Operating manual • English
EN
HiFeed
OPERATING MANUAL
English
HiFeed / © Kemppi Oy / 1102
EN
CONTENTS
1.1 General ....................................................................................................................................... 3
1.2 About HiFeed wire feeder ................................................................................................... 3
1.3 General Safety Instructions ................................................................................................ 3
1. MACHINE INTRODUCTION ........................................................6
1.1 Before use .................................................................................................................................. 6
1.2 Wire feeder front and side view ........................................................................................ 6
1.3 Wire feed mechanism ........................................................................................................... 7
2. INSTALLATION ............................................................................7
2.1 Power source connection .................................................................................................... 7
2.2 Shielding gas connection .................................................................................................... 8
2.3 Installing ller wire ................................................................................................................. 9
2.3.1 Mounting the wire spool ................................................................................................. 9
2.3.2 Feeding the welding wire .............................................................................................10
2.4 Setting the pressure of the feed rolls ............................................................................12
2.5 Setting the spool brake force ..........................................................................................12
2.6 Changing the feed rolls ......................................................................................................13
3. CONTROLLING WELDING FUNCTIONS ................................... 13
3.1 Control panel functions in basic operation ................................................................13
4. MAINTENANCE ......................................................................... 14
4.1 Regular maintenance ..........................................................................................................14
4.2 Disposal of the machine ....................................................................................................14
5. TECHNICAL DATA ..................................................................... 14
6. ORDERING CODES ....................................................................15
7. WARRANTY POLICY .................................................................. 16
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HiFeed / © Kemppi Oy / 1102
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1.1 GENERAL
Congratulations on choosing the HiFeed wire feeder. Used correctly, Kemppi products can
signicantly 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 specications of the device can be found at the end of the
manual.
Please read the manual carefully before using the equipment for the rst 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 specications presented in this manual are subject to change without prior notice.
NOTE! Items in the manual that require particular attention in order to minimise damage and
personal harm are indicated with this symbol. Read these sections carefully and follow their
instructions.
1.2 ABOUT HIFEED WIRE FEEDER
Kemppi’s HiFeed wire feeder in designed to be used especially with Kemppi’s HiArc power
sources. They are inverter MIG/MAG welding power sources to be used in 3-phase mains
power supply.
The HiArc power sources are equipped with semisynergic adjustment features. The HiArc
chooses automatically arc dynamic setting according to your gas selection.
Enjoy welding with your Kemppi product!
1.3 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 reecting 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.
• Never wear any welding device on the shoulder during welding and never suspend it by
the carrying strap during welding.
• 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 eects on welding
performance. This also minimizes your exposure to harmful magnetic elds, which may,
for example, interfere with a pacemaker.
• Do not wrap the welding cables around your body.
• In environments classied as dangerous, only use S-marked welding equipments with
a safe idle voltage level. These work environments include, for example, humid, hot or
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HiFeed / © Kemppi Oy / 1102
EN
small spaces, where the user may be directly exposed to the surrounding conductive
materials.
• Do not use arc welding equipment for pipe thawing.
Spatter and re safety
• Welding is always classied as hot work, so pay particular attention to the re safety
regulations during welding and after it.
• Remember that re 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
ammable liquid from the welding vicinity, and supply the welding site with adequate
re ghting equipment.
• In special welding jobs, be prepared for hazards such as re 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
ammable materials.
• Beware of hot objects or spatter falling on the machine when working above. Welding in
ammable 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 re.
• 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 o 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 sucient supply of fresh air, particularly in closed spaces. You can also ensure
an adequate supply of clean breathing air by using a ltered 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
• Pay attention to correct working position when lifting a heavy device – risk of injury to
the back.
• 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.
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HiFeed / © Kemppi Oy / 1102
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• 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 eciency
decreases 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 airow to and from the machine is unrestricted.
• Always use the machine in an upright position only.
• Arc welding equipments cause electromagnetic disturbance. To minimize the harmful
eects, strictly use the equipment according to the operating manual and other
recommendations.
Gas cylinders and regulators
• Adhere to the instructions for handling gas cylincers and regulators.
• Make sure that gas bottles are used and stored in properly ventilated spaces.
• A leaking gas bottle may replace the breathable air, causing suocation.
• Before use, make sure that the gas bottle contains gas suitable for the intended welding
purpose.
• Always x 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 ow adjuster is in place. Replace the
valve cover during transportation. Close the bottle valve after use.
Circuit diagram and spare part lists
If the circuit diagram and the spare parts list are not included in delivery package, please
inquire for them at your local Kemppi service representative. For more information, please visit
www.kemppi.com.
Disclaimer
While every eort 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 specication 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.
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HiFeed / © Kemppi Oy / 1102
EN
1. MACHINE INTRODUCTION
1.1 BEFORE USE
The product is packed in cartons designed specically for them. However, always make sure
before use that the products have not been damaged during transportation.
Check also that you have received the components you ordered and the instruction manuals
needed. Product packaging material is recyclable.
NOTE! When moving the welding machine, always lift it from the handle, never pull it from the
welding gun or other cables.
Operating environment
This machine is suitable for both indoor and outdoor use. Always make sure that the air ow in
the machine is unrestricted. The recommended operating temperature range is -20 °C…+40 °C.
Please read also the safety instructions concerning the operating environment earlier in this
manual.
1.2 WIRE FEEDER FRONT AND SIDE VIEW
5.
6.
8.
7.
9.
1
2
3
4
7
8
9
1
2
3
4
7
65
8
9
10
WIRE INCH
1.
2.
3.
4.
Front
1. EURO connector for welding gun
2. Amperage/WFS control knob
3. Voltage control knob
4. Wire inch button
Side
5. Wire feed mechanism
6. Wire spool hub
7. Pressure adjustment arm
8. Shielding gas connector
9. Spool locking lever
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HiFeed / © Kemppi Oy / 1102
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1.3 WIRE FEED MECHANISM
2.
3.
4.
6.
5.
1.
1. Pressure adjustment arm
2. Wire guide tube
3. Wire drive roll
4. Straightening rolls adjustment knob
5. Straightening rolls
6. Top feed roll holder
2. INSTALLATION
2.1 POWER SOURCE CONNECTION
The HiFeed wire feeder is recommended to be used with the HiArc power source, but it can be
used with other power source brands as well.
To connect the wire feeder to the power source, do the following:
1.
2.
3.
1. Attach the HiFeed wire feed unit power cable to the + connector of the HiArc power
source. Hand tighten the connector with a clockwise push and twist action to lock.
2. Attach the HiFeed wire feed unit control cable plug to the control socket of the power
source.
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HiFeed / © Kemppi Oy / 1102
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3. Connect the shielding gas hose to the gas bottle or to the shielding gas distribution
system.
NOTE! Normally the wire feeder should be connected to the plus pole. However, with some ller
wires and shielding gases, you should connect the feeder to the minus pole, and the earth return
cable to the plus pole..
2.2 SHIELDING GAS CONNECTION
The shielding gas hose is xed to the solenoid valve of the wire feeder.
Connect the other end of the gas hose to a gas cylinder’s control valve or to the shielding gas
distribution network at your worksite.
The thickness of the parent material, joint type and welding power dene the required
shielding gas ow rate.
NOTE! Make sure that you are using the correct type of shielding gas for the welding application.
When using pure CO₂ shielding gas, make sure you use a gas pre-heater. A 110V power supply
is provided for CO₂ gas pre-heaters at the rear of the HiArc power source. See the HiArc M400i
operating manual for further details.
To connect the shielding gas hose to a suitable regulator for MIG/MAG welding
1. Connect the shielding gas hose to the gas cylinder’s control valve and tighten the
connector (connector is not supplied in the package).
2. Adjust the shielding gas ow rate with the control valve screw.
3. Always close the cylinder valve after use.
Parts of the gas ow regulator
5
2
4
7
1
6
3
1. Gas bottle valve
2. Flow regulation screw
3. Connecting nut
4. Hose tail
5. Hose tail nut
6. Gas bottle pressure gauge
7. Shielding gas ow meter
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HiFeed / © Kemppi Oy / 1102
EN
Connector for shielding gas heater
• When using CO₂ shielding gas, a 110V gas heater can be connected to the power supply
located at the back of the HiArc power source. Please see the plug-in delivery package
for usage and tting instructions.
2.3 INSTALLING FILLER WIRE
With HiFeed you can use 0.8 to 1.6 mm ller wires. The wire spool can be up to 300 mm in
diametre and 105 mm in width.
When selecting a suitable ller wire, the material grade and alloy should suitably match the
base material.
NOTE! When changing the ller wire, always check that the feed rolls, their groove shape and size
and the wire liner inside the welding gun are suitable for the wire you are using. Also check that you
are using right polarity for the ller wire.
2.3.1 Mounting the wire spool
To mount the wire spool:
1.
2.
3.
1. Turn the locking lever to the open position.
2. Check the rotating direction of the wire spool and push the spool into place, so that it
rotates in the right direction.
3. Turn the locking lever to closed position and tighten the securing screw.
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HiFeed / © Kemppi Oy / 1102
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2.3.2 Feeding the welding wire
To feed the wire from the spool to the welding gun:
1. a
1. b
2
.
4.
3.
1. Open the pressure arm of the wire feed mechanism (a) and lift the top roll holder (b) to
its up position.
2. Draw some loose wire from the spool and push it through the straightening rolls at
the back of the mechanism. You can loosen the bottom straightening roll with the
adjustment screw located below it.
3. Adjust the straightening rolls so that the wire is rmly fed into the drive roll.
4. Push the wire over the feed roll groove and through the front wire guide until it comes
out from the Euro connector by about 150 mm.
5. Replace the top feed roll holder (a) over the wire and close the pressure arm (b).
5. a
5. b
6. Cut away any deformed wire section and dress the sharp wire tip.
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HiFeed / © Kemppi Oy / 1102
EN
NOTE! Remember to remove the sharp cut tip of the ller wire before loading the wire to the
welding gun, so preventing damage to the liner inside the welding gun cable. It will also improve
feed quality and increase the service life of your gun liner.
NOTE! When feeding the welding wire into the gun, be sure that you are not pointing the gun at
anyone and that there isn’t anything in front of the gun.
7. Connect the welding gun and tighten the collar.
Connect the welding gun cable to the Euro adapter socket located on the front of the machine
and hand tighten only. Do not over tighten the collar.
8. Press the Wire inch button and allow the ller wire to feed through the gun cable to the
contact tip.
1
2
3
4
7
8
9
1
2
3
4
7
65
8
9
10
WIRE INCH
The welding gun leads the ller wire, shielding gas and electric current to the weld piece.
When you press the welding gun trigger, shielding gas will ow and ller wire will begin to
feed.
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HiFeed / © Kemppi Oy / 1102
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2.4 SETTING THE PRESSURE OF THE FEED ROLLS
To make ller wire run smoothly into the wire liner and to the welding gun you can adjust the
pressure of the feed rolls of the wire feed mechanism.
To increase the pressure applied to the welding ller wire, turn the black pressure
adjustment knob in a clockwise direction.
To decrease the pressure applied to the welding ller wire, turn the black pressure
adjustment knob in an anti-clockwise direction.
0.9
1.2
1.6
There is a graduation scale marked on the arm of the adjustment knob. The more pressure
applied, the fewer number of graduation marks are visible.
For hard steel and stainless steel ller wires, make sure there is sucient pressure applied, so
avoiding ller wire slippage in the feed rolls.
NOTE! Too much pressure may atten the ller wire, damage its coating, cause friction and
excessive wear to drive roll bearings and therefore reduced life.
2.5 SETTING THE SPOOL BRAKE FORCE
To prevent the ller wire from uncoiling on overrun, following use at high wire feed speeds,
you can adjust the braking force of the ller wire spool holder.
The spool brake adjustment screw is located inside the spool hub. To adjust the brake force,
unscrew the spool locking mechanism on the tip of the wire spool hub.
To increase the force turn the screw clockwise, and to decrease it, by turning the screw
anticlockwise.
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HiFeed / © Kemppi Oy / 1102
EN
NOTE! Do not over tighten, and reduce the pressure for light ller wire types.
2.6 CHANGING THE FEED ROLLS
The drive roll has two dierent sized grooves in it. You can choose which groove to use by
opening the drive roll securing screw and turning the drive roll the other way around. The size
of the groove currently in use is facing outward.
3. CONTROLLING WELDING FUNCTIONS
1.
3.
2.
1
2
3
4
7
8
9
1
2
3
4
7
65
8
9
10
WIRE INCH
1. Wire feed speed
2. Welding voltage
3. Wire inch
In the control panel you can adjust the welding wire feed speed (1) and welding voltage (2).
With the Wire inch button you can feed the ller wire into the welding gun.
3.1 CONTROL PANEL FUNCTIONS IN BASIC OPERATION
With the amperage knob (A) you can adjust the welding current and the wire feed speed.
The wire feed speed increases with the amperage level.
With the voltage knob (V) you can adjust the welding voltage level. The voltage level
determines the arc length.
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HiFeed / © Kemppi Oy / 1102
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4. MAINTENANCE
4.1 REGULAR MAINTENANCE
Check regularly the electrical connections of the machine. Clean any oxidised connections,
and tighten the loosened cable connections. Remove regularly any dust and lings from the
wire conduit tip and feed rolls.
Do not try to open the motor and the reductor of the machine for repair or lubrication. They
do not need maintenance.
NOTE! Remember that the machine may be repaired only by an electrical contractor or installer
authorised to perform such operations.
4.2 DISPOSAL OF THE MACHINE
Do not dispose of electrical equipment with normal waste!
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 you will improve the environment and human health.
5. TECHNICAL DATA
HiFeed
Operating voltage
24 V
Rated power
65 W
Output
60% ED 500 A
100% ED 390 A
Feed mechanism
2-roll feed
Wire spool
max. ø 300 mm
Feed roll
ø 40 mm
Wire feed speed
0…18 m/min
Filler wires
0.8…1.6 mm
Gun connection
Euro
Operating temperature
-20 °C…+40 °C
Storage temperature
-40 °C…+60 °C
External dimensions
L x W x H 480 x 200 x 280 mm
Weight
9 kg
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HiFeed / © Kemppi Oy / 1102
EN
6. ORDERING CODES
Wire feeder
HiFeed 6310100
Wire feeder consumables
Intermediate cable set, 5 m W005805
Pressure arm assembly W004642
Pressure roller assembly W004643
Euro adapter W004648
Wire feeder roll 0.8 / 1.2 mm, factory setting W004653
Wire feeder roll 1.2 / 1.6 mm W004646
Wire guide tube 0.8 – 1.2 mm, factory setting W006117
Wire guide tube 1.2 – 1.6 mm W004644
Straightening roll assembly W004647
Wire spool shaft W004649
Gas pre-heater 6314010
Welding guns
MMT 42, 3 m 6254213MMT
MMT 42, 4.5 m 6254214MMT
Interconnection cables – optional extensions
HiArc 10-70-G 6310710
HiArc 15-70-G 6310715
HiArc 10-50-G 6310510
HiArc 15-50-G 6310515
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HiFeed / © Kemppi Oy / 1102
EN
7. 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 specications), incorrect gas pressure, anomalies or failures in the
electric network, transport or storage damage, and re 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, feeder
guide tubes, and shielding gas regulator and CO₂ heater. Direct or indirect damage caused by
a defective product is not covered under the warranty.
The warranty becomes void if modications 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 also
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.
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HiFeed / © Kemppi Oy / 1102
www.kemppi.com
1921690
1102
KEMPPI OY
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PL 13
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Tel +358 3 899 11
Telefax +358 3 899 428
export@kemppi.com
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Kotimaan myynti:
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myynti.@kemppi.com
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BEDFORD, MK44 3WH
ENGLAND
Tel +44 (0)845 6444201
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sales.uk@kemppi.com
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78681 EPONE CEDEX
FRANCE
Tel +33 1 30 90 04 40
Telefax +33 1 30 90 04 45
sales.fr@kemppi.com
KEMPPI GmbH
Otto-Hahn-Straße 14
D-35510 BUTZBACH
DEUTSCHLAND
Tel +49 6033 88 020
Telefax +49 6033 72 528
sales.de@kemppi.com
KEMPPI SPÓŁKA Z O.O.
Ul. Borzymowska 32
03-565 WARSZAWA
POLAND
Tel +48 22 7816162
Telefax +48 22 7816505
info.pl@kemppi.com
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
info.au@kemppi.com
OOO KEMPPI
Polkovaya str. 1, Building 6
127018 MOSCOW
RUSSIA
Tel +7 495 739 4304
Telefax +7 495 739 4305
info.ru@kemppi.com
ООО КЕМППИ
ул. Полковая 1, строение 6
127018 Москва
Tel +7 495 739 4304
Telefax +7 495 739 4305
info.ru@kemppi.com
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
sales.cn@kemppi.com
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
sales.cn@kemppi.com
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
sales.india@kemppi.com
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