MXF 33 Wire Feeder User Manual - Rapid Welding and Industrial
Contents
1. 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 Hanging MF 33 can be hanged from the handle to the barrier 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 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 using2. Operating manual K ytt ohje Bruksanvisning Bruksanvisning Brugsanvisning Gebrauchsanweisung Gebruiksaanwijzing Manuel d utilisation Manual de instrucciones Instrukcja obstugi Manual de utilizac o Manuale d uso The Joy of Welding EN Fl sy NO DA DE ES PL RU PT IT 1152 OPERATING MANUAL English EN 5 1 14 2 2 1 2 2 2 3 3 3 1 3 2 33 3 4 3 5 3 6 3 7 3 8 3 9 3 10 3 11 3 12 4 5 6 7 eee 3 Generale 3 Product introduction 4 Op ration control and 5 4 Connection once een panneau 5 4 roll wire feed mechanism 6 Installation demnuvemoemnte 7 Assembly of MIG MAG systen na a 7 Mounting of MIG welding gun an 7 Mounting and locking of wire spool 7 Automatic wire feed tO lares 8 Adjustment of Pressure sek 8 Adjustment of tightness of spool brake 8 A nec ina dote 8 Ground cable a a 8 A ER 9 39 1 Installing gas bottle 9 Main 5 0 VO aaa dada 10 Operation of cooling unit FastCool 10 10 ee ee ee 10 Service operation disturbances
3. mm 0 6 0 8 0 8 0 8 L 1 0 1 2 1 0 1 0 L 1 2 1 2 L 1 4 1 6 2 0 1 6 1 6 L 2 4 3 2 1 0 1 2 1 2 1 2 L 1 4 1 6 2 0 1 6 1 6 L 2 4 3 2 1 2 1 2 L 1 4 1 4 L 1 6 1 6 2 0 2 0 L 2 4 L L L L L orange 2 0mm 3134120 blue 40mm 3134110 silver 2 5mm 3134300 yellow 3 0mm 3134720 3133810 3143180 3133210 3138650 3137390 3133820 3141120 3133880 3133910 3133940 3137380 3133990 3141130 3134030 3134060 3142210 3142220 3142200 3142230 3142240 plastic 2 0mm 4267220 plastic 2 0mm 4266970 plastic 40mm 4270180 brass 40mm 4267030 plastic 2 0mm 4267220 yellow 2 4mm 4268210 for Promig 511 yellow 3 0mm 4268560 plastic 40mm 4270180 Feed roll groove selection A o Ehe Transfer of gear wheel selector plate Gear wheel 928mm 0 18 4265240 plastic 028 0 18 4287860 steel 040 0 25 4265250 plastic 040 0 25 m min 4297270 steel 3 1 3 2 3 3 INSTALLATION 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 accordin
4. 10 Disposal of the 2 10 Ordering 22 222 11 Technical data iesen enna a 12 FastMig MF 33 1 1 PREFACE General Congratulations on choosing the FastMig MF equipment Used correctly Kemppi products can significantly 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 specifications of the equipment can be found at the end of the manual Please read the manual carefully before using the equipment for the first 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 specifications 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 VOTE notation Read these sections carefully and follow their instructions Disclaimer While every effort has been made to ensure that the information contained in this guide is accurate and complete no liability can be accep
5. hub by turning locking knob a quarter round e Mount the spool at its place Note rotating direction of spool e Lock the spool with locking knob locking nails of hub remain to outside position and will lock the spool NOTE Check that in filler 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 EN 3 4 3 5 3 6 3 7 3 8 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 filler 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 off 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 file off 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 fee
6. sales nl kemppi com www kemppi com KEMPPI UK Ltd Martti Kemppi Building Fraser Road Priory Business Park BEDFORD MK44 3WH UNITED KINGDOM Tel 44 0 845 6444201 Telefax 44 0 845 6444202 sales uk kemppi com KEMPPI FRANCE S A S 65 Avenue de la Couronne des Pr s 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 StraBe 14 D 35510 BUTZBACH DEUTSCHLAND Tel 49 6033 88 020 Telefax 49 6033 72 528 sales de kemppi com KEMPPI SPOLKA 70 0 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 Box 5256 Greystanes NSW 2145 SMITHFIELD NSW 2164 AUSTRALIA Tel 61 2 9605 9500 Telefax 61 2 9605 5999 info au kemppi com 000 KEMPPI Polkovaya str 1 Building 6 127018 MOSCOW RUSSIA Tel 7 495 739 4304 Telefax 7 495 739 4305 info ru kemppi com 000 1 6 127018 Tel 7 195 739 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 BRD 165 ARAA RRA RK 125 4202 100176 FIG 86 10 6787 606
7. 4 86 10 6787 1282 86 10 6787 5259 sales cn kemppi com KEMPPI INDIA PVT LTD LAKSHMI TOWERS New No 2 770 First Main Road Kazura Garden Neelankarai CHENNAI 600 041 TAMIL NADU Tel 91 44 4567 1200 Telefax 91 44 4567 1234 sales india kemppi com CSLL 0759061 The Joy of Welding
8. 4MMT 6254203MMT 6254204MMT 6255203MMT 6255204MMT 6260411 6260412 6260413 6260414 EN 11 7 TECHNICAL DATA MF 33 Operating voltage safety voltage 24V DC Connection capacity 100 W Output 40 C 60 ED 520A 100 ED 440A Wire feed mechanism 4 roll feed Diameter of feed roll 32mm Wire feed speed 0 25 m min Filler wires Fe Ss 0 6 1 6 0 Cored wire 08 20 Al 10 2 4 Wire spool max weight 20 kg max 0 6300 Gun connection Euro Operation temperature range 20 40 C Storage temperature range 40 60 C EMC dass Degree of protection 235 External dimensions LxWxH 590x240x445 mm Weight 13 6 kg Changes of speed are carried out by changing gear wheel D 28 D 40 OY Kempinkatu 1 PL 13 FIN 15801 LAHTI FINLAND Tel 358 3 899 11 Telefax 358 3 899 428 export kemppi com www kemppi com Kotimaan myynti Tel 358 3 899 11 Telefax 358 3 734 8398 myynti fi kemppi com KEMPPI SVERIGE AB Box 717 5 194 27 UPPLANDS V SBY SVERIGE Tel 46 8 590 783 00 Telefax 46 8 590 823 94 sales se kemppi com KEMPPI NORGE A S Postboks 2151 Postterminalen N 3103 TONSBERG NORGE Tel 47 33 346000 Telefax 47 33 346010 sales no kemppi com KEMPPI DANMARK A S Literbuen 11 DK 2740 SKOVLUNDE DANMARK Tel 45 4494 1677 Telefax 45 4494 1536 sales dk kemppi com KEMPPI BENELUX B V Postbus 5603 NL 4801 EA BREDA NEDERLAND Tel 31 765717750 Telefax 31 765716345
9. compressed air always protect your eyes with proper eye protection In case of problems contact your KEMPPI dealer 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 6 ORDERING NUMBERS MF 33 KM 300 KM 400 KM 500 Cooling unit FastCool 10 Transport unit PM 500 Accessories KWF 300 protection slides MIG guns MMT 25 MMT 25 MMT 27 MMT 27 MMT 32 MMT32 MMT 35 MMT 35 MMT 42 MMT 42 MMT 30W MMT 30W MMT 42W MMT 42W MMT 52W MMT 52W Interconnecting cables KM 70 1 8 WH KM 70 15 WH KM 70 1 8 GH KM 70 15 GH 3 ph 400V 3 ph 400V 3 ph 400V 3m 45m 3m 45m 3m 45m 3m 45m 3m 45m 3m 45m 3m 45m 3m 45m 6063300 6033000 6034000 6035000 6068100 6185291 6185287 6252513MMT 6252514MMT 6252713MMT 6252714MMT 6253213MMT 6253214MMT 6253513MMT 6253514MMT 6254213MMT 6254214MMT 6253043MMT 625304
10. d 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 Adjustment of pressure Adjust the pressure of feed rolls with the control screw 20 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 flattening of the filler wire and damage to the coating It also causes undue wear of the feed rolls as well as friction Adjustment of tightness of spool brake J 2 Kr i ieee A Brake force is adjusted through hole in locking device of spool hub 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 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 Ground cable Connecting of earth cable sho
11. g to that Mounting of KM power sources to transport wagon Read and follow the instructions given in the transport cart installation assembly manual 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 fixing point in handle 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 Mounting and locking of wire spool LOCKED OPEN e Release locking nails of wire spool
12. low out possible impurities from the bottle valve Turn the press regulation screw B of the regulator until no spring pressure can be felt Close needle valve if there is one in the regulator Install the regulator on bottle valve and tighten connecting nut C with a wrench Install hose spindle D and jacket nut E into gas hose and tighten with hose clamp Connect the hose with the regulator and the other end with the wire feed unit Tighten the jacket nut 7 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 filled when the bottle pressure is 2 bar 8 Open needle valve if there is one in the regulator 9 Turn regulation screw until hose pressure meter G shows the required flow or pressure When regulating flow amount the power source should be in switched on and the gun switch pressed simultaneously su PWN NOTE Close bottle valve after having finished welding If the machine will be out of use for a long time unscrew the pressure regulation screw Kemppi 1152 EN 10 3 10 Main switch I O 3 12 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 off the machine with the main switch never use the mains plug as a switch
13. ted for any errors or omissions Kemppi reserves the right to change the specification 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 PRODUCT INTRODUCTION FastMig MF is basic wire feeder designed for demanding enviroment It can be used with Kemppi s basic FastMig power sources KM 300 400 and KM 500 Operation control and connectors 1 Operation panel 4 Shielding gas connection 2 Connection of welding gun EURO 5 Connection for control cable 3 Lead in and clamping of cooling liquid 6 Welding current cable connection hoses KEMPPI 1 Selection of gun switch function 2 Adjustment of wire feed speed 3 Adjustment of welding voltage ction of system 2 2 2 3 4 roll wire feed mechanism Wire mm Fe 0 6 0 8 white Mc 1 0mm Fc 3134140 0 9 1 6 orange 2 0 mm 3133700 1 6 2 4 blue 4 0 mm 3134130 Ss 0 8 1 6 silver Al 2 5 mm 3134290 yellow 3 0 mm 3134710 1 6 2 4 I Feed rolls 4 rolls Colour white Fe Ss Al white red red Plain V groove orange yellow yellow black blue Fe Fc Mc red orange Knurled V groove yellow yellow black blue Fe Fc Mc Ss Al orange brown Trapetsoid yellow groove grey black L Fitted with ball bearings Wire guide tube
14. uld 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 mm 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 3 9 3 9 1 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 flow rate is set according to the welding power used in the job A suitable flow rate is normally 8 10 l min If the gas flow is not suitable the welded joint will be sporous Contact your local Kemppi dealer for choosing gas and equipment Installing gas bottle NOTE Always fasten gas bottle properly in vertical position in a special holder on the wall or ona carriage Remember to close gas bottle valve after having finished welding Parts of gas flow regulator A bottle valve Press regulation screw Connecting nut D Hose spindle E Jacket nut Gas hose pressure meter The following installing instructions are valid for most of the gas flow regulator types Step aside and open the bottle valve A for a while to b
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