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Kemppi FastMig WFX 200 AMC Handleiding

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Operating manual
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EN
DA
DE
ES
FI
FR
IT
NL
NO
PL
PT
RU
SV
ZH
WFX
200, 300
200 P Fe, 300 P Fe
200 P Ss, 300 P Ss
200 AMC, 300 AMC
200-T, 300 P-T, 300-T
OPERATING MANUAL
English
WFX 200, 300, 200 P Fe/Ss, 300 P Fe/Ss, 200-T, 300 P-T, 300-T, 200 AMC, 300 AMC
2
EN
CONTENTS
1. Introduction ................................................................................................. 3
1.1 General ....................................................................................................................................... 3
1.2 About WFX wire feeders ...................................................................................................... 3
2. Installation .................................................................................................... 4
2.1 Machine introduction ........................................................................................................... 4
2.2 Connecting cables ................................................................................................................. 6
2.3 Assembly of MIG/MAG system .......................................................................................... 8
2.4 Accessories corresponding to wire diameter .............................................................. 8
2.5 Welding gun selection .......................................................................................................... 8
2.6 Mounting and locking of wire spool ............................................................................... 9
2.7 Loading the ller wire and automatic feed .................................................................. 9
2.8 GT04 wire feed mechanism ..............................................................................................10
2.9 DuraTorque™ 400, 4-wheel wire feed mechanism ................................................... 12
2.10 Adjustment of pressure arms ...........................................................................................14
2.11 Adjustment of spool brake ...............................................................................................14
2.12 Burn back time ......................................................................................................................14
2.13 Earth return cable .................................................................................................................14
2.14 Shielding gas ..........................................................................................................................15
2.15 Main switch I/O .....................................................................................................................16
2.16 Operation of cooling unit, Cool X ...................................................................................16
2.17 Hanging kit .............................................................................................................................16
3. XF 37 and XF 38 control panel .............................................................. 16
3.1 Connecting and mounting ...............................................................................................16
3.2 Layout .......................................................................................................................................17
3.3 Button functions ...................................................................................................................17
3.4 Welding software .................................................................................................................20
3.5 Arc voltage display ............................................................................................................... 24
4. Basic troubleshooting ............................................................................. 25
5. Maintenance .............................................................................................. 27
5.1 Daily maintenance ...............................................................................................................27
5.2 Periodic maintenance .........................................................................................................27
5.3 Service Workshop maintenance .....................................................................................27
6. Disposal of the machine ......................................................................... 28
7. Ordering codes..........................................................................................28
8. Technical data ............................................................................................ 32
3
© Kemppi Oy / 1736
EN
1. INTRODUCTION
1.1 General
Congratulations on choosing the Kemppi WFX welding 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 WFX wire feeders
Kemppi WFX 200 and 300 are basic wire feeders for regular pulse welding. They are equipped
with the WiseFusion™ welding process and are best suitable for basic MIG/MAG welding
purposes with robust thick metal plates.
Kemppi WFX 200 P Fe, WFX 300 P Fe, WFX 200 P Ss and WFX 300 P Ss are wire feeders for
more demanding professional use for example in pipe welding. They are equipped with the
WiseRoot+™ welding process developed especially for ecient root welding on pipes and
plates. Based on the model chosen, the wire feeder comes with either steel (Fe) or stainless
steel (Ss) pack preinstalled.
Kemppi WFX 200 AMC and 300 AMC are wire feeders designed for demanding professional
use featuring most of the Kemppi software options available. They are equipped for example
with the WiseThin+™ welding process, developed especially for ecient welding for thin
sheets and position welding, also with CO
2
shielding gas.
WFX 200 AMC and 300 AMC wire feeders can also be controlled in conjunction with FastMig
X power sources through Kemppi's ARC Mobile Control, which is a tablet computer based
wireless control interface. The required ARC Mobile Control adapter is included with the AMC
wire feeder models and provided as an option for the rest of the WFX wire feeders.
If a customer needs a specic set of software for their production, there is a tailored wire
feeder option available. With a special conguration tool customers can select the desired
software products to be factory-installed on the wire feeder, or they can just order an empty
wire feeder with no software pre-installed and only MIG welding enabled.
WFX wire feeders can be used with FastMig X power sources.
Operation of the wire feeder is controlled and adjusted by microprocessor. By adding an
optional synchronization unit MXF Sync 65, the SuperSnake sub-feeder device may be
connected to the WFX 300 series wire feeders (not available for WFX 200 series).
WFX 200, 300, 200 P Fe/Ss, 300 P Fe/Ss, 200-T, 300 P-T, 300-T, 200 AMC, 300 AMC
4
EN
2. INSTALLATION
2.1 Machine introduction
WFX 300 P Fe, WFX 300 P Ss, WFX 300 P-T WFX 300, WFX 300 AMC, WFX 300-T
4.
2.
1.
3.
5.
2.
1.
3.
5.
4.
6.
1. Control panel
2. ON/OFF button
3. Euro gun connection
4. Voltage sensing cable connection
5. Remote control connection
6. Sub-feeder sync connector (kit optional)
8.
11.
10.
9.
7.
8.
10.
9.
7.
7. Shielding gas connection
8. Control cable connection
9. Measurement cable connection
10. Welding current cable connection
11. Lead-in and clamping of cooling
liquid hoses
7. Shielding gas connection
8. Measurement cable connection
9. Control cable connection
10. Welding current cable connection
5
© Kemppi Oy / 1736
EN
WFX 200, WFX 200 P Fe, WFX 200 P Ss, WFX 200 AMC and WFX 200-T
4.
1.
2.
3.
7.
6.
5.
8.
9.
1. Control panel
2. Remote control connector
3. Voltage sensing cable connection
4. Euro gun connector
5. Shielding gas connection
6. Connection for control cable
7. Welding current cable connector
8. Lead-in and clamping of cooling
liquid hoses
9. Measurement cable connection
WFX 200, 300, 200 P Fe/Ss, 300 P Fe/Ss, 200-T, 300 P-T, 300-T, 200 AMC, 300 AMC
6
EN
2.2 Connecting cables
2.2.1 Liquid-cooled system: FastMig X + WFX + Cool X
1.
4.
8.
10.
2.
3.
9.
5.
6.
11.
7.
V
V
1. WFX wire feed unit
2. FastMig X power source
3. Cool X cooling unit 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 cable and clamp
10. Measurement cable (from power source to wire feeder)
11. Voltage sensing cable (from wire feeder to work piece)
NOTE! WFX wire feeders can also be used with FastMig Pulse power source, but in that case
measurement cable and voltage sensing cable will not be used.
7
© Kemppi Oy / 1736
EN
2.2.2 Air-cooled system: FastMig X + WFX
1.
4.
5.
10.
6.
8.
2.
3.
7.
9.
V
V
1. WFX wire feed unit
2. FastMig X power source
3. Gas supply
4. MMA electrode holder
5. Remote control device
6. Air-cooled welding gun
7. Power cable
8. Earth return cable and clamp
9. Measurement cable (from power source to wire feeder)
10. Voltage sensing cable (from wire feeder to work piece)
NOTE! WFX wire feeders can also be used with FastMig Pulse power source, but in that case
measurement cable and voltage sensing cable will not be used.
WFX 200, 300, 200 P Fe/Ss, 300 P Fe/Ss, 200-T, 300 P-T, 300-T, 200 AMC, 300 AMC
8
EN
2.3 Assembly of MIG/MAG system
Assemble the units in the order mentioned below. Follow the additional mounting and
operation instructions delivered with each package.
1. Installation of power source
Read and follow the installation instructions given in the FastMig power source operating
manual.
2. Mounting of power sources to transport cart
Read and follow the instructions given in the transport cart assembly instructions.
3. Mounting the FastMig WFX 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
WFX 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 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.
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. Feed roll groove geometry and design vary depending on the application. Further
details are available in the spare parts 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. Kemppi
welding 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.
For FastMig X pipe welding package Kemppi oers the PMT MN welding gun model, which is
specially designed for welding root and ll passes on pipe. The neck is replaceable, so you can
select just the right bending angle for dierent work stages.
Distance wire feeding is accommodated with WeldSnake and SuperSnake products in either
air or liquid cooled models.
9
© Kemppi Oy / 1736
EN
2.6 Mounting and locking of wire spool
NOTE! Check that in 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 not 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 that 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 switch on
the wire feeder panel. Feed the wire to the gun contact tip and prepare to weld.
NOTE! Smaller diameter ller wires may need to be loaded manually and with the feed roll pressure
arms released. This is because it is easy to over estimate 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.
23
© Kemppi Oy / 1736
EN
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
Fe Fe 1.0 Ar+15–25%CO₂ Pulse/Double Pulse F03
Fe Fe 1.2 Ar+15–25%CO₂ Pulse/Double Pulse F04
More welding programs are available by purchasing MatchCurve and MatchCustom products.
WFX 200, 300, 200 P Fe/Ss, 300 P Fe/Ss, 200-T, 300 P-T, 300-T, 200 AMC, 300 AMC
24
EN
3.5 Arc voltage display
FastMig X is capable of measuring and showing the voltage close to the welding arc. By taking
this feature into use you don't need to be concerned about the voltage losses in welding
cables anymore. With this feature you are only required to set the voltage for the arc before
welding and after welding you can see the voltage close to the arc.
In order to use the arc voltage feature, follow these steps:
1. After setting up the welding equipment for the rst time, connect the voltage sensing
cable to the welding piece and the measurement cable between the wire feeder and the
power source.
2. If you are using a sub-feeder, enter the length of the sub-feeder to the SubFeederLength
parameter.
3. Set the welding parameters according to your application. Note that the set voltage
when using 1-MIG, MIG and WiseThin+ welding processes means always the voltage in
the arc despite of ArcVoltage setting.
4. Weld with 1-MIG, MIG or with Pulse MIG for at least 5 seconds. During that time the
welding machine calibrates itself for the welding cable length in question. Calibration
values are stored into the welding machine, therefore this calibration is required only
once after installing the welding machine package.
5. If you want to see arc voltage in panels during and after welding, turn the ArcVoltage
setting to ON in X 37 setup panel. Dot after voltage value in XF 37 or XF 38 panel means
that showed value is arc voltage. In the weld data after welding in X 37 panel 'AVol'
means also the arc voltage.
6. Voltage sensing cable can be removed after the calibration procedure, but it is
recommended to use it always.
NOTE! Steps 1-3 should be repeated every time, when the length of the welding or grounding cable
is changed.
25
© Kemppi Oy / 1736
EN
4. 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 with FastMig X 350 or X 450 and WFX wire feeders.
Problem Check the following
Machine won’t work
• Check mains plug is connected correctly
• 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.
Dirty, poor quality
weld
• Check shielding gas supply
• Check and set gas ow rate
• Check gas type for application
• Check gun/electrode polarity
• Check correct welding program selected
• Check correct channel number selected on wire feeder control panel
• Check power supply – Phase down?
Variable welding
performance
• 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.
Filler wire won’t feed
• Check that pressure arms are closed and adjusted in wire feed mechanism
• Check welding gun switch function
• Check Euro gun collar is correctly fastened
• Check gun liner is not blocked
• Check contact tip, size, type, wear
• Check and try alternative gun
High spatter volume
• Check welding parameter values
• 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 channel number selection
• Check ller wire delivery system
• Check power supply – 3-phase present?
1 …

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