Kemppi MF 33 User Manual

FastMig
MF 33
Operating manual
Bruksanvisning
Gebrauchsanweisung
Manual de instrucciones
Käyttöohje
Manuel d’utilisation
Manuale d’uso
Gebruiksaanwijzing
Brugsanvisning
Instrukcja obsługi
Manual de utilização
EN
DA
DE
ES
FI
FR
NL
NO
PL
PT
Инструкции по эксплуатации
Bruksanvisning
RU
SV
OPERATING MANUAL
English
EN
© Kemppi Oy / 1515
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 4-roll wire feed mechanism ................................................................................................ 6
3. Installation ..................................................................................... 7
3.1 Assembly of MIG/MAG system .......................................................................................... 7
3.2 Mounting of MIG welding gun .......................................................................................... 8
3.3 Mounting and locking of wire spool ............................................................................... 8
3.4 Automatic wire feed to gun................................................................................................ 8
3.5 Adjustment of pressure ........................................................................................................ 8
3.6 Adjustment of tightness of spool brake ........................................................................ 9
3.7 Burn back time ........................................................................................................................ 9
3.8 Ground cable ............................................................................................................................ 9
3.9 Shield gas ................................................................................................................................10
3.9.1 Installing gas bottle .......................................................................................................10
3.10 Main switch I/O .....................................................................................................................11
3.11 Operation of cooling unit, FastCool 10 ........................................................................11
3.12 Hanging....................................................................................................................................11
4. Service, operation disturbances .................................................. 11
5. Disposal of the machine .............................................................. 11
6. Ordering numbers ....................................................................... 12
7. Technical data .............................................................................. 13
2
FastMig MF 33
1. PREFACE
1.1 General
Congratulations on choosing the FastMig MF equipment. Used correctly, Kemppi products can signicantly 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 specications of the equipment 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 specications 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 eort 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 specication 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 / 1515
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.
4.
5.
2.
6.
3.
1. Operation panel
2. Connection of welding gun EURO
3. Lead-in and clamping of cooling liquid hoses
4T
2T
5
4
3
2
1
0
MIN
6
7
8
2
9
1
10
MAX MAXMIN
3
0
4. Shielding gas connection
5. Connection for control cable
6. Welding current cable connection
1.
5
4
6
7
8
2.
3.
W001320
10
MF
MF
9
4
1. Selection of gun switch function
2. Adjustment of wire feed speed
3. Adjustment of welding voltage
FastMig MF 33
2.2 Connection of system
EN
© Kemppi Oy / 1515
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EN
2.3 4-roll wire feed mechanism
Wire ø, mm Wire guide tube ø, mm
0,6...0,8 white
Fe, Mc, Fc
0,9...1,6 orange
1,6...2,4 blue
0,8...1,6 silver
Ss, Al
1,6...2,4 yellow
1,0 mm 3134140
2,0 mm 3133700
4,0 mm 3134130
2,5 mm 3134290
3,0 mm 3134710
orange 2,0 mm 3134120
blue 4,0 mm 3134110
silver 2,5 mm 3134300
yellow 3,0 mm 3134720
plastic 2,0 mm 4267220
plastic 2,0 mm 4266970
plastic 4,0 mm 4270180
brass 4,0 mm 4267030
plastic 2,0 mm 4267220
plastic 4,0 mm 4270180
yellow 2,4 mm 4268210
for Promig 511
yellow 3,0 mm 4268560
Feed rolls, 4-rolls
Colour ø, mm
Fe, Ss, Al
Plain, V-groove
Fe, Fc, Mc
Knurled, V-groove
Fe, Fc, Mc, Ss, Al
Trapetsoid groove
(L) = Fitted with ball bearings
white 0,6/0,8 3133810 white 0,8/0,8 (L) 3143180 red 1,0/1,2 3133210 red 1,0/1,0 (L) 3138650 orange 1,2/1,2(L) 3137390 yellow 1,4-1,6/2,0 3133820 Feed roll groove selection yellow 1,6/1,6 (L) 3141120 black 2,4 3133880 blue 3,2 3133910 red 1,0/1,2 3133940 orange 1,2/1,2 (L) 3137380 yellow 1,4-1,6/2,0 3133990 yellow 1,6/1,6 (L) 3141130 black 2,4 3134030 blue 3,2 3134060 Transfer of gear wheel selector plate orange 1,2/1,2 (L) 3142210 brown 1,4/1,4 (L) 3142220 ø 28 mm (0–18 m/min) 4265240 plastic yellow 1,6/1,6 (L) 3142200 ø 28 mm (0–18 m/min) 4287860 steel grey 2,0/2,0 (L) 3142230 ø 40 mm (0–25 m/min) 4265250 plastic black 2,4 (L) 3142240 ø 40 mm (0–25 m/min) 4297270 steel
Gear wheel
6
FastMig MF 33
NOTE! Mount the lower feed roll, ensuring that the pin on the shaft ts in the cut on the feed roll.
3. INSTALLATION
3.1 Assembly of MIG/MAG 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
EN
Mounting the FastMig MF on to the power source
Screw the fastening pivot on the power source. Lift the wire feeder on fastening pivot.
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 xing point in handle.
© Kemppi Oy / 1515
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EN
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
LOCKED OPEN
• Release locking nails of wire spool hub by turning locking knob a quarter round.
• Mount the spool at its place. Note rotating direction of spool!
• Lock the spool with locking knob, locking nails of hub remain to outside position and
will lock the spool.
NOTE! Check that in ller 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 ller 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 o 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 (le o if necessary). A sharp edge may damage the wire guide tube and contact tip of the welding gun.
FastMig MF wire feed units:
• 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 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 – 0,8 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 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 attening of the ller wire and damage to the coating. It also
causes undue wear of the feed rolls as well as friction.
8
FastMig MF 33
3.6 Adjustment of tightness of spool brake
A
Brake force is adjusted through hole in locking device of spool hub by screwing the control screw (A) with screwdriver.
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!
EN
© Kemppi Oy / 1515
9
3.9 Shield gas
NOTE! 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 ow rate is set according to the welding power used in the job. A suitable ow rate is normally 8 – 10 l/min. If the gas ow is not suitable, the welded joint will be sporous. Contact your local Kemppi-dealer for choosing gas and equipment.
3.9.1 Installing gas bottle
NOTE! 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 nished welding.
EN
A
Parts of gas ow regulator
A. Gas bottle valve B. Press regulation screw C. Connecting nut D. Hose spindle E. Jacket nut F. Gas hose pressure meter
The following installing instructions are valid for most of the gas ow 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 lled 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 ow (or pressure). When regulating ow amount, the power source should be in switched on and the gun switch pressed simultaneously.
NOTE! Close bottle valve after having nished welding. If the machine will be out of use for a long
time, unscrew the pressure regulation screw.
F
C
G
B
E D
10
FastMig MF 33
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 o the machine with the main switch, never use the mains plug as a
switch.
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 33 can be hanged from the handle to the barrier.
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. Lubricate the feed rolls twice a year.
NOTE! When using compressed air, always protect your eyes with proper eye protection.
In case of problems contact your KEMPPI dealer.
EN
5. 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.
© Kemppi Oy / 1515
11
EN
6. ORDERING NUMBERS
MF 33 6063300 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 PM 500 6185291
Accessories
KWF 300 protection slides 6185287
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
12
FastMig MF 33
7. TECHNICAL DATA
MF 33 Operating voltage (safety voltage) Connection capacity Output 40 °C
Wire feed mechanism Diameter of feed roll Wire feed speed ¹) Filler wires
Wire spool
Gun connection Operation temperature range Storage temperature range EMC class Degree of protection External dimensions Weight
24 V DC
100 W 60 % ED 520 A 100 % ED 440 A
4-roll feed
32 mm
0 – 25 m/min ø Fe, Ss 0.6 – 1.6 ø Cored wire 0.8 – 2.0 ø Al 1.0 – 2.4 max. weight 20 kg max. ø ø 300 mm
Euro
-20 ... +40 °C
-40 ... +60 °C
A
IP23S LxWxH 590x240x445 mm
13.6 kg
EN
¹) Changes of speed are carried out by changing gear wheel (D 28/D 40).
© Kemppi Oy / 1515
13
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