Kemppi SuperSnake GT02SW User manual

SuperSnake
GT 02S, GT 02SW
Operating manual
Bruksanvisning
Gebrauchsanweisung
Manual de instrucciones
Käyttöohje
Manuel d’utilisation
Manuale d’uso
Gebruiksaanwijzing
Brugsanvisning
Instrukcja obsługi
Инструкции по эксплуатации
Bruksanvisning
操作手册
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OPERATING MANUAL
English

EN
CONTENTS
1. Preface........................................................................................................... 3
1.1 General ....................................................................................................................................... 3
1.2 About SuperSnake products.............................................................................................. 3
2. Installation.................................................................................................... 4
2.1 Before use.................................................................................................................................. 4
2.2 Machine introduction........................................................................................................... 4
2.3 Connecting cables ................................................................................................................. 5
2.3.1 Water cooled system ....................................................................................................... 5
2.3.2 Gas cooled system........................................................................................................... 6
3. Assembly of SuperSnake GT02S and GT02Sw .................................... 7
3.1 Before connection.................................................................................................................. 7
3.2 Mounting and locking of wire spool............................................................................... 8
3.3 Loading the ller wire and automatic feed .................................................................. 9
3.4 Adjustment of MXF/MXP pressure arms .....................................................................10
3.5 Adjustment of spool brake ...............................................................................................10
3.6 Automatic wire feed to intermediate cable and gun .............................................11
4. Maintenance.............................................................................................. 15
4.1 Daily maintenance ...............................................................................................................15
4.2 Service shop maintenance ...............................................................................................15
5. Disposal of the machine ......................................................................... 16
6. Ordering numbers.................................................................................... 16
7. Technical data............................................................................................ 17
SuperSnake GT 02S, GT 02SW
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EN
1. PREFACE
1.1 General
Congratulations on choosing the SuperSnake 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 device can be found at the end of the
manual.
Please read the manual carefully before using the equipment for the rst time. For your
own safety and that of your working environment, pay particular attention to the safety
instructions in the manual.
For more information on Kemppi products, contact Kemppi Oy, consult an authorised Kemppi
dealer, or visit the Kemppi web site at www.kemppi.com.
The specications presented in this manual are subject to change without prior notice.
Important notes
Items in the manual that require particular attention in order to minimise damage and
personal harm are indicated with the ’NOTE!’ notation. Read these sections carefully and follow
their instructions.
Disclaimer
While every eort has been made to ensure that the information contained in this guide
is accurate and complete, no liability can be accepted for any errors or omissions. Kemppi
reserves the right to change the specication of the product described at any time without
prior notice. Do not copy, record, reproduce or transmit the contents of this guide without
prior permission from Kemppi.
1.2 About SuperSnake products
SuperSnake is a combined solution for distance wire feeding and restricted access welding. It
extends the reach of standard euro MIG/MAG welding guns up to 30 metres, providing simple
distance wire feeding for a variety of ller wires, taking quality welding to locations other
welding equipment can’t reach.
SuperSnake models connect easily to FastMig MXF/MXP wire feed units with a special MXF
synchronisation kit, and to ProMig 501, 501L and 530 wire feed units with a ProMig 50
synchronisation kit.
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2. INSTALLATION
2.1 Before use
The product is packed in specially designed transport cartons. However, before use always
make sure 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 pack. Product packaging material is recyclable.
2.2 Machine introduction
1. 2. 3. 4. 5.
m/min
A
V
1. Euro gun connector
2. Feed mechanism door
3. Feed mechanism door lock
4. Bumper prole body
5. Meter display (Not available in ProMig applications)
1.
2.
3.
4. 6. 7.
5.
1. Wire speed/Arc length regulation
2. Voltage/Power regulation
3. Pressure arm adjuster
4. Wire guide tube
5. Powered drive roll
6. Pressure drive roll
7. Brights LED
SuperSnake GT 02S, GT 02SW
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2.3 Connecting cables
NOTE! Always check before use that the interconnecting cable, shielding gas hose, earth return
lead/clamp, and mains cable is in a serviceable condition. Ensure that connectors are correctly
fastened. Lose connectors can impair welding performance and damage connectors.
Sub feeder syncronization kit
To enable SuperSnake connection, MXF/MXP wire feed units must rst be tted with a FastMig
MXF synchronisation kit (W004030), and ProMig wire feed units with ProSync 50 kit (6263121).
Follow the installation instructions provided in the kit delivery.
2.3.1 Water cooled system
FastMig KMS/Pulse/X + MXF/MXP + FastCool 10
Pro Evolution + ProMig + ProCool 30
1.
4.
9. 2.
3.
10.
5.
6.
8.
7.
1. MXF, MXP or ProMig wire feed unit
2. FastMig Pulse or Pro Evolution power source
3. FastCool or ProCool 30 water cooler and power connection
4. Gas supply
5. MMA electrode holder
6. Remote control device
7. SuperSnake GT02SW
8. Liquid cooled welding Gun
9. Power cable
10. Earth return lead and clamp
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2.3.2 Gas cooled system
FastMig KMS/Pulse/X + MXF/MXP
1.
4.
5.
7.
6.
9.
2.
3.
8.
1. MXF, MXP or ProMig wire feed unit
2. FastMig Pulse or Pro Evolution power source
3. Gas supply
4. MMA electrode holder
5. Remote control device
6. SuperSnake GT02S
7. Air cooled welding Gun
8. Power cable
9. Earth return lead and clamp
SuperSnake GT 02S, GT 02SW
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3. ASSEMBLY OF SUPERSNAKE GT02S AND GT02SW
3.1 Before connection
Uncoil SuperSnake taking the feed mechanism body towards the intended welding area, and
away from the welding machine. Ensure there are no tight bends before you load the ller
wire.
Ensure that the correct ller wire support liner is tted and installed correctly for the intended
welding application. Kemppi manufacturer a range of support liners for dierent ller material
types, including Steel wound and DL Chili. Please read the guide notes on liner selection and
installation before use.
SuperSnake wire feed mechanism
Before loading the ller wire to SuperSnake please set the wire feed mechanism. Ensure the
grooved drive rolls suit the ller wire size and type. Close and adjust the pressure arm.
Wire feed roll, wire guide tubes and wire liners
Wire feed rolls ø, mm
Fe, Ss (Al, Mc, Fc)
V groove
0.8 W004276
1.0 W004277
1.2 W004278
1.6 W004279
Mc, Fc (Fe)
V groove, knurled
1.2 W004281
1.6 W006608
2.0 W006609
Al (Ss, Fe, Mc, Fc)
U groove
1.2 W004280
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ø, mm inlet tube wire liner
Fe, Mc, Fc
steel
0.8 – 1.2 W004083 W004214 10.5 m
W004216 15.5 m
W004217 20.5 m
W004218 25.5 m
1.4 – 2.0 W006617 4308620 15.5 m
4308630 25.5 m
Ss, Al (Fe, Mc, Fc)
plastic
0.8 – 1.6 W004185 W004145 10 m
W004219 15 m
W004220 20 m
W004221 25 m
3.2 Mounting and locking of wire spool
Ensure quality ller wire is loaded to the wire feed cabinet. Check that the correct wire guide
tube and wire drive rolls are selected and tted for the ller wire type used.
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.
SuperSnake GT 02S, GT 02SW
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3.3 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 the wire does not spill from the spool sides. Straighten about
20 cm of ller and present the ller wire tip to the back of the wire feed rolls and press the wire
inch button on the wire feed panel.
Now take a ne le or abrasive cloth and remove any sharp edges from the ller wire end,
before loading to SuperSnake. This prevents damage to plastic liners in particular, and also
prevents pick-up and stubbing inside metal liners when loading.
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 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.
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3.4 Adjustment of MXF/MXP 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.
3.5 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.
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 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.
Communication cables
Support the SuperSnake coupling and guide the ller wire into the SuperSnake liner.
Then carefully mate and connect SuperSnake to the wire feed unit connector. Secure the
SuperSnake by hand tightening the orange collar. The SuperSnake coupling transfers welding
power, shielding gas and gun trigger lines. In addition you must connect both cable plugs
to the FastMig or ProMig wire feed unit sockets (from MXF synchronisation kit W004030 or
ProMig ProSync 50 kit 6263121). This ensures wire feed motor synchronization, metering and
remote control functions. Align and connect the plugs to the sockets and lightly tighten by
hand. In ProSync applications, welding values are not shown. Instead, the display shows only
dashes – – – .
SuperSnake GT 02S, GT 02SW
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SuperSnake GT02S SuperSnake GT02SW
3.6 Automatic wire feed to intermediate cable and gun
WF #1.
1. WIRE INCH button
You are now ready to ‘Auto Load’ the ller wire. Ensure the FastMig or ProMig wire feed
mechanism pressure arms are in place and correctly adjusted. Press the WIRE INCH button on
the wire feed panel. MXF/PF system will automatically load the ller wire to the SuperSnake
feed mechanism, and through the gun connector block. There should be a small amount of
ller wire sticking out ready for gun connection.
NOTE! In ProMig applications, the automatic Wire Inch function is not available. You must press
and hold the Wire Inch button or welding gun trigger, until the ller wire reaches SuperSnake.
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Connecting the welding gun
Prepare your welding gun for connection. SuperSnake is designed to accept a wide variety of
welding guns tted with the standard Euro tting. To ensure reliable welding performance,
please ensure the gun is suitable for the intended welding application and is in good working
order, correctly tted with a suitable liner and contact tip.
Tread the ller wire into the welding gun and connect to the SuperSnake. Hand tighten the
gun collar.
NOTE! Kemppi manufacture a range of quality welding guns, low friction loss gun liners and gun
consumables, designed to compliment our welding products. Please consider these products
before selecting an alternative.
Welding power controls
Ensure Remote control function is selected on the wire feed unit. SuperSnake provides
wire feed speed and voltage control in Basic MIG/MAG mode, plus Power and Arc length in
1-MIG and Pulse MIG. Note that Pulse MIG is not available in ProMig applications. Convenient
welding parameter adjustments can be made during welding, allowing easy ne tuning of the
welding arc.
1.
1. Welding power adjustment
SuperSnake GT 02S, GT 02SW
12

EN
Meter display (not available in ProMig applications)
The meter display provides essential welding data indicators. Depending on the MIG/MAG
process selected, Voltage, Amperage, Wire feed speed, Plate thickness and Polarity will be
indicated. Power and arc length adjustment can be made, prior to, and during welding via the
potentiometers housed under the SuperSnake cabinet door. Post weld data is retained in the
display for approximately 30 seconds after welding stops, providing that no additional control
signals are received during this time.
m/min
A
V
1.2.
3.
1. Voltage
2. Welding current
3. Wire feed speed
Water cooled models
Water cooled SuperSnake models allow connection to the cooling uid supply for liquid
cooled guns. Snap connectors tted at either end of SuperSnake unit are marked RED and
BLUE, allowing simple, fast and convenient connection. Ensure the cooling uid circuit is
correctly connected.
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Setting the shielding gas
The 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.
MMT 32
l/min
5
10
15
20
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.
SuperSnake GT 02S, GT 02SW
14

EN
4. 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 mains before handling the electrical cables.
4.1 Daily maintenance
• Check the overall condition of SuperSnake and 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.
NOTE! Clean system with dry compressed air at least every 5 x wire spool changes. Keep sub feeder
cover open during the cleaning process.
4.2 Service shop maintenance
Kemppi Service Workshops complete maintenance according to their Kemppi service
agreement.
Regular preventative maintenance by trained technicians will increase equipment life and
ensure reliable operation.
15
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5. DISPOSAL OF THE MACHINE
Do not dispose of electrical equipment with normal waste!
In observance of European Directive 2002/96/EC on waste electrical and electronic
equipment, and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and taken to an appropriate
environmentally responsible recycling facility.
The owner of the equipment is obliged to deliver a decommissioned unit to a regional
collection centre, per the instructions of local authorities or a Kemppi representative. By
applying this European Directive you will improve the environment and human health.
6. ORDERING NUMBERS
SuperSnake GT02S 10m Gas cooled 6153100
SuperSnake GT02S 15m Gas cooled 6153150
SuperSnake GT02S 20m Gas cooled 6153200
SuperSnake GT02S 25m Gas cooled 6153250
SuperSnake GT02SW 10m Water cooled 6154100
SuperSnake GT02SW 15m Water cooled 6154150
SuperSnake GT02SW 20m Water cooled 6154200
SuperSnake GT02SW 25m Water cooled 6154250
SuperSnake GT02SC
For MagTrac F61 welding carriage
15m Gas cooled 61531501
MXF sync kit W004030
Rubber protection cover (for liquid cooled models) W004466
SuperSnake GT 02S, GT 02SW
16

EN
7. TECHNICAL DATA
Connection voltage 50V DC
Output 40 °C 380 A
Cabel ø 50 mm
Welding current I 100% 300 A
I 60% 380 A
Supply voltage U 50V DC
Supply current I 20 mA
Motor voltage Umotor 0 – 24V DC
Motor current Imotor 5 A
Wire feed mechanism 2 roll
Filler wires, 25 m Fe/Ss ø 1.0 – 1.6
Al ø 1.2 – 1.6
FCW/MCW ø 1.2 – 1.6
Wire feed speed 0 – 25 m/min
Gun connection Euro
Maximum pressure 0.5 Mpa
External dimensions LxWxH GT02S 371 x 94 x 125
GT02SW 371 x 102 x 138
Weight GT02S 10m 13.5 kg
15m 20.5 kg
20m 27.5 kg
25m 34.5 kg
GT02SW 10m 14.5 kg
15m 22 kg
20m 29.5 kg
25m 37 kg
Operating temperature range –20 ... +40 °C
Storage temperature range –40 ... +60 °C
Degree of protection IP23S
EMC class A
17
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