FitWeld - Kemppi
Contents
1. 5 When using hard flux cored filler wires you should select a knurled feed roll to achieve better grip 2 6 Controlling welding functions With FitWeld 300 you can easily control welding parameters change the welding polarity and gun operating mode The control panel provides two adjustment knobs You can set the desired welding voltage and wire feed speed before or during welding so easily tuning the desired arc performance to the weld 2 6 1 Control panel functions A FitWeld O ON 10 PANI 1U TAN 91 12 91 i210 8 3 8 3 a erre erre O 8117734 uti With the left hand control knob set the value for filler wire feed speed The maximum value is 18 meters per minute With the right hand control knob set the welding voltage Adjustment range is from 11V to 32V FitWeld 300 The leds on the front panel indicate the following from top to bottom Machine is turned on Machine is overheated Error in shielding gas flow 2 6 2 Controls inside the machine 2 6 3 a IN 1 Welding gun operation mode switch 2 Shielding gas adjustment screw 3 Cable connections for reversing polarity Selecting the gun operating mode With the three position switch 1 you can set the MIG welding gun to two sequence 2T or four sequence 4T mode with GasGuard feature on If you are using self shielded flux cored filler wire gasless wire you must select the upmost switch2. 11 2 604 Adjusting the shielding gas flow 12 2 65 Reversing polafity trementes 12 27 Troubleshooting 13 3 CupcurpsM 14 3 1 Daily maintenance cc 14 3 2 Maintenance of the wire feed mechanism 14 3 2 1 Cleaning the gun wire liher erected 14 3 2 2 Replacing the wire liner 14 zo HT 14 Ordering codes aen epp xp I MR IE DUM 15 5 WCNC fo r 5 15 FitWeld 300 1 1 1 2 INTRODUCTION General Congratulations on choosing the FitWeld welding machine Used correctly Kemppi welding machines can increase your productivity and provide years of economical service This user manual contains important information on the use maintenance and safety of your Kemppi product The technical specifications of the device 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 first time For your 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 NOTE Items in the manual that require particular attention in order to minimise damage and personal harm are indicated with this
3. EN EN 2 4 4 Welding gun Connect the welding gun cable to the Euro adapter socket located on the front panel and hand tighten only Do not over tighten the collar The welding gun leads the filler wire shielding gas and electric current to the weld piece When you press the welding gun trigger shielding gas will flow and filler wire will begin to feed The arc will ignite when the filler wire touches the weld piece If no ignition check that the earth return cable is connected and the clamp has good contact to the work piece 2 5 Installing filler wire With FitWeld 300 you can use up to 200 mm diameter wire spools and the following filler wire types e solid wires flux cored wires e self shielded flux cored wires e stainless steel wires aluminium wires When choosing the filler wire remember that the wire must have approximately the same melting point as the base material to be welded NOTE When changing the filler wire always check that the feed rolls their groove shape and size and the wire liner inside the welding cable are suitable for the wire you are using Also check that you are using right polarity for the filler wire 2 5 1 Mounting the wire spool NOTE The liner and the feed rolls are colour coded See that you are using feed rolls that match the colour of the wire liner inside the welding gun cable See the table of feed rolls and wire liners later in this chapter With FitWeld 300 you can use wire spools
4. To reverse polarity 1 Disconnect the machine from the mains 2 Pull away the rubber covers to expose the terminal pole connections and allow access to the Allen screws 3 Usingthe Allen key attached to the wire cabinet wall unscrew the pole connection bolts Note the correct order of washers 4 Interchange the cables 5 Install the washers in order and tighten the bolts firmly 6 Replace the rubber covers correctly NOTE The rubber cover must always protect the poles FitWeld 300 2 7 Troubleshooting Problem The machine stops working and the shielding gas indicator is lit Poor welding result Overheating indicator lit The wire does not move or wire feed entangles Main switch indicator does not switch on Cause The maximum flow rate at the gas cylinder is set to a lower value than the flow rate you are trying to set with the FitWeld 300 flow adjustment screw At the gas cylinder flow regulator set the flow rate much higher than what you are using in welding The final adjustment of the gas flow rate is accomplished with the adjustment screw located inside the FitWeld s wire cabin Several factors affect the welding quality Check that the earth return clamp is properly attached the point of contact is clean and that the cable and its connectors are intact e Check the voltage and wire speed settings on the control panel are correct for the given wire size and type Check that the shie
5. KEMPPI UK LTD Martti Kemppi Building Fraser Road Priory Business Park BEDFORD MK44 3WH UNITED KINGDOM www kemppi com 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 33130900440 Telefax 33 130 90 04 45 sales fr kemppi com KEMPPI GMBH Perchstetten 10 D 35428 LANGG NS DEUTSCHLAND Tel 49 6 403 77920 Telefax 49 6 403 779 79 74 sales de kemppi com KEMPPI SPOLKA Z 0 0 Ul Borzymowska 32 03 565 WARSZAWA POLAND Tel 48 22 7816162 Telefax 4 48 22 7816505 info pl kemppi com KEMPPI AUSTRALIA PTY LTD 13 Cullen Place P 0 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 KEMNINU yn MonkoBaa 1 crpoenue 6 127018 MockBa Tel 7 495 739 4304 Telefax 7 495 739 4305 info ru kemppi com KEMPPI TRADING BEIJING COMPANY LTD 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 BASS HR BIRAR ILA AK BIA Bus AA AE BAB 420 100176 Hi 86 10 6787 6064 86 10 6787 1282 E 86 10 6787 5259 sales cn kemppi com KEMPPI INDI
6. FitWeld 300 Operating manual Bruksanvisning Gebrauchsanweisung Manual de instrucciones Kaytt6ohje Manuel d utilisation anuale d uso Gebruiksaanwijzing Brugsanvisning Instrukcja obstugi Manual de utilizac o VIHCTPyKUNNM no 3KcnnyaTauun Bruksanvisning BREST I KEMPPI The Joy of Welding EN DA DE ES FI FR IT NL NO PL PT RU sy ZH OPERATING MANUAL English EN CONTENTS i as sss Tra 91 lt 9 Pero corr 3 11 eee 3 1 2 Aboutwelding arri 3 2 Deos WV AC TAINS een 4 ZU Before use 4 2 2 Machine Introduction 4 23 Distribution network 4 24 Connecting cables uotis aaa 4 244 Connecting TO malns eon eene HERE i QN e botes ees 5 242 Earthireturn cable eerte reden Het oe Pede an ident 5 2 4 3 Shielding 85 oo ed de deret o in etie d mae a ten 5 24 4 Welding GUN erisir eesi dine oleole 6 2 5 Inst llnghller Wie en 6 2 5 1 Mounting the wire spool tenentes 6 2 5 2 Feeding in the welding wire 7 2 5 3 Setting the pressure of the feed rolls sss 7 2 5 4 Setting the spool brake force 8 2 5 5 Wire guide tubes and wire feed rolls sss 9 2 5 6 Changing the feed rolls 10 2 6 Controlling welding unions 10 2 6 1 Control panel functions trennen 10 2 6 0 Controls inside the machine 11 2 6 3 Selecting the gun operating MOde
7. mains before handling the electrical cables 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 Maintenance of the wire feed mechanism It is recommended to service the wire feed mechanism every time the you change the wire spool Checkthe wear of the feed roll groove and change the feed roll if necessary Clean the welding gun wire guide with compressed air if necessary Cleaning the gun wire liner Pressure of the feed rolls remove metal dust from the filler wire s surface which then travels in the wire liner inside the gun cable If the wire liner is not cleaned it gradually clogs up increasing drag impairing wire feed performance and weld quality Ultimately this will will causes wire feed malfunctions To clean the wire liner Remove the welding gun from the machine Remove the welding gun s gas nozzle contact tip and contact tip adapter With a pneumatic pistol blow dry and filtered compressed air through the wire liner Clean t
8. symbol 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 accepted 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 About welding FitWeld 300 is suitable for many MIG MAG welding applications but its quick ignition and high efficiency make it especially fast safe and economic for tack welding of steel materials It can be used for welding with ferrous stainless steel and aluminium filler materials FitWeld 300 is designed for use in demanding environments It has wire feed cabinet illumination to facilitate wire adjustment in dark conditions and its case is made of reinforced fibre plastic Tack welding with the MIG MAG process Tack welding is used during the fabrication and fitting process using spot like welds to establish the joints before primary welding Using MIG MAG process for tack welding makes this phase fast and efficient It is also a safer compared to traditional MMA tack welding O Kemppi Oy 1336 EN EN 2 1 2 2 2 3 2 4 USING THE MACHINE Before use The product is packed in cartons designed specifically for them However always make sure
9. with a diameter of 200 mm maximum To mount the wire spool 1 Turn the locking knob of the spool holder so that the locking clips are opened 1 2 Checkthe rotating direction of the wire spool and push the spool into its place so that it rotates in the right direction 3 Turn the locking knob of the spool holder to close the locking clips 2 FitWeld 300 2 5 2 2 5 3 Feeding in the welding wire NOTE Remember to remove the sharp cut tip of the filler wire before loading the wire to the welding gun so preventing damage to the liner inside the welding gun cable This is particularly important for soft filler wires such as aluminium it will also improve feed quality and increase the service life of your gun liner LC For reliable performance only use Kemppi gun liner materials specially developed for use with Kemppi machines For information on recommended liners and wire feed rolls selection please see the relevant sections later in this chapter Be careful not to let the wire unwind from the spool NOTE When feeding the welding wire into the gun be sure that you are not pointing the gun at anyone and that there isn t anything in front of the gun To feed the wire from the spool to the welding gun 1 Open the pressure arm of the GT02 mechanism and lift the top roll clear on its pivot 2 Draw some loose wire from the spool and carefully push it through the bronze wire guide at the back of the mechanism Push the wire over t
10. 9 Wire feed mechanism Filler wires Fe solid Fe cored Ss AI External dimensions LxWxH Weight EMC class Minimun short circuit power Ssc of supply network Degree of protection Operating temperature range Storage temperature range Standards IEC EN 60974 1 IEC EN 60974 5 IEC EN 60974 10 See paragraph 2 3 Kemppi Oy 1336 P2101 P2102 6253213MMT 6253214MMT 6184311 W000566 380 440 V 10 11 0 KVA 16 4 A 73A 300A 29V 180 A 23V 140A 21V 461 5 5 m 10A 40 46V 0 95 0 85 11 32V 200 mm 2 roll feed 0 8 1 2 mm 0 8 1 2 mm 0 8 1 2 mm 1 0 1 2 mm 457 x226x 339mm 14 5 kg A 1 9 MVA IP235 20 C 40 C 40 C 60 C EN 15 KEMPPI 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 sales nl kemppi com
11. A 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 KEMPPI WELDING SOLUTIONS SDN BHD No 12A Jalan TP5A Taman Perindustrian UEP 47600 Subang Jaya SELANGOR MALAYSIA Tel 60 3 80207035 Telefax 4 60 3 80207835 sales malaysia kemppi com 9EEL Orrrrz6l KEMPPI The Joy of Welding
12. W003962 plastic Fe Mc Fc W003881 W003536 metal Wire feed rolls plastic mm lower upper Fe Ss M Mc Fc 0 8 0 9 W001047 W001048 V groove y 10 o W000675 W000676 12 ES W000960 W000961 Fc Mc Fe 10 MM s W001058 V groove knurled Y 12 Es W001059 W001060 AI Fc Mc Ss Fe 10 nU W001068 W001067 U groove U 12 Es W001070 W001069 Wire feed rolls metal Ii mm lower upper Fe Ss Al Mc Fc 08 09 W006074 W006075 V groove V 10 DH W006076 W006077 12 IC W004754 W004753 Fc Mc Fe 10 Hm W006080 WO06081 V groove knurled VE 2 ME vos W006083 AI Fc Mc Ss Fe 10 RM woososs W006089 U groove U 2 MM woooso W006091 Kemppi Oy 1336 EN 10 2 5 6 Changing the feed rolls To change the feed rolls 1 Pull and release the pressure tension arm via the aluminium head above the orange plastic adjuster Lift the upper feed roll on its pivot to the maximum open position Pull out mounting pin of the upper feed pressure roll and replace the roll with a new one Open the locking screw of the lower feed roll and replace the roll with a new one Return the upper pressure feed roll to its down position and replace the locking arm latch Adjust the pressure tension as instructed in the earlier section DAE e o
13. before use that the products have not been damaged during transportation Check also that you have received the components you ordered and the instruction manuals needed as described in the Quick start guide Product packaging material is recyclable NOTE When moving the welding machine always lift it from the handle never pull it from the welding gun or other cables Operating environment This machine is suitable for both indoor and outdoor use Always make sure that the air flow in the machine is unrestricted The recommended operating temperature range is 20 40 C Please read also the safety instructions concerning the operating environment earlier in this manual Machine introduction ON OFF Mains supply cable Earth return cable Shielding gas connector EURO gun connector AE alia N gt Distribution network AII regular electrical devices without special circuits generate harmonic currents into distribution network High rates of harmonic current may cause losses and disturbance to some equipment This equipment complies with IEC 61000 3 12 provided that the short circuit power Ssc is greater than or equal to 1 9 MVA at the interface point between the user s supply and the public supply network It is the responsibility of the installer or user of the equipment to ensure by consultation with the distribution network operator if necessary that the equipment is connected only to a supply with a short ci
14. he feed roll groove and through the front wire guide until it comes out from the Euro connector by about 150mm Replace the top feed roll over the wire and close the pressure arm Cut away any deformed wire section and dress the sharp wire tip as described above Connect the welding gun and tighten the collar Press the welding gun trigger and allow the filler wire to feed through the gun cable to the contact tip Check once again that the wire is still properly in the grooves of both feed roll pairs Now the FitWeld is ready to weld Ov Ur d UJ Setting the pressure of the feed rolls To make filler wire run smoothly into the wire liner and to the welding gun you can adjust the pressure of the feed rolls of the GT02 WireDrive mechanism Turn the orange coloured pressure adjustment knob in a clockwise direction to increase the pressure applied to the welding filler wire and anti clockwise to decrease it There is a graduation scale marked on the aluminium arm above the orange adjustment knob The more pressure applied the greater the number of graduation marks visible O Kemppi Oy 1336 EN EN For hard steel and stainless steel filler wires make sure there is sufficient pressure applied so avoiding filler wire slippage in the feed rolls NOTE Too much pressure may flatten the filler wire damage its coating cause friction and excessive wear to drive roll bearings and therefore reduced life F
15. he wire feed mechanism and spool housing with compressed air Reassemble the welding gun Firmly tighten the contact tip and contact tip s adapter UI M Nt Replacing the wire liner If the wire liner is too worn or totally clogged you must replace it according to the instructions in welding gun operating manual Disposal 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 FitWeld 300 4 5 ORDERING CODES FitWeld 300 Fitweld 300 MMT 32 3 m Fitweld 300 MMT 32 4 5 m MMT 32 3 m MMT 32 4 5 m Earth return cabel 35 mm 5 m Shield gas hose 6 m TECHNICAL DATA Connection voltage 3 50 60 Hz Rated power at max current Supply current 20 ED L 20 ED ler Output 40 C 20 ED 60 ED 100 ED Connection cable HO7RN F Fuse delayed Open circuit voltage Power factor at max current Efficiency at max current Welding range Wire spool max
16. lding gas Secure the snap connector of the shielding gas hose to the gas connector on the back of the FitWeld machine Connect the other end of the gas hose to a gas cylinder s control valve or to the shielding gas distribution network at your worksite Make sure that you are using the correct type of shielding gas for the welding application The shielding gas used for steel wires is carbon dioxide or a mixture of argon and carbon dioxide The shielding gas used for stainless steel filler wires is a mixture of argon and carbon dioxide 2 For aluminium filler wires use pure argon shielding gas The thickness of the parent material joint type and welding power define the required shielding gas flow rate To connect the shielding gas hose to a suitable regulator for MIG MAG welding 1 Connect the shielding gas hose to the gas cylinder s control valve and tighten the connector connector is not supplied in the package 2 Adjustthe shielding gas flow rate with the control valve screw 3 Always close the cylinder valve after use NOTE The shielding gas flow rate set from the gas cylinder regulator must exceed the flow rate measured at the welding gun if GasGuard function is active If the flow rate and pressure are the same the gas indicator light will shine on the control panel and welding is prevented See also instructions and warnings about adjusting the FitWeld s gas flow rate later in this manual O Kemppi Oy 1336
17. lding gas flow rate at the gun nozzle is correct Check that the shielding gas is suitable for the filler wire used Check that the wire feed is constant and adjust if necessary e Check that the mains voltage is not irregular too low or too high The device has overheated Ensure that cooling air has unrestricted flow The machine duty cycle has been exceeded Wait for indicator to turn off Too low or high supply voltage Feed rolls wire liner or contact tips may be defective Check that feed rolls are not too tight or too loose Check that the feed roll groove is not too worn or incorrect size for the filler wire used Check that the wire liner is the correct size and is not blocked or worn out Replace if necessary Check that the contact tip is suitable for the wire used and and is not worn out or blocked The machine has no mains voltage Check the mains fuses Check the mains cable and the wall plug If the machine s malfunction can not be corrected with these measures contact the KEMPPI maintenance service O Kemppi Oy 1336 EN 13 EN 14 3 1 3 2 3 2 1 3 2 2 3 3 MAINTENANCE When considering and planning routine maintenance please consider the 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
18. or aluminium filler wires select the correct feed roll type from the chart supplied and adjust for the minimum pressure necessary for reliable filler wire drive NOTE Slight slippage is recommended in the case of aluminium filler wires This ensures that the soft wire is not deformed and flattened and that the feed rolls skid over the soft wire if gets stuck on the gun contact tip For Aluminium and Stainless Steel filler wires always use Kemppi DL Teflon gun liners These liners are especially developed by Kemppi and significantly reduce friction loses so improving welding performance 2 5 4 Setting the spool brake force To prevent the filler wire from uncoiling on overrun following use at high feed speeds you can change the brake force of the welding spool Adjust the spool brake force through the hole in the spool locking mechanism with the Allen key supplied and mounted below the wire drive mechanism Increase the force by turning the Allen key clockwise and decrease it by turning it anticlockwise NOTE Do not over tighten and reduce the pressure for light filler wire types FitWeld 300 2 5 5 Wire guide tubes and wire feed rolls Make sure that you select appropriate wire feed rolls groove type welding gun contact tip and wire liner for the filler wire used Kemppi feed rolls and gun liners are colour coded in order to make identification easy Wire guide tubes mm outlet tube inlet tube Ss AI Fe Mc Fc W003963
19. position This position provides 2T operation with GasGuard feature disabled allowing welding without shielding gas U A ZT 4T To use the welding gun in 2T operating mode 1 Pressthe gun trigger down to start welding 2 Release the gun trigger to stop welding To use the welding gun in 4T operating mode Press the gun trigger down to start the flow of the shielding gas 2 Release the trigger to start welding 3 Pressthe trigger down again to stop the arc The shielding gas continues to flow 4 Release the switch again to stop the flow of the shielding gas Kemppi Oy 1336 EN 11 EN 12 2 6 4 Adjusting the shielding gas flow 2 6 5 Using a rotameter as shown in the picture you can adjust the gas flow rate to the gun by turning the shielding gas adjustment regulation valve screw inside the FitWeld 300 wire cabinet By turning the screw anticlockwise you increase the gas flow to the gun nozzle Clockwise adjustment will reduce the gas flow rate HOGS NOTE The shielding gas flow rate set from the gas cylinder regulator must exceed the flow rate measured at the welding gun If these rates are the same the gas indication light will shine on the control panel and welding is prevented Reversing polarity Some filler wires are recommended to be welded with the gun in the minus pole so the polarity should be reversed Check the recommended polarity from the filler wire package
20. rcuit power Ssc greater than or equal to 1 9 MVA Connecting cables Before you can start welding with FitWeld 300 you must connect the machine to the mains power supply attach the welding gun and the earth return cable and the shielding gas supply You must also equip the machine with a filler wire spool suitable for your welding application For quick help about starting with FitWeld please refer to the Quick Guide delivered with the product information package FitWeld 300 2 4 1 2 4 2 2 4 3 Connecting to mains FitWeld 300 is connected to a 3 phase network using the mains cable supplied with the machine The cable is not equipped with a wall plug so you must install a suitable plug before you use the machine for the first time Check also that the mains cable complies with the local electrical regulations and replace the cable if necessary See Technical specifications NOTE The mains cable or wall plug may be installed or replaced only by an electrical contractor or installer authorised to perform such operations Earth return cable For creating a closed electric circuit needed in welding you must connect the earth return cable to the connector located on the back of the FitWeld The other end of this cable will be connected to the workpiece before welding NOTE When attaching the earth return clamp to the work piece remember to clean the work piece surface so as to achieve safe and undisturbed operation Shie
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