsätt
Start mode selecting switch
Wahlschalter für Startmethode
Keuzeschakelaar voor startmethode
Sélecteur du mode de démarrage
Jäähdytysnesteletkujen lukitus
Låsning av kylvätskeslangar
Locking of cooling liquid hoses
Verriegelung der Kühlflüssigkeitsschläuche
Aansluiting van de koelvloeistofslangen
Verrouillage des tuyaux du liquide de
refroidissement
Langansyötön kokeilu
Test för trådmatning
Wire inch
Testen des Drahtvorschubs
Testen draadanvoer
Avance-fil manuelle
Kaasun kokeilukytkin
Testbrytare för gasflöde
Gas purge switch
Testschalter der Gasströmung
Testschakelaar voor gasstroom
Bouton test gaz
Suojakaasuliitäntä
Skyddsgasanslutning
Shielding gas connection
Schutzgasanschluß
Aansluiting voor beschermgas
Raccord gaz de protection
Ohjauskaapeliliitäntä (kaukosäädin)
Anslutning för manöverkabel (Fjärreglage)
Connection for control cable (Remote control unit)
Anschluß für Steuerkabel (Fernregeleinheit)
Aansluiting voor stuurstroomkabel (Afstandsbediening)
Connexion du câble de commande (Commande à distance)
4 / 1923590 / 9907
Ohjauskaapeliliitäntä
Anslutning för manöverkabel
Connection for control cable
Anschluß für Steuerkabel
Aansluiting voor stuurstroomkabel
Connexion du câble de commande
Hitsausvirtaliitäntä
Svetsströmanslutning
Welding current connection
Schweißstromanschluß
Lasstroomaansluiting
Connexion du courant de soudage
Langansyöttömekanismin osat
Delar i trådmatarmekanismen LSL FU 11
Parts of wire feed mechanism LSL FU 11
Teile im drahtvorschubmechanismus LSL FU 11
Onderdelen im het draadaanvoer-mechnisme LSL FU 11
Pieces du mecanisme de devidage LSL FU 11
Suomi
EnglishDeutschFrançaisNederlandsSvenska
9907 / 1923590 / 5
Operation safety
Never watch the arc without a face shield designed for arc welding!
The arc damages unprotected eyes!
The arc burns unprotected skin!
Be careful for reflecting radiation of arc!
Protect yourself and the surroundings against the arc and hot spray!
Remember general fire safety!
Pay attention to the fire safety regulations. Welding is always classified as a fire risk operation.
Welding where there is flammable or explosive material is strictly forbidden.
If it is essential to weld in such an area remove inflammable material from the immediate vicinity of the welding
site.
Fire extinguishers must always be on site where welding is taking place.
Note! Spars may cause fire many hours after completion of welding.
Watch out for the mains voltage!
Take care of the cables - the connection cable must not be compressed, touch sharp edges or hot work pieces.
Faulty cables are always a fire risk and highly dangerous.
Do not locate the welding machine on wet surfaces.
English
Do not take the welding machine inside the work piece (i.e. in containers, cars etc.)
Ensure that neither you nor gas bottles or electrical equipment are in contact with live wires or connections!
Do not use faulty welding cables.
Isolate yourself by using dry and not worn out protective clothes.
Do not weld on wet ground.
Do not place MIG gun or the welding cables on the power source or other electrical equipment.
Dont press on mig gun switch, if the gun is not directed towards work piece.
Watch out for the welding fumes!
Ensure that there is sufficient ventilation.
Follow special safety precautions when you weld metals which contain lead, cadmium, zinc, mercury or beryllium.
Note the danger caused by special welding jobs!
Watch out for the fire and explosion danger when welding container type work pieces.
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 an Authorized KEMPPI Service Agent. Packing, freight
and insurance costs to be paid by third party. The guarantee is effected on the day 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 terms of guarantee: defects due to fair 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 or
damage due to natural causes i.e. ligthning or flooding.
This guarantee does not cover direct or indirect travelling costs, daily allowances or accomodation.
Note: Under the terms of the guarantee, Welding torches and their consumables, feed, drive rollers 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.
Guarantee period
The guarantee is valid for one year from date of purchase, provided that the machine is used for single-shift
operation.
The guarantee period for double and treble shift operation is six months and four months respectively.
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 purchase and serial number of
the equipment in order to validate the guarantee.
The parts replaced under the terms of the 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.
18 / 1923590 / 9907
English
FU 11 is 4-roll driven light weight wire feeder unit, designed for demanding professional use. The FU 11 is
suitable to be used with the MULTISYSTEM power sources.
Technical data
FU 11
Working voltage30 VAC 50/60 Hz
Connection power120 VA
Loading capacity 60 % ED
Operation principle
Diameter of feed roll
Wire feed speed
Filler wiresø Fe, Ss
Wire reelmax. weight
Gun connectorEuro
Operation temperature range
Storage temperature range
Degree of protection
Dimensions
without handles
Weight11,8 kg
) Concerns electronic components.
*
The product meets conformity requirements for CE marking.
100 % ED
ø Cored wire
ø Al
max. size
length
width
height
500 A
390 A
4-roll drive
32 mm
0...18 m / min
0,6...2,4 mm
0,8...2,4 mm
1,0...2,4 mm
20 kg
ø 300 mm
-20...+40 °C
-40...+60 °C
IP 23 *)
440 mm
220 mm
400 mm
English
Assembly of MIG equipment
= Instruction = Warning = Prohibition
The connections of the FU 11 are shown on page 4.
Cablings between different power sources and the FU are described in the operation instructions of the MULTISYSTEM power sources. The cablings of the FU 11 are carried out in the same way like in the FU 10, 20 and 30 wire
feeder units.
The FU 11 can be mounted to the MULTISYSTEM trolleys in the same way like the FU 10, 20 and 30 wire feeder
units. The FU 11 can be installed to boom using the metal lift hook (3135870), which is mounted to the plastic
handle.
Wire feeder 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 feeder unit can be changed by moving fixing point in handle.
Installation
Accessories corresponding to wire diameter
The wire feed rolls are available with plain groove, knurled
groove and with U groove for different purposes.
Feed rolls with plain groove:
Universal feed roll for welding of all kinds of wires.
Feed rolls with knurled groove:
Special feed roll for cored wires and steel wires.
Feed rolls with U groove:
Special feed roll for aluminium wires.
The wire feed rolls have two grooves for different filler
wire diameters. Correct wire groove is selected by moving selecting washer (28) from one side to another in feed roll.
Feed rolls and wire guide tubes of wire feeder unit have colour codes in order to make identification easier (see
table on page 5).
In delivery the the FU 11 is equipped with red feed rolls with plain groove and with orange wire guide tubes for
welding filler wires of 0.9-1.2mm (0.035", 0.045" and 0.052").
colourfiller wire ø mm (inch)
white0.6 and 0.8 (0.030)
red0.9/1.0 and 1.2 (0.035, 0.045 and 0.052)
yellow1.4, 1.6 and 2.0 (1/16 and 5/64)
black2.4 (3/32)
For very heavy welding with 1.0-1.2 mm filler wires we recommend you to use the following feed rolls with ballbearing, where there are deviating from other feed rolls two similar grooves:
3138650red, with plain groove, for 1.0 mm wires
3137390orange, with plain groove, for 1.2 mm wires
3137380orange, with knurled groove, for 1.2 mm wires
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 manufacturers recommendation suitable to be used for wire feed diameter and
type in question. Too tight a wire guide tube might cause for wire feeder unit a bigger stress than normally as well as
disturbances in wire feed.
Screw snap connector of gun tight that there wont come any voltage losses on connecting surface.
Loose connection will heat gun and wire feeder unit.
When you are using liquid-cooled gun, mount cooling liquid hoses in such a way that the ones with the red code
always are connected to the corresponding red counter-connectors and the blue ones correspondingly to the blue
counter-connectors.
Mounting and locking of wire reel
English
LOCKED OPEN
Check that in filler wire reel are no parts sticking out, which could e.g. chafe against chassis of the wire feeder
unit. Dragging parts might expose chassis of wire feeder unit under voltage.
Release locking nails of wire reel hub by turning locking
knob a quarter round.
Mount the reel at its place. Note rotating direction of
reel!
Lock the reel with locking knob, locking nails of hub re-
main to outside position and will lock the reel.
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 match the diameter of
welding wire used. Feed roll groove is selected by moving the groove selecting washer (28).
Release the wire end from reel and cut off the bent
28 28
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.
Draw a bit of loose wire from wire reel. Feed wire through back liner to feed rolls. Dont release pressure of feed
rolls!
Press the gun switch and feed a bit 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...0,8mm, Al: 0,8...1,0 mm). Then it might be
possible that you must open feed rolls and feed wire manually through feed rolls.
length. Be careful that the wire does not spill from the
reel to sides!
Adjustment of pressure
Adjust the pressure of feed rolls with the control screw 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.
Adjustment of tightness of reel brake
41
20 / 1923590 / 9907
Brake force is adjusted through hole in locking device of reel
hub by screwing the control screw (41) with screwdriver.
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 shouldnt keep it unnecessarily tight.
Ground cable
Fasten earthing press of ground cable carefully, preferably direct to welding piece. Contact surface of press always
should be as large as possible.
Clean the fastening surface from paint and rust!
Use in your MIG equipment 70mm2 copper-cables. 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!
Shielding gas
As MIG shielding gas is used carbon dioxide, mixed gases and argon. Shielding gas flow rate is defined by welding
current size.
Gas flow regulator
Gas flow regulator should be suitable for shielding gas used by you. The regulator being in your use might be
different from the one in picture, however, following general instructions are valid for all pressure regulators.
Before mounting of flow regulator
Step aside, open cylinder valve (51) somewhat for a
51
moment, in this way you can blow out any dirt that may
be in the valve of bottle.
Screw press regulation screw (52) of regulator outwards
so long that no spring pressure can be felt (screw is
turning freely).
Close needle valve (53) if there is one in regulator
Connect regulator onto valve of bottle
Tighten connecting nut (54) preferably with a wrench.
Put hose spindle (55) of regulator with jacket nuts (56)
onto gas hose, connection should be ensured with hose
clamp (57)
Connect hose onto regulator and machine, tighten jacket
nuts.
55
56
57
P1P2
53
54
52
56
English
Open valve of bottle slowly
Pressure meter (P1) shows pressure of bottle. Never use up all the gas in the bottle, send the bottle for filling up
when bottle pressure still is 2bar.
Open needle valve if there is one in regulator
Screw regulation screw (52) inwards until hose pressure meter (P2) shows flow (or pressure) required. By
regulation of flow amount the machine has to be in operation and the gun switch should be pressed on at the
same time.
Close valve of bottle always after having stopped welding
If the machine will be unused for a longer time, you should also unscrew pressure regulation screw (52).
Gas bottle
The gas bottle may explode if it falls!
Always fasten gas bottle tightly in vertical position, to wall stand or bottle cart, specially designed for it!
For safety reasons always remove gas bottle from transport stand of machine before lifting or car transport of
machine!
9907 / 1923590 / 21
Operation control
See OPERATION CONTROL AND CONNECTORS page 4.
Local control of wire feed speed
Stepless control of wire feed speed is
0...18m/min. The potentiometer is
equipped with the memory scale from 1
to 10.
Local control for welding voltage
Stepless control of power source´s voltage. The potentiometer is equipped with
the memory scale from 1 to 10.
Control mode selecting switch
(local / remote control)
English
With the switch is selected, if control of
wire feed and voltage is carried out from
control potentiometers of the FU 11 or
from the remote control unit, which is connected to the machine.
Start mode selecting switch
2-sequence procedure
1. Switch pressed: welding starts
2. Switch open: welding stops
4-sequence procedure
1. Switch pressed: shielding gas is flowing
2. Switch open: welding starts
3. Switch pressed: welding stops
4. Switch open: gas flow stops after the burn back time
Burn back time adjustment
The burn back time is adjusted between
0,05 - 0,5s.
You must possibly adjust the burn back
time among others then when you go
over to welding of different filler wire
types, for example when you go over from steel welding
to aluminium welding. The burn back time is adjusted as
such that the filler wire doesn´t stick to weld piece or
burn fastened to contact tip at the end of welding.
Remote control units
To the machine connector on the front wall of the FU you can connect the MULTISYSTEM remote control units,
which are designed for the MIG welding and which have stepless control for wire feed and voltage. By use of the
remote control turn the local/remote control switch into the remote control position.
C 110D
C 120SC 120P
C 110D (order number 6185421)
MIG/MAG remote control unit with controls for wire feed and voltage (memory scale 110).
C 120S (order number 6185427)
The remote control unit, into which you can program three different welding parameters for the MIG/MAG or MMA
welding. The parameters are selected from the selecting switch of the C 120S.
NOTE! In the MMA welding the MIG gun and the filler wire always are under voltage.
C 120P (order number 6185426)
Use is possible only with the PS 5000 or PSS 5000 power sources.
The C120P is pulsed MIG remote control unit, with which the PS/PSS5000 MIG equipment can be changed into
the pulsed MIG equipment. The use and operation of the C 120P has been described in the operation instructions
of the C 120P.
22 / 1923590 / 9907
Service, operation disturbances
The amount of use and the working environment should be taken into consideration when planning the frequency of
maintenance of the FU 11. 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 the wire feeder unit. 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
*Oxidezed 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
English
KEMPPI service repair shops make regular maintenance according to agreement.
The major points in the maintenance procedure are listed as follows:
Cleaning of the equipment
Checking and maintenance of the welding tools
Checking of connectors, switches and potentiometers
Checking of electric connections
Metering units checking
Checking of mains cable and plug
Damaged parts or parts in bad connection are replaced by new ones
Maintenance testing. Operation and performance values of the equipment are checked, and adjusted when nec-
essary by means of test equipment.
9907 / 1923590 / 23
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