Kemppi MXF 63 User Manual

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FastMig

MXF 63, 65, 67

Operating manual

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Manual de instrucciones

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Manuel d’utilisation

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操作手册

OPERATING MANUAL

English

CONTENTS

1. Preface ........................................................................................................... 3

1.1 General ....................................................................................................................................... 3

1.2 About FastMig products ...................................................................................................... 3

2. Installation .................................................................................................... 4

2.1 Machine introduction, MXF 65, MXF 67 and MXF 63 ................................................ 4

2.2 Connection of system ........................................................................................................... 5

2.3 Assembly of MIG/MAG system .......................................................................................... 6

2.4 Accessories corresponding to wire diameter ..............................................................7

2.5 Welding gun selection .......................................................................................................... 7

2.6 Mounting and locking of wire spool ............................................................................... 7

2.7 Loading the ller wire and automatic feed ..................................................................8

2.8 DuraTorque™ 400, 4-wheel wire feed mechanism ..................................................... 8

2.9 Wire liners ................................................................................................................................10

2.10 Adjustment of pressure arms ...........................................................................................11

2.11 Adjustment of spool brake ...............................................................................................11

2.12 Burn back time ......................................................................................................................11

2.13 Earth return cable .................................................................................................................11

2.14 Shielding gas ..........................................................................................................................12

2.15 Main switch I/O .....................................................................................................................13

2.16 Operation of cooling unit, FastCool 10 ........................................................................13

2.17 MXF hanging kit ....................................................................................................................14

3. Control panel operations ........................................................................15

3.1 Connecting and mounting ...............................................................................................15

4. Welding software delivery prole ........................................................ 16

5. Panel button functions ...........................................................................19

5.1 PF 63 and PF 65 control panel for FastMig Pulse ...................................................... 19

5.2 PF 63 and PF 65 control panel button functions ......................................................20

5.3 SF 51 and 54 control panel for FastMig KMS ..............................................................23

5.4 SF 52W and 53W control panel for FastMig KMS .....................................................24

5.5 MS 200 and MS 300 control panel for FastMig M ..................................................... 25

5.6 MR 200 and MR 300 control panel for FastMig M ....................................................26

6. Basic troubleshooting ............................................................................. 27

7. Maintenance .............................................................................................. 28

7.1 Daily maintenance ...............................................................................................................28

7.2 Service shop maintenance ...............................................................................................28

8. Disposal of the machine ......................................................................... 28

9. Ordering numbers .................................................................................... 29

10. Technical data ............................................................................................ 33

FastMig MXF 63, 65, 67

1. PREFACE

1.1 General

Congratulations on choosing the FastMig MXF 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 operating manual and the safety instructions booklet 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.

1.2 About FastMig products

Kemppi FastMig™ MXF 63, MXF 65 and MXF 67 are wire feeders designed for demanding professional use. MXF 63 is intended for 200 mm wire spool, MXF 65 and MXF 67 for 300 mm wire spool. Wire feeders can be used with FastMig Pulse, FastMig KMS and FastMig M power sources.

Which alternative panel to choose for MXF 63, 65 and 67 depends on the used power source i.e. FastMig KMS becomes compatible by connecting SF 51, SF 52W, SF 53W or SF 54 control panels with MXF wire feed unit, and in the case of PF 63 and PF 65 control panels FastMig Pulse power source can be connected. With FastMig M the MR 200, MR 300, MS 200 or MS 300 panels are used. Operation of wire feed units is controlled and adjusted by microprocessor. By adding an optional synchronization unit (MXF Sync 65), SuperSnake sub-feeder device may be connected to MXF 63, 65 and 67.

This manual provides instructions on the start-up and use of the MXF 63, 65 and 67 MIG/MAG wire feeding units.

2. INSTALLATION

2.1 Machine introduction, MXF 63, MXF 65 and MXF 67

WF #

1. Control panel

2. Remote control connector

3. Sub-feeder sync connector (kit optional)

4. Gun water connections (cooling optional)

5. Euro gun connector

6. Shielding gas connection

7. Connection for control cable

8. Welding current cable connector

9. Lead-in and clamping of cooling liquid hoses

FastMig MXF 63, 65, 67

10. 11.

10. Wire Inch button

11. Gas Test button

2.2 Connection of system

2.2.1 Liquid cooled system: FastMig power source + MXF + FastCool 10

1. MXF wire feed unit

2. FastMig power source

3. FastCool water cooler and power connection

4. Gas supply

5. MMA electrode holder

6. Remote control device

7. Liquid cooled welding Gun

8. Power cable

9. Earth return lead and clamp

2.2.2 Air cooled system: FastMig power source + MXF

1. MXF wire feed unit

2. FastMig power source

3. Gas supply

4. MMA electrode holder

5. Remote control device

6. Air cooled welding gun

7. Power cable

8. Earth return lead and clamp

2.3 Assembly of MIG/MAG system

Assemble the units in the order mentioned below. Follow the additional mounting and operating instructions delivered with each package.

1. Installation of power source

Read paragraph: ”Installation” in the operation instructions for FastMig power sources, and complete the installation according to that advice.

2. Mounting of power sources to transport wagon

Read and follow the instructions given in the transport cart installation/assembly manual.

3. Mounting the FastMig MXF wire feed unit to the power source

Remove the cover sticker on top of the power source. Screw the fastening pivot into the power source – hand tighten only. Place the supplied plastic spacers over the pivot. Lift the MXF wire feeder into place, locating over the pivot.

4. Connecting cables

Connect the cables in accordance with the equipment notes provided in this manual. The polarity of the welding wire (+ or –) can be selected by connecting the wire feed unit to

either the positive or the negative power source terminals. Most MIG/MAG applications run the wire feed unit connected to the positive terminal of the

power source.

5. Mounting FastMig wire feed units to boom and swing arms

When mounting wire feed units to boom and swing arms, the unit must be electrically isolated from both.

Suspension angle of wire feed unit can be changed by moving the xing point in handle.

FastMig MXF 63, 65, 67

2.4 Accessories corresponding to wire diameter

Colour coded wire feed rolls and guide tubes are available to suit a variety of ller wire types and sizes. Drive roll groove geometry and design vary depending on the application. Further details are available in the spare part tables.

Please ensure you select the correct drive rolls and guide tubes from the table to suit your particular welding application.

2.5 Welding gun selection

Please ensure that the welding gun selected is suitable for the target application. Check the gun manufacturer's specication and ensure the gun meets the welding duty requirements. Also consider the extra heating eects of Pulse MIG/MAG welding on the gun selected.

Kemppi gun products are designed to meet many dierent applications. Special wire liners and contact tips are available for dierent wire types and sizes.

Distance wire feeding is accommodated with WeldSnake and SuperSnake products in either air or liquid cooled models.

Thermal and load protection is also designed to some Kemppi Gun models and feed units, so carefully consider your requirements and consult your local Kemppi sales team to ensure you choose the correct alternative for your needs.

2.6 Mounting and locking of wire spool

NOTE! Check that the ller wire spool is correctly mounted and locked into position. Ensure the

spool is not damaged or deformed in such a way that it can rub or cha against the internal surface of the wire feed unit chassis or door. This may result in increased drag, impacting on weld quality. This may also result in long term wire feed unit damage, rendering the unit unserviceable or unsafe to use.

2.7 Loading the ller wire and automatic feed

Automatic wire feed makes wire spool changes faster. When changing the wire spool, the pressure of feed rolls need to be released.

Simply ensure that the groove of the feed roll matches the diameter of ller wire used. Release the wire end from the spool and cut o any deformed section. Be careful the wire does not spill from the spool sides.

Straighten about 20 cm of ller wire and ensure the tip has no sharp edges. File if necessary, as a sharp wire edge may damage the wire gun liner - particularly softer plastic liners.

Present the ller wire tip to the back of the wire feed rolls and press the Wire Inch button on the wire feed panel or use the switch inside the wire spool cabinet. Feed the wire to the gun contact tip and prepare to weld.

NOTE! Smaller diameter ller wires may need to be loaded manually – with the feed roll pressure

arms released. This is because it is easy to overestimate the pressure required to feed these smaller ller wires. Too high feed roll pressures can easily deform ller wires and contribute to later feeding problems.

2.8 DuraTorque™ 400, 4-wheel wire feed mechanism

Wire guide tubes

Ss, Al, (Fe, Mc, Fc) plastic

Fe, Mc, Fc metal

ø mm outlet tube middle tube inlet tube

0.6 W007437 W007429 W007293

0.8 – 0.9 W007438 W007430 W007294

1.0 W007439 W007431 W007295

1.2 W007440 W007432 W007296

1.4 W007441 W007433 W007297

1.6 W007442 W007434 W007298

2.0 W007443 W007435 W007299

2.4 W007444 W007436 W007300

0.8 – 0.9 W007454 W007465 W007536

1.0 W007455 W007466 W007537

1.2 W007456 W007467 W007538

1.4 – 1.6 W007458 W007469 W007539

2.0 W007459 W007470 W007540

2.4 W007460 W007471 W007541

FastMig MXF 63, 65, 67

Wire feed rolls, plastic

Fe, Ss, (Al, Mc, Fc)

V-groove

Fc, Mc, (Fe)

V-groove, knurled

Al, (Fc, Mc, Ss, Fe)

U-groove

ø mm lower upper

0.6 W001045 W001046

0.8 – 0.9 W001047 W001048

1.0 W000675 W000676

1.2 W000960 W000961

1.4 W001049 W001050

1.6 W001051 W001052

2.0 W001053 W001054

2.4 W001055 W001056

1.0 W001057 W001058

1.2 W001059 W001060

1.4 – 1.6 W001061 W001062

2.0 W001063 W001064

2.4 W001065 W001066

1.0 W001067 W001068

1.2 W001069 W001070

1.6 W001071 W001072

Wire feed rolls, metal

ø mm lower upper

Fe, Ss, (Al, Mc, Fc)

V-groove

Fc, Mc, (Fe)

V-groove, knurled

Al, (Fc, Mc, Ss, Fe)

U-groove

NOTE! Mount the lower feed roll, ensuring that the pin on the shaft ts in the cut on the feed roll.

0.8 – 0.9 W006074 W006075

1.0 W006076 W006077

1.2 W004754 W004753

1.4 W006078 W006079

1.0 W006080 W006081

1.2 W006082 W006083

1.4 – 1.6 W006084 W006085

2.0 W006086 W006087

1.0 W006088 W006089

1.2 W006090 W006091

1.6 W006092 W006093

2.9 Wire liners

Designed to suit specic ller wire materials and applications, Kemppi liners support the ller wire and ensure reliable delivery to the welding arc. The liner selection tables describe gun type, ller material, liner colour, item code and gun length. Steel spiral liners carry the same colour coding as Kemppi machine feed rolls and drive rolls, making wire size, liner and drive roll matching easier if the gun is connected to Kemppi equipment. Steel spiral liners are suitable for welding solid and cored ller wires of corresponding wire diameter.

Kemppi DL Chili -Teon liners are the latest solution for reliable feeding of aluminium, stainless steel, acid-resistant and solid steel ller wires. Kemppi’s patented technology, two layer DL Chili liner material signicantly reduces friction losses between the ller wire material and liner wall, ensuring reliable and worry-free feeding for listed wires types, even with guns up to 8 meters in length. Please refer to the following tables to ensure accurate selection of liners for your chosen welding gun and application.

Wire liners for MMT, PMT guns

Steel/cored wire Filler wire ø, mm Order number, 3 m Order number, 4.5 m

Steel/Aluminium/ Stainless steel

DL Chili 5.9/1.5 0.6…1.0 W005920 W005937 DL Chili 5.9/2.0 1.0…1.2 W005921 W005938 DL Chili 5.9/2.5 1.2…1.6 W005922 W005939

Aluminium

DL Chili 5.9/3.0 1.6 W007671 W007957

0.6…0.8 4188571 4188572

0.9…1.2 4188581 4188582

1.4…1.6 (1.2) 4188591 4188592

1.6…2.0 4188601 4188602

2.0…2.4 4188611 4188612

2.8…3.2 4188621 4188622

Filler wire ø, mm Order number, 3 m Order number, 4.5 m

Wire liners for Weldsnake

Steel/Aluminium/

Filler wire ø, mm Order number, 6 m Order number, 8 m

Stainless steel

DL Chili 5.9/1.5 0.6…1.0 W005943 W005946 DL Chili 5.9/2.0 1.0…1.2 W005944 W005947 DL Chili 5.9/2.5 1.2…1.6 W005945 W005948

Aluminium

DL Chili 5.9/3.0 1.6 W007672 W007958

FastMig MXF 63, 65, 67

2.10 Adjustment of pressure arms

Adjust the drive pressure to the ller wire with the thumb screws mounted over the pressure arms. Notice the graduated scales indicating load. The load applied should be sucient to overcome a light braking force applied by hand to the ller wire, as it exits the welding gun contact tip.

For smaller diameter and soft ller wires, less feed pressure is required. It should be possible to apply a light breaking force to the ller wire by hand, as it exits the gun contact tip. But slightly more wire ow restriction should render the drives rolls to slip slightly over the ller wire without deforming the wire.

NOTE! Excessive pressure causes attening of the ller wire and damage to coated or cored ller

wires. It also causes undue wear of the feed rolls and increases gearbox load, so reducing service life.

2.11 Adjustment of spool brake

Brake force is adjusted through the hole behind the locking clip. Remove the locking clip by hand, and adjust the tension and pressure to the friction pads mounted inside with a screw driver. See diagram and location A.

The load applied varies depending on the size and weight of the ller wire and spool, but also the ller wire feed speed set. The heavier the wire spool and the faster the feed speed, the greater the need to increase the braking load. Adjust the pressure, secure the locking clip, set the wire feed speed and check that the braking force is enough to ensure the ller wire does not spill from the spool on overrun.

NOTE! Too much or unnecessary loads can impact welding quality, load and wear to the wire feed

system.

2.12 Burn back time

FastMig electronics controls the burn back time. When welding stops, an automatic sequence ensures that the ller wire does not stick to the work piece and that no ball is formed at the wire tip, ensuring reliable re-ignition. This system works regardless of the wire feed speed set.

2.13 Earth return cable

Preferably the earth return cable and clamp should be connected directly to the welding material.

Always use a good quality, 70 mm heavy copper cable, and if possible a screw type 600 A clamp. Ensure that the surface contact to the work piece is clean of metal oxide and or paint. Make sure the clamp is rmly secured.

MMT 32

2.14 Shielding gas

NOTE! Handle shielding gas bottle with care. Assess the risks associated with handling and using

compressed gas. Always use a cylinder transport carriage and secure the cylinder safely.

There are many dierent suppliers of quality shielding gases for welding. Please ensure that you are selecting the correct gas for your application. FastMig products uses welding programs for Synergic and Pulsed welding. These curves are created and recommend against a particular shielding gas.

Shielding gas eects welding performance and is a fundamental component to overall weld quality.

l/min

NOTE! Shielding gas ow rate from the welding gun is set according to the application, weld joint,

gas type and gas nozzle shape and size. The ow rate should be measured at the welding gun nozzle before welding via a rotameter, and normally measure's between 10 – 20 litres per minute for many welding applications.

2.14.1 Installing gas bottle

Always fasten the gas bottle properly in the vertical position, in a special holder against the wall or on a cylinder carriage. Remember to close gas bottle valve after welding.

Parts of gas ow regulator

5 4

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

FastMig MXF 63, 65, 67

2.15 Main switch I/O

WIRE INCH

weld data

m/min

DYNAMICS

ARC FORCE

GAS TEST

When you turn the main switch of the FastMig power source into I-position, the pilot lamp closest to this switch will illuminate, indicating the power source is ready for welding. The equipment will return to the operation state as before the main switch was turned to the zero position.

Always start and switch o the machine with the main switch, never use the mains plug as a switch.

2.16 Operation of cooling unit, FastCool 10

When FastCool 10 is connected to the FastMig power source for the rst time, the cooler function is normally active. To deselect the cooler function, follow the instructions below depending on the power source type in use.

FastMig KMS and FastMig M

When leaving the factory, cooling unit status is set 'ON'. If no cooling unit is connected, set the cooling unit status to 'OFF'. Depending on your panel type follow the instructions described in the graphic below. Having selected the cooling state required, reset the power source by switching o at the main on/o switch. Restart the power source and weld.

SF 51/SF 54

MR 200/MR 300

ARC FORCE

DYNAMICS

ARC FORCE

DYNAMICS

GAS TEST

WIRE INCH

GAS TEST

weld data

ARC FORCE

DYNAMICS

POWER

m/min mm

WIRE INCH

weld data

SF 52W/SF 53W and MS 200/MS 300

SETUP

A + D B

> 5 s

FastMig Pulse

The factory default setting for FastMig Pulse is AUTO. If a cooling unit is not connected and the operator tries to establish air cooled operation together with an air cooled gun, Err 27 is displayed. To establish air cooled operation, select cooler ‘OFF’. This is done in the ‘System Cong Menu’ as follows: Press the Menu button on the P65 power source panel. Move the menu display arrow (via panels left-hand up-down arrow keys) to select ‘System Cong Menu’ and then press select button. Choose ‘Water Cooling:Auto’ and change via control knob to setting ‘Water Cooling:OFF’, then press Back/Exit. Cooler will then be set to the ‘OFF’ state for air cooled operation. Reset power source via on/o switch and continue welding.

When selected, the operation of the cooling unit is automatic, starting when welding commences. When welding stops the pump will continue operation for approx. 5 min, so reducing the gun and the cooling liquid to ambient temperature. Read the operation instructions for the FastCool 10 unit.

2.17 MXF hanging kit

The MXF 63, 65 and 67 wire feed units can be hanged from a special hanging kit available as an accessory. This allows the wire feed unit to be suspended above the work area.

3. CONTROL PANEL OPERATIONS

MXF wire feeders can be connected to either FastMig Pulse, FastMig KMS or FastMig M power sources.

PF 63 and PF 65 control panel are compatible with FastMig Pulse. SF 53W and SF 54 or SF 51 and SF 52W panels enable compatibility with FastMig KMS power

sources. MR 200, MR 300, MS 200 and MS 300 panels are compatible with FastMig M power sources.

FastMig MXF 63, 65, 67

3.1 Connecting and mounting

Fasten the ribbon cable connector from the MXF wire feed unit to the control panel. Attach the yellow-green earth lead into the fork connector on the PF panel.

MXF 65

1. Place the bottom edge of the panel behind the securing clips on the machine. Remove the xing pin from the top edge with, for example, a screwdriver. Then gently push the upper part of the panel into place. Make sure that the cables do not get damaged, continue gently pushing the upper part of the panel until it clips into place.

2. Finally secure the panel into place with the additional black plastic security clip provided (MXF 65 only). Ensure that the clip is positioned correctly. You will notice that the clip does not seat snuggly if its positioned upside down.

MXF 63 + MXF 67

MXF 63 MXF 67

4. WELDING SOFTWARE DELIVERY PROFILE

FastMig Pulse

The following information details welding software options for FastMig Pulse. Welding software is developing regularly as new function and performance is designed for specic applications. If you have a specic need beyond your standard equipment prole, check Kemppi DataStore for new welding software options or discuss with your supplier.

FastMig Pulse is designed to allow customer specied welding software choice. Following delivery and installation your machine will include welding software specied at the point of order. The tables below show typical welding programs, but there are more of them available. Please check availability from your supplier. If the delivery specication is focused to a specic project and you wish to update the machine in the future, you can select additional welding software from the Wise & Match software products. Order and load these software products to your machine with Kemppi DataGun eld program device.

Wise and Match products provide optional welding application solutions. Wise and Match products menu includes special weld process for (1) root pass and (2) thin plate welding, (3) auto power regulation and (4) arc length recognition, (5) minilog function, plus additional base material welding programs and optional panel function.

1. WiseRoot

2. WiseThin

3. WisePenetration

4. WiseFusion

5. MatchLog

Kemppi DataStore oers new welding software packages and special enhanced arc performance solutions.

Customization of FastMig Pulse systems can make welding more ecient. Solutions oered are designed to meet the needs of wide ranging welding environments.

You can order materials specic welding programs and Wise solutions separately through Datastore or via your local supplier.

6265011 9991013 9991000 9991014 9991017

FastMig MXF 63, 65, 67

ALUMINIUM PACK

Group Material Wire ø (mm) Shielding gas Process Number

Al AlMg5 1.0 Ar Pulse/Double Pulse A01 Al AlMg5 1.2 Ar Pulse/Double Pulse A02 Al AlMg5 1.6 Ar Pulse/Double Pulse A03 Al AlSi5 1.0 Ar Pulse/Double Pulse A11 Al AlSi5 1.2 Ar Pulse/Double Pulse A12 Al AlSi5 1.6 Ar Pulse/Double Pulse A13 Al AlMg5 1.0 Ar 1-MIG A01 Al AlMg5 1.2 Ar 1-MIG A02 Al AlMg5 1.6 Ar 1-MIG A03 Al AlSi5 1.0 Ar 1-MIG A11 Al AlSi5 1.2 Ar 1-MIG A12 Al AlSi5 1.6 Ar 1-MIG A13

STAINLESS STEEL PACK

Group Material Wire ø (mm) Shielding gas Process Number

Ss CrNiMo 19 12 0.8 Ar+2%CO₂ Pulse/Double Pulse S01 Ss CrNiMo 19 12 0.9 Ar+2%CO₂ Pulse/Double Pulse S02 Ss CrNiMo 19 12 1.0 Ar+2%CO₂ Pulse/Double Pulse S06 Soft Ss CrNiMo 19 12 1.2 Ar+2%CO₂ Pulse/Double Pulse S04 Ss CrNiMo 19 12 1.0 Ar+He+CO₂ Pulse/Double Pulse S26 Soft Ss CrNiMo 19 12 1.2 Ar+He+CO₂ Pulse/Double Pulse S24 Ss CrNiMo 19 12 0.8 Ar+2%CO₂ 1-MIG S01 Ss CrNiMo 19 12 0.9 Ar+2%CO₂ 1-MIG S02 Ss CrNiMo 19 12 1.0 Ar+2%CO₂ 1-MIG S03 Ss CrNiMo 19 12 1.2 Ar+2%CO₂ 1-MIG S04 Ss FC-CrNiMo 19 12 1.2 Ar+15–25%CO₂ 1-MIG S84 Ss MC-CrNiMo 19 12 1.2 Ar+2%CO₂ 1-MIG S87

STEEL PACK

Group Material Wire ø (mm) Shielding gas Process Number

Fe Fe 0.8 Ar+15–25%CO₂ 1-MIG F01 Fe Fe 0.9 Ar+15–25%CO₂ 1-MIG F02 Fe Fe 1.0 Ar+15–25%CO₂ 1-MIG F03 Fe Fe 1.2 Ar+15–25%CO₂ 1-MIG F04 Fe Fe 0.8 CO₂ 1-MIG F21 Fe Fe 0.9 CO₂ 1-MIG F22 Fe Fe 1.0 CO₂ 1-MIG F23 Fe Fe 1.2 CO₂ 1-MIG F24 Fe Fe Metal 1.2 Ar+15–25%CO₂ 1-MIG M04 Fe Fe Metal 1.2 CO₂ 1-MIG M24 Fe Fe Rutil 1.2 Ar+15–25%CO₂ 1-MIG R04 Fe Fe Rutil 1.2 CO₂ 1-MIG R14

WORK PACK

Group Material Wire ø (mm) Shielding gas Process Number

Al AlMg5 1.2 Ar Pulse/Double Pulse A02 Al AlSi5 1.2 Ar Pulse/Double Pulse A12 Fe Fe 1.0 Ar+15–25%CO₂ Pulse/Double Pulse F03 Fe Fe 1.2 Ar+15–25%CO₂ Pulse/Double Pulse F04 Ss CrNiMo 19 12 1.0 Ar+2%CO₂ Pulse/Double Pulse S06 Ss CrNiMo 19 12 1.2 Ar+2%CO₂ Pulse/Double Pulse S04 Al AlMg5 1.2 Ar 1-MIG A02 Al AlSi5 1.2 Ar 1-MIG A12 Fe Fe 0.9 Ar+15–25%CO₂ 1-MIG F02 Fe Fe 1.0 Ar+15–25%CO₂ 1-MIG F03 Fe Fe 1.2 Ar+15–25%CO₂ 1-MIG F04 Fe Fe 0.9 CO₂ 1-MIG F22 Fe Fe 1.0 CO₂ 1-MIG F23 Fe Fe 1.2 CO₂ 1-MIG F24 Fe Fe Metal 1.2 Ar+15–25%CO₂ 1-MIG M04 Fe Fe Metal 1.2 CO₂ 1-MIG M24 Fe Fe Rutil 1.2 Ar+15–25%CO₂ 1-MIG R04 Fe Fe Rutil 1.2 CO₂ 1-MIG R14 Ss CrNiMo 19 12 1.0 Ar+2%CO₂ 1-MIG S03 Ss CrNiMo 19 12 1.2 Ar+2%CO₂ 1-MIG S04 Ss FC-CrNiMo 19 12 1.2 Ar+15–25%CO₂ 1-MIG S84

More welding programs are available by purchasing MatchCurve and MatchCustom products. You can also order welding program packs together with WiseFusion function.

FastMig MXF 63, 65, 67

5. PANEL BUTTON FUNCTIONS

5.1 PF 63 and PF 65 control panel for FastMig Pulse

1. 4.3. 5.

2. 6.

PF 65

9. 13.10.11. 12.7.

1. ON/OFF button

2. a) Wire feed speed/welding current display b) Display of selected adjustable parameter

3. a) Activation of MIG welding dynamics / Arc Force adjustment b) Selection of Wire Feeder (= paralleled wire feeders)

4. Gas test

5. Wire inch

6. a) Display of welding voltage /plate thickness /timer settings b) Display of selected adjustable parameter

7. Selection of MIG gun trigger function: 2T/4T/MATCHLOG long press *

8. Display of welding process: MIG, 1-MIG, PULSE, DOUBLE PULSE, WISE *

9. a) Selection of additional MIG functions b) Activation of MMA welding process (long press) *

10. a) Adjustment of wire feed speed b) Adjustment of welding power (Synergic 1-MIG and PULSE) c) Adjustment of electrode welding (MMA) current *) d) Adjustment of additional parameters when selected (ie Wire inch, Gas Test)

11. Memory channels 0 – 9, programming through P65 panel on the power source, panel lock (long press on +)

12. a) Adjustment of welding voltage b) Adjustment of length of welding arc (Synergic 1-MIG and PULSE) c) Adjustment of additional parameters when selected (ie MIG Dynamics)

13. Panel control/remote control unit selection, channel remote control (long press)

*) Not included in standard delivery. See chapter Ordering numbers

W003712

Automatic Weld Data display:

Last recorded welding values are displayed post welding. See power source panel P65. Select MENU and then Weld Data.

5.2 PF 63 and PF 65 control panel button functions

1. 3.

10.

11.

5. 6. 7. 8. 9.

5.2.1 ON/OFF button

Short Press: Panel returns to default display. Long Press: When welding panel (PF 65) is ON => Welding panel is turned OFF. When welding

panel (PF 65) OFF => welding panel is turned ON and Setup Panel (P65) turns ON and selects automatically that welding panel (WF#).

5.2.2 Dynamics button

Short Press: Dynamics setting if welding process is MIG/Synergic MIG. ArcForce setting if welding process is MMA. Forming Pulse setting if welding process is Wise-Root/WiseThin.

Long Press: Wire Feeder number selection (WF#). If more than one wire feeder is connected to system WF number selection must be made. Every wire feeder must be dierent WF number.

PF 65

W003712

5.2.3 Gas Test button

Gas Test function. Pressing the button will show the gas test time. Gas test time can be adjusted by using the

pulse encoder. Gas test will proceed after time adjustment is complete (short delay). Gas test can be stopped by pressing any button. (Gas test can also be started by pressing the Gas Test button inside the wire spool cabinet.)

FastMig MXF 63, 65, 67

5.2.4 Wire Inch button

Wire Feeder will start immediately when the button is pressed. The default wire inch speed is 5.0m/min. Wire Inch speed can be adjusted (+/-) using the pulse encoder. When the button is released the wire feeder will stop. If the button is pressed again, the wire

feeder starts again and slopes to selected wire feed speed (if higher speed is adjusted). (Wire Feeder can also be started by pressing the Wire Inch button inside the wire spool

cabinet.)

5.2.5 Channel -

Memory channel down selection. Panel jumps directly to the previous memory channel that can be found from memory.

5.2.6 Channel +

Short Press: Memory channel up selection. Panel jumps directly to next memory channel that can be found from memory. Long Press: Selected memory channel is locked / unlocked. No panel parameter changes

allowed to that memory channel (panel lock).

5.2.7 2T/4T button

Gun trigger logic selection. Short Press: 2T / 4T selection. Long Press: MatchLog ON/OFF selection if licence found.

5.2.8 Extra functions button

Short Press: Crater Filling selection / Hot Start Selection. Long Press: MMA ON/OFF selection if licence found.

5.2.9 Remote Selection button

Short Press: Panel /Gun Remote / Hand remote selection. If remote auto recognition is selected ON (see P65 panel menu) only those remote controls which can be found are selected.

Long Press: CH remote function ON/OFF. Gun remote or Hand remote control must be rst selected before CH remote function can be selected ON/OFF. When active, memory channels are selectable from the remote control device.

5.2.10 Power encoder control knob

10.

The power encoder knob allows adjustment of the wire feed speed or power in either Basic, Synergic and Pulse MIG/MAG process. MMA current level is also adjusted here if the process licence is active. Adjustments can be made before or during the arc process. This control also adjusts additional parameter values when selected.

5.2.11 Arc length/voltage/adjustment control knob

11.

Arc length, voltage and parameter adjustments can be made using this knob. Adjustments can be made before or during welding.

FastMig MXF 63, 65, 67

5.3 SF 51 and 54 control panel for FastMig KMS

For full operational descriptions for SF 51 and SF 54 control panels refer to the digital storage device delivered with the product.

1. 2. 3. 4. 5. 6. 7.

SETUP

MIG

MMA

ARC FORCE

DYNAMICS

m/min

GAS TEST

weld data

WIRE INCH

PANEL

SF 51

9. 10. 11. 12. 13.

1. ON/OFF button

2. a) Wire feed speed/welding current display b) Display of selected SETUP entry

3. MIG dynamics/MMA Arc Force selection

4. Selection of air/liquid cooled MIG gun

5. Gas test

6. Weld data: Last used welding parameters shown in displays

7. Wire inch

8. a) Welding voltage display b) Adjustable parameters display

9. Selection of MIG/MMA process

10. a) Selection of switching logic: 2T/4T b) Long press: Setting the basic parameters (SETUP)

11. a) Adjustment of wire feed speed b) Adjustment of MMA current c) Selection of SETUP parameter

12. a) Adjustment of welding voltage b) Adjustment of MIG dynamics or MMA Arc Force c) Adjustment of SETUP parameters

13. Manual control/remote control unit selection

W001318

5.4 SF 52W and 53W control panel for FastMig KMS

For full operational descriptions for SF 52W and SF 53W control panels refer to the digital storage device delivered with the product.

WIRE INCH

15.

13.

SET

SAVE

PANEL

ch remote

W004270

10.

SELECT

SYNERGIC

PROGRAM

SETUP

MMA

WISE

1-MIG

MIG

MMA

quick setup

/ MINILOG

3. 4.

ARC FORCE

DYNAMICS

PEN

GAS TEST

m/min mm

POWER

MEMORY

SET

weld data

ch clear

SF 53W

11.

12.

16.14.

1. ON/OFF button

2. a) Wire feed speed/welding current/sheet thickness display b) Selected SETUP entry display

3. MIG dynamics/MMA Arc Force/Wise Forming Pulse selection **

4. Display of air/liquid cooled MIG gun (selection from setup)

5. Gas test

6. Weld data: Last used welding parameters shown in displays

7. Wire inch

8. a) Welding voltage display b) Selection display for adjustable parameters

9. a) 1-MIG/WISE synergic welding program check ** b) 1-MIG/WISE synergic welding program selection (long press) **

10. a) Selection of switching logic: 2T/4T/4T Minilog * b) Long press: Setting the basic parameters (SETUP)

11. Selection of welding process MIG,1-MIG, MMA, WISE **

12. Selection of additional MIG functions/WisePenetration ** (long press)

13. a) Adjustment of wire feed speed b) Adjustment of welding power setting 1-MIG/WiseRoot/WiseThin ** c) Adjustment of MMA current d) Selection of SETUP parameter e) Selection of 1-MIG/WiseRoot/WiseThin welding program (material group) **

14. Memory channels, storage of MIG parameters

15. a) Welding voltage adjustment b) Adjustment of length of welding arc (1-MIG) c) Adjustment of MIG dynamics d) Adjustment of SETUP parameter e) Selection of 1-MIG/WiseRoot/WiseThin welding program (program number) ** f) WiseRoot and WiseThin base current adjustment

16. Manual control/remote control unit selection

*) Minilog is not included in standard delivery **) Wise products are available as optional welding process solutions. Not included in the

standard delivery. Please visit www.kemppi.com or Kemppi Datastore.

FastMig MXF 63, 65, 67

5.5 MS 200 and MS 300 control panel for FastMig M

For full operational descriptions for MS 200 and MS 300 control panels refer to the digital storage device delivered with the product.

1. 2.

9. 10. 11. 12.

1. ON/OFF button

2. Memory channels for welding parameters (short press selects, long press saves)

3. a) Wire feed speed/welding current/sheet thickness display b) Selected SETUP entry display

4. a) Adjustment of wire feed speed b) Adjustment of welding power setting 1-MIG/WiseRoot/WiseThin ** c) Adjustment of MMA current d) Selection of SETUP parameter e) Selection of 1-MIG/WiseRoot/WiseThin welding program (material group) **

5. a) Selection of switching logic: 2T/4T/4T Minilog * b) Long press: Setting the basic parameters (SETUP)

6. a) 1-MIG/WISE synergic welding program check ** b) 1-MIG/WISE synergic welding program selection (long press) **

7. a) Welding voltage display b) Adjustable parameters display

8. a) Welding voltage adjustment b) Adjustment of length of welding arc (1-MIG) c) Adjustment of MIG dynamics d) Adjustment of SETUP parameter e) Selection of 1-MIG/WiseRoot/WiseThin welding program (program number) ** f) WiseRoot and WiseThin base current adjustment **

9. Selection LED indicators for synergic welding program – indicators for material, wire thickness and gas type

10. Selection of welding process

11. a) Activation of additional MIG function parameter adjustment b) Weld data: Show last used welding parameters in displays (long press)

12. Manual control/remote control unit selection (long press for channel remote usage)

13. MIG dynamics/MMA Arc Force/Wise Forming Pulse selection **

14. Display of air/liquid cooled MIG gun (selection from setup)

*) Minilog is not included in standard delivery **) Wise products are available as optional welding process solutions. Not included in the

standard delivery. Please visit www.kemppi.com or Kemppi Datastore.

NOTE! With MS 200 and MS 300 panels 'Wire Inch' and 'Gas Test' buttons should be used from inside

the wire feed unit.

14.

13.

5.6 MR 200 and MR 300 control panel for FastMig M

For full operational descriptions for MR 200 and MR 300 control panels refer to the digital storage device delivered with the product.

1. 2. 3. 4. 5.

7. 8. 9. 10. 11.

1. ON/OFF button

2. a) Wire feed speed/welding current display b) Selected SETUP entry display

3. MIG dynamics/MMA Arc Force selection

4. Selection of air/liquid cooled MIG gun

5. Weld data: Last used welding parameters shown in displays

6. a) Welding voltage display b) Adjustable parameters display

7. Selection of MIG/MMA process

8. a) Selection of switching logic: 2T/4T b) Long press: Setting the basic parameters (SETUP)

9. a) Adjustment of wire feed speed b) Adjustment of MMA current c) Selection of SETUP parameter

10. a) Adjustment of welding voltage b) Adjustment of MIG dynamics c) Adjustment of SETUP parameters

11. Manual control/remote control unit selection

NOTE! With MR 200 and MR 300 panels 'Wire Inch' and 'Gas Test' buttons should be used from

inside the wire feed unit.

FastMig MXF 63, 65, 67

6. BASIC TROUBLESHOOTING

NOTE! The problems listed and the possible causes are not denitive, but serve to suggest some

standard and typical situations that may present during normal environmental use when using the MIG/MAG process.

Problem Check the following

Machine won’t work? • Check mains plug is connected

• Check mains power distribution is switched on

• Check the mains fuse and or circuit breaker

• Check power source 0/I switch is ON

• Check interconnection cable set and connectors between the power source and wire feed unit

are correctly fastened. See the manual schematic

• Check earth return lead is connected

• Check control panels are switched on – Orange buttons top left, long press.

Dirty, poor quality weld? • Check shielding gas supply

• Check and set gas ow rate

• Check gas type for application

• Check gun/electrode polarity. Example: Fe solid ller wire: Earth return should be connected

to the – pole, wire feed unit to the + pole connector

• Check correct welding program selected

• Check correct memory channel selection

• Check power supply – Phase down?

Variable welding performance?

Filler wire won’t feed? • Check wire feed mechanism. Pressure arms are closed? Close and adjust

High spatter volume? • Check welding parameter values

NOTE! Many of these checks may be carried out by the operator. However certain checks relating to

mains power must be completed by an authorised trained electrician.

• Check wire feed mechanism is correctly adjusted

• Check correct drive rolls are tted

• Check wire spool overrun tension is correctly adjusted

• Check gun liner is not blocked. Replace if necessary

• Check correct gun liner is tted for the ller wire size and type

• Check contact tip for size, type and wear

• Check gun is not over heating in application

• Check cable connections and earth return clamp

• Check welding parameter settings.

• Check welding gun switch function.

• Check euro gun collar is correctly fastened to euro block

• Check gun liner is not blocked

• Check contact tip, size, type, wear

• Check and try alternative gun.

• Check inductance/Dynamics values

• Check cable compensation value if long cables are tted

• Check gas type and ow

• Check welding polarity – cable connections

• Check ller material selection

• Check correct welding program selected

• Check correct memory channel selection

• Check ller wire delivery system

• Check power supply – 3 x phase present?

7. MAINTENANCE

When considering and planning routine maintenance, please consider the frequency of machine use and the working environment.

Correct operation of the machine and regular maintenance will help you avoid unnecessary downtime and equipment failure.

NOTE! Disconnect the machine from the mains before handling the electrical cables.

7.1 Daily maintenance

• Check the overall condition of the welding gun. Remove welding spatter from the contact tip and clean the gas nozzle. Replace worn or damaged parts. Only use original Kemppi spare parts.

• Check the condition and connection of the welding circuit components: welding gun, earth return cable and clamp, sockets and connectors.

• Check the condition of the feed rolls, needle bearings and shafts. Clean and lubricate bearings and shafts with a small quantity of light machine oil if necessary. Assemble, adjust and test function.

7.2 Service shop maintenance

Kemppi Service Workshops complete maintenance according to their Kemppi service agreement. Recommended termed service and cleaning is listed in the FastMig Pulse Power source manual.

Regular preventative maintenance by trained technicians will increase equipment life and ensure reliable operation.

8. 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.

FastMig MXF 63, 65, 67

9. ORDERING NUMBERS

FastMig Pulse

PF 63 panel

PF 65 panel

FastMig Pulse 350, 3 ~ 400V

FastMig Pulse 450, 3 ~ 400V

MXF 63 EL wire feeder

MXF 65 EL wire feeder

MXF 67 EL wire feeder

MXF 63 wire feeder

MXF 65 wire feeder

MXF 67 wire feeder

6155200 6155100 6150400

6150500 Work pack prole 6152300EL Work pack prole 6152100EL Work pack prole 6152200EL Project pack custom 6152300 Project pack custom 6152100 Project pack custom 6152200

FastMig KMS

MXF 63 wire feeder

MXF 65 wire feeder

MXF 67 wire feeder

SF 51 panel, 200 mm

SF 52W panel, 200 mm

SF 53W panel, 300 mm

SF 54 panel, 300 mm

FastMig KMS 300, 3 ~ 400V

FastMig KMS 400, 3 ~ 400V

FastMig KMS 500, 3 ~ 400V

FastMig M

MXF 63 EL wire feeder

MXF 65 EL wire feeder

MXF 67 EL wire feeder

MXF 63 wire feeder

MXF 65 wire feeder

MXF 67 wire feeder

FastMig MR 200 panel

FastMig MR 300 panel

FastMig MS 200 panel

FastMig MS 300 panel

FastMig M 320, 3 ~ 400V

FastMig M 420, 3 ~ 400V

FastMig M 520, 3 ~ 400V

6152300

6152100

6152200

6085100

6085200W

6085300W

6085400

6053000

6054000

6055000

To be used with MS panels 6152300EL To be used with MS panels 6152100EL To be used with MS panels 6152200EL To be used with MR panels 6152300 To be used with MR panels 6152100 To be used with MR panels 6152200

6136100

6136200

6136300

6136400

6132320

6132420

6132520

Cooling unit FastCool 10

Sub feeder synchronisation unit MXF Sync 65

SuperSnake GT02S sub feeder

SuperSnake GT02S W sub feeder

6068100 W004030

10m 6153100 15m 6153150 20m 6153200 25m 6153250 10m 6154100 15m 6154150 20m 6154200 25m 6154250

Transport unit PM500

Transport unit P 501

Transport unit PM 501

Transport unit PM 502

MSF 55 & MXF 65 hanging kit

KFH 1000 hanging device

KV 200 mounting kit for 2 wire feeders

Remote control units

R20

R30 DataRemote

RMT 10 (for PMT MIG gun)

6185291

6185269

6185292 6185293

W001694 6185100 6185249

5 m 6185419 5 m 6185420 10 m 618542001

6185475

FastMig MXF 63, 65, 67

MIG guns

PMT 35

PMT 42

PMT 50

PMT 30W

PMT 42W

PMT 52W

WS 35

WS 30 W

WS 42 W

WS 35

WS 30 W

WS 42 W

For a complete list of welding guns, please visit Kemppi website at www.kemppi.com.

AL 1.2 mm 6 m 6253516A12 AL 1.2 – 1.6 mm 6 m 6253046A12 AL 1.2 – 1.6 mm 8 m 6253048A12 AL 1.2 – 1.6 mm 6 m 6254206A12 AL 1.2 – 1.6 mm 8 m 6254208A12 Ss 1.0 mm 6 m 6253516S10 Ss 1.0 mm 6 m 6253046S10 Ss 1.2 mm 6 m 6253046S12 Ss 1.0 mm 8 m 6253048S10 Ss 1.2 mm 8 m 6253048S12 Ss 1.0 mm 6 m 6254206S10 Ss 1.2 mm 6 m 6254206S12 Ss 1.0 mm 8 m 6254208S10 Ss 1.2 mm 8 m 6254208S12

3 m 6253513 4,5 m 6253514 3 m 6254213 4,5 m 6254214 3 m 6255013 4,5 m 6255014 3 m 6253043 4,5 m 6253044 3 m 6254203 4,5 m 6254204 3 m 6255203 4,5 m 6255204

Interconnection cable

Interconnection cable, water cooled

Other lengths available

1.8 m 6260401 5 m 6260405 10 m 6260326 15 m 6260325 20 m 6260327 30 m 6260330

1.8 m 6260410 5 m 6260407

10 m 6260334 15 m 6260335 20 m 6260337 30 m 6260340

WiseFusion welding function

WisePenetration welding function

WiseRoot welding process

WiseThin welding process

WiseSynergicMig (for FastMig M)

9991014 9991000 6265011 9991013 9990420

MatchLog

MatchPIN

MMA welding process (for FastMig Pulse)

Welding program packages for FastMig Pulse

Work Pack

Aluminium Pack

Steel Pack

Stainless Steel Pack

Work Pack + Wise Fusion

Aluminium Pack + Wise Fusion

Steel Pack + Wise Fusion

Stainless Steel Pack + Wise Fusion

9991017

6265026

9991016

99904230 99904231 99904232 99904233 99904234 99904235 99904236 99904237

FastMig MXF 63, 65, 67

10. TECHNICAL DATA

FastMig MXF 63 MXF 65 MXF 67

Operating voltage (safety voltage)

Rated power

Output 40 °C

Wire feed speed

Wire feed mechanism

Diameter of feed rolls

Filler wires

Wire spool

Maximum gas pressure

Gun connection

Operation temperature range

Storage temperature range

EMC class

Degree of protection

External dimensions

Weight

50 V DC 50 V DC 50 V DC

100 W 100 W 100 W 60 % ED 520 A 520 A 520 A 100 % ED 440 A 440 A 440 A

0 – 25 m/min 0 – 25 m/min 0 – 25 m/min

4-roll 4-roll 4-roll

32 mm 32 mm 32 mm ø Fe, Ss 0.6 – 1.6 mm 0.6 – 1.6 mm 0.6 – 1.6 mm ø Cored wire 0.8 – 1.6 mm 0.8 – 2.0 mm 0.8 – 2.0 mm ø Al 1.0 – 1.6 mm 1.0 – 2.4 mm 1.0 – 2.4 mm max. weight 5 kg 20 kg 20 kg max. ø 200 mm 300 mm 300 mm

0.5 MPa 0.5 MPa 0.5 MPa

Euro Euro Euro

-20 ... +40 °C -20 ... +40 °C -20 ... +40 °C

-40 ... +60 °C -40 ... +60 °C -40 ... +60 °C

A A A

IP23S IP23S IP23S L x W x H 510 x 200 x 310 mm 620 x 210 x 445 mm 625 x 243 x 476 mm

9.4 kg 11.1 kg 12.5 kg

KEMPPI OY

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Kotimaan myynti:

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Telefax +44 (0)845 6444202 sales.uk@kemppi.com

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电话：+86-10-6787 6064/1282 传真：+86-10-6787 5259

sales.cn@kemppi.com

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KEMPPI WELDING SOLUTIONS SDN BHD

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1923680

1515

www.kemppi.com

Kemppi MXF 63 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual