Kemppi FE20 User manual

Operating manual
Käyttöohje
Bruksanvisning
Bruksanvisning
Brugsanvisning
Gebrauchsanweisung
Gebruiksaanwijzing
Manuel d’utilisation
Manual de instrucciones
Instrukcja obsługi
Инструкции по эксплуатации
操作手册
Manual de utilização
Manuale d’uso
EN
FI
SV
NO
DA
DE
NL
FR
ES
PL
RU
ZH
PT
IT
FE
20, 25, 27, 32, 35, 42

OPERATING MANUAL
English

EN
CONTENTS
1. Introduction ......................................................................................................................... 3
1.1 General ....................................................................................................................................... 3
1.2 Produktintroduktion ............................................................................................................. 3
1.3 Operation Safety..................................................................................................................... 4
2. Connecting the gun........................................................................................................ 5
3. Use and maintenance.................................................................................................... 7
4. Operation disturbances ............................................................................................... 9
5. Ordering numbers.........................................................................................................10
6. Technical data...................................................................................................................15
FE 20, 25, 27, 32, 35, 42
2

EN
1. INTRODUCTION
1.1 General
Congratulations on choosing the Kemppi 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 Produktintroduktion
Kemppi FE MIG/MAG guns are designed for professional users, mainly welding ferrous
materials. They are compatible with all MIG/MAG welding equipments tted with a Euro
connector.
3
© Kemppi Oy / 1135

EN
1.3 Operation Safety
Please read and follow these operational safety instructions when installing, operating and
servicing the welding gun.
Welding arc and welding spatter
Welding arc can harm unprotected eyes. Also be aware of the risks to other people in and
around the working area, as reected arc and arc ash presents a serious risk. Welding arc
and hot spatter will burn unprotected skin. Use specied, good quality safety equipment and
protective clothing.
Danger for re or explosion
Observe the local re safety regulations and complete an adequate risk assessment, prior to
commencing work. Remove ammable or explosive materials from welding place. Always
ensure there is adequate re-ghting equipment available. Be aware of welding hazards eg.
the danger of re or explosion when welding container type work pieces or enclosed spaces.
NOTE! Fire can start from welding sparks and hot spatter, even several hours after the welding
work has nished!
Mains voltage
Never take the welding machine inside a work piece (eg. container or truck). Do not place
the welding machine on a wet surface. Always check cables before operating the machine.
Change defective cables without delay. Defective cables may cause an injury or increase
the risk of re. Connection cables and hoses should be protected from damage from heavy
objects, sharp edges or hot work pieces.
Welding power circuit
Protect yourself by using proper protective clothing suitable for the welding application
and environment. Do not work in wet or damp conditions. Do not wear wet clothing when
welding. Never use equipment with defective or damaged cables. Unless in a designed gun
holder, do not place the welding gun on the welding machine if the machine is live. Never
point the welding gun towards your face or that of others.
Welding fumes
Ensure there is sucient ventilation during welding. Observe safety recommendations and
precautions when welding metals which contain lead, cadmium, zinc, mercury or beryllium
and other harmful substances. Ensure you use appropriate protective respiratory equipment
suitable for the welding application, environment and materials being welded.
FE 20, 25, 27, 32, 35, 42
4

EN
2. CONNECTING THE GUN
Check wire liner and contact tip suit the wire type and size used. For further information,
please refer to section 5. Ordering numbers in this manual.
Dress the sharp ller wire. Improves wire loading and consumables life.
Connect the welding gun and hand tighten the collar.
5
© Kemppi Oy / 1135

EN
FE32
WIRE INCH
GAS TEST
SET
ON
CH
PANEL
SAVE
SET
ch clear
ch remote
MEMORY
SELECT
quick
setup
weld
data
ARC FORCE
DYNAMICS
4T
2T
SETUP
MMA
PEN
MMA
WISE
1-MIG
MIG
POWER
U
SYNERGIC
PROGRAM
AV
m/min
mm
SF 53W
W004270
/ MINILOG
Load ller wire using the WIRE INCH button, or use the gun trigger.
FE 32
l/min
5
10
15
20
WIRE INCH
GAS TEST
SET
ON
CH
PANEL
SAVE
SET
ch clear
ch remote
MEMORY
SELECT
quick
setup
weld
data
ARC FORCE
DYNAMICS
4T
2T
SETUP
MMA
PEN
MMA
WISE
1-MIG
MIG
POWER
U
SYNERGIC
PROGRAM
AV
m/min
mm
SF 53W
W004270
/ MINILOG
Check gas ow rate and adjust to suit your application.
Trim excess ller wire at a slight angle before welding. This improves ignition.
FE 20, 25, 27, 32, 35, 42
6

EN
FE 32
Enjoy using FE welding gun!
3. USE AND MAINTENANCE
The amount of use and working environment should be taken into consideration when
planning the maintenance of MIG guns. Correct use and preventive maintenance will help
ensure trouble-free operation and excellent gun life.
Due to high temperatures and wear, the welding end of the MIG gun requires the most
frequent maintenance. The condition of other parts, including the gun cable, should also be
checked for wear or damage.
When tting new liners, lay the gun straight on a at surface.
The gun is equipped at the factory with a spiral liner for welding normal steel wire. Before
connecting the gun to the welding machine, make sure that the liner type meets the
recommendations for the welding ller wire to be used.
7
© Kemppi Oy / 1135

EN
Components can become lose during welding heat cycles. Check regularly.
Gun cable
Clear dust from the liner every day during heavy use.
• Clean wire liner when replacing wire reel, or more often.
• Check daily that insulations of handle and gun cable are undamaged.
• Check that there are no sharp bends in gun cable.
Check and remove any spatter build-up from the nozzle.
FE 20, 25, 27, 32, 35, 42
8

EN
4. OPERATION DISTURBANCES
Welding performance can be eected by a number of issues, including the welding gun and/
or other parts of the welding system. The following information will help you to check, identify
and rectify possible causes of welding malfunction.
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 use when using the MIG/MAG
process.
Dirty, poor quality weld?
• Checkthatspatterisnotblockingthenozzleorcontacttipadapter
• Checkshieldinggassupply
• Checkandsetgasowrate
• Checkgastypeforapplication
• Checkgunpolarity.Example:Fesolidllerwire:Earthreturnsocketshouldbeconnectedtothe-pole,wirefeed/Gun
connectiontothe+pole
• Checkpowersupply–Phasedown?
Variable welding performance?
• Checkwirefeedmechanismiscorrectlyadjusted
• Checkcorrectdriverollsaretted
• Checkwirespool/hub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fortheapplication
• Checkcableconnectionsandearthreturnclamp
• Checkweldingparametersettings.
Filler wire won’t feed?
• Checkwirefeedmechanism.Adjustasnecessary
• Checkweldinggunswitchfunction.
• Checkeurogunconnectoriscorrectlytted
• Checkgunlinerisnotblocked
• Checkcontacttip,size,type,wear
• Checkllerwirediameterforcorrectsize
High spatter volume?
• Checkweldingparametervalues
• Checkinductance/Dynamicsvalues
• Checkgastypeandow
• Checkweldingpolarityandcableconnections
• Checkllermaterialselection
• Checkllerwiredeliverysystem
• Checkpowersupply.Areallelectricalphasespresent?
• Checkthatoperatormaintainscorrecttechnique/Arclength/travelspeed/Gunangle
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.
9
© Kemppi Oy / 1135

EN
5. ORDERING NUMBERS
NOTE! Orange part code colour denotes standard delivery specication.
FE 20: 6602003 (3.5 m), 6602004 (5.0 m)
Gas nozzle
(AxBxC)
9580101 60.5x18x14mm,standard
958010101 60.5x18x14mm,withinsulatingbush
(=95801010+9591079)
4113470 60.5x18x14mm,forspotwelding
9580101E 60.5x20x14mm,thickwall
Insulating bush 9591010
Contact tip (M6) 9876634 ø0.6
9876635 0.8
9876633 0.9
9876636 1.0
9876637 1.2
Contact tip
adapter (M6)
9580173
Insulating ring 9591079
Locking spring 4275240
Neck 4153040 45°
Wire liner 4188573 ø0.6–0.8mm 3.5m
W006453 0.9–1.2mm 3.5m
W006457 0.8–1.0mm Al/Ss 3.5m
W006459 1.0–1.6mm Al/Ss 3.5m
4188576 0.6–0.8mm 5m
W006454 0.9–1.2mm 5m
W006458 0.8–1.0mm Al/Ss 5m
W006460 1.0–1.6mm Al/Ss 5m
FE 20, 25, 27, 32, 35, 42
10
A
B
C

EN
FE 25: 6602503 (3.5 m), 6602504 (5.0 m)
Gas nozzle
(AxBxC)
9580101 60.5x18x14mm,standard
958010101

60.5x18x14mm,withinsulatingbush
(=95801010+9591079)
4113470 60.5x18x14mm,forspotwelding
9580101E 60.5x20x14mm,thickwall
Insulating bush 9591010
Contact tip (M6) 9876634 ø0.6
9876635 0.8
9876633 0.9
9876636 1.0
9876637 1.2
Contact tip adapter (M6) 9580173
Insulating ring 9591079
Locking spring 4275240
Neck 4153040 45°
Wire liner 4188573 ø0.6–0.8mm 3.5m
W006453 0.9–1.2mm 3.5m
W006457 0.8–1.0mm Al/Ss 3.5m
W006459 1.0–1.6mm Al/Ss 3.5m
4188576 0.6–0.8mm 5m
W006454 0.9–1.2mm 5m
W006458 0.8–1.0mm Al/Ss 5m
W006460 1.0–1.6mm Al/Ss 5m
11
© Kemppi Oy / 1135
A
B
C

EN
FE 27: 6602703 (3.5 m), 6602704 (5.0 m)
FE 32: 6603203 (3.5 m), 6603204 (5.0 m)
Gas nozzle
(AxBxC)
4295760 76x20x14mm,standard/M8
4295760L 79x20x14mm,long/M8
4295760C 76x20x12mm,conical/M8
4294970 70x20x14mm,standard/M6
Contact tip
(M6)
9876634 ø0.6mm
9876635 0.8
9876633 0.9
9876636 1.0
9876637 1.2
9876639 1.6
(M8) 9580122 ø0.8mm 9580122A ø0.8mm
9580121 0.9 9580121A 0.9
9580123 1.0 9580123A 1.0
9580124 1.2 9580124A 1.2
9580125 1.4 9580125A 1.4
9580126 1.6 9580126A 1.6
9580123ZR 1.0 CuCr1Zr 9580122SS 0.8
9580124ZR 1.2 CuCr1Zr 9580121SS 0.9
9580125ZR 1.4 CuCr1Zr 9580123SS 1.0
9580123AG 1.0 CuAg 9580124SS 1.2
9580124AG 1.2 CuAg 9580126SS 1.6
Contact tip
adapter
4294890 M6
4295740 M8
Gas diffuser 4294880
4294880CER
Neck 3146780 50°
Wire liner 4188573 ø0.6–0.8mm 3.5m
W006453 0.9–1.2mm 3.5m
W006455 1.4–1.6mm 3.5m
W006457 0.8–1.0mm Al/Ss 3.5m
W006459 1.0–1.6mm Al/Ss 3.5m
4188576 0.6–0.8mm 5m
W006454 0.9–1.2mm 5m
W006456 1.4–1.6mm 5m
W006458 0.8–1.0mm Al/Ss 5m
W006460 1.0–1.6mm Al/Ss 5m
FE 20, 25, 27, 32, 35, 42
12
M8 M6
A
B
C

EN
FE 35: 6603503 (3.5 m), 6603504 (5.0 m)
Gas nozzle
(AxBxC)
4300260 77x22x16mm,standard
4300260L 80x22x16mm,long
4300260C 77x22x13mm,conical
4307050 77x22x16mm,standard,spatterprotectionbush
Insulating bush 4307020
Contact tip (M8) 9580122 ø0.8mm 9580122A ø0.8mm
9580121 0.9 9580121A 0.9
9580123 1.0 9580123A 1.0
9580124 1.2 9580124A 1.2
9580125 1.4 9580125A 1.4
9580126 1.6 9580126A 1.6
9580123ZR 1.0 CuCr1Zr 9580122SS 0.8
9580124ZR 1.2 CuCr1Zr 9580121SS 0.9
9580125ZR 1.4 CuCr1Zr 9580123SS 1.0
9580123AG 1.0 CuAg 9580124SS 1.2
9580124AG 1.2 CuAg 9580126SS 1.6
Contact tip
adapter
4295740 M8
Gas diffuser W004390
Insulator W004165
Neck SP004585 50°
SP600317 50°,includestemperatureprotectionspringasstandard.
Wire liner 4188573 ø0.6–0.8mm 3.5m
W006453 0.9–1.2mm 3.5m
W006455 1.4–1.6mm 3.5m
W006457 0.8–1.0mm Al/Ss 3.5m
W006459 1.0–1.6mm Al/Ss 3.5m
4188576 0.6–0.8mm 5m
W006454 0.9–1.2mm 5m
W006456 1.4–1.6mm 5m
W006458 0.8–1.0mm Al/Ss 5m
W006460 1.0–1.6mm Al/Ss 5m
13
© Kemppi Oy / 1135
SP004585 SP600317
A
B
C

EN
FE 42: 6604203 (3.5 m), 6604204 (5.0 m)
Gas nozzle
(AxBxC)
4300380 80x25x18mm,standard
4300380L 83x25x18mm,long
4300380C 80x25x14mm,conical
4307070 80x25x18mm,standard,spatterprotectionbush
4308190 89.5x25x18mm,speciallong
Insulating bush 4307030
Contact tip
(M8)
9580122 ø0.8mm 9580122A ø0.8mm
9580121 0.9 9580121A 0.9
9580123 1.0 9580123A 1.0
9580124 1.2 9580124A 1.2
9580125 1.4 9580125A 1.4
9580126 1.6 9580126A 1.6
9580123ZR 1.0 CuCr1Zr 9580122SS 0.8
9580124ZR 1.2 CuCr1Zr 9580121SS 0.9
9580125ZR 1.4 CuCr1Zr 9580123SS 1.0
9580123AG 1.0 CuAg 9580124SS 1.2
9580124AG 1.2 CuAg 9580126SS 1.6
Contact tip
adapter
4304600 M8
Gas diffuser W004505
Insulator W004579
Neck SP004578 50°
SP600316 50°,includestemperatureprotectionspringasstandard.
Wire liner 4188573 ø0.6–0.8mm 3.5m
W006453 0.9–1.2mm 3.5m
W006455 1.4–1.6mm 3.5m
W006457 0.8–1.0mm Al/Ss 3.5m
W006459 1.0–1.6mm Al/Ss 3.5m
4188576 0.6–0.8mm 5m
W006454 0.9–1.2mm 5m
W006456 1.4–1.6mm 5m
W006458 0.8–1.0mm Al/Ss 5m
W006460 1.0–1.6mm Al/Ss 5m
FE 20, 25, 27, 32, 35, 42
14
SP600316SP004578
A
B
C

EN
6. TECHNICAL DATA
Gun Loading capacity
Ar + CO₂(A)
Duty cycle (%) Wire diameters
(mm)
Type of cooling
FE 20 200 35 0.6–1.0 Air
FE 25 250 35 0.6–1.2 Air
FE 27 270 35 0.6–1.2 Air
FE 32 320 35 0.8–1.6 Air
FE 35 350 35 0.8–1.6 Air
FE 42 420 35 0.8–1.6 Air
Connection to MIG unit: Euro adapter
NOTE! Make sure that the gun selected is designed for the maximum welding current needed.
Kemppi welding guns meet construction and safety requirements according to the norm
IEC / EN 60974-7.
15
© Kemppi Oy / 1135

1925080
1135
KEMPPI OY
Kempinkatu1
PL13
FIN-15801LAHTI
FINLAND
Tel+358389911
Telefax+3583899428
[email protected]
www.kemppi.com
Kotimaan myynti:
Tel+358389911
Telefax+35837348398
myynti.@kemppi.com
KEMPPI SVERIGE AB
Box717
S-19427UPPLANDSVÄSBY
SVERIGE
Tel+46859078300
Telefax+46859082394
[e-mail]
KEMPPI NORGE A/S
Postboks2151,Postterminalen
N-3103TØNSBERG
NORGE
Tel+4733346000
Telefax+4733346010
[e-mail]
KEMPPI DANMARK A/S
Literbuen11
DK-2740SKOVLUNDE
DANMARK
Tel+4544941677
Telefax+4544941536
[e-mail]
KEMPPI BENELUX B.V.
Postbus5603
NL-4801EABREDA
NEDERLAND
Tel+31765717750
Telefax+31765716345
[e-mail]
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
[e-mail]
KEMPPI FRANCE S.A.S.
65AvenuedelaCouronnedesPrés
78681EPONECEDEX
FRANCE
Tel+33130900440
Telefax+33130900445
[e-mail]
KEMPPI GmbH
Otto-Hahn-Straße14
D-35510BUTZBACH
DEUTSCHLAND
Tel+49603388020
Telefax+49603372528
[e-mail]
KEMPPI SPÓŁKA Z O.O.
Ul.Borzymowska32
03-565WARSZAWA
POLAND
Tel+48227816162
Telefax+48227816505
info[email protected]
KEMPPI AUSTRALIA PTY LTD.
13CullenPlace
P.O.Box5256,GreystanesNSW2145
SMITHFIELDNSW2164
AUSTRALIA
Tel.+61296059500
Telefax+61296055999
info[email protected]
OOO KEMPPI
Polkovayastr.1,Building6
127018MOSCOW
RUSSIA
Tel+74957394304
Telefax+74957394305
info[email protected]
ООО КЕМППИ
ул.Полковая1,строение6
127018Москва
Tel+74957394304
Telefax+74957394305
info[email protected]
KEMPPI, TRADING (BEIJING) COMPANY,
LIMITED
Room420,3Zone,BuildingB,
No.12HongdaNorthStreet,
BeijingEconomicDevelopmentZone,
100176Beijing
CHINA
Tel[phone]6064
[phone]1282
Telefax[phone]5259
[e-mail]
肯倍贸易（北京）有限公司
中国北京经济技术开发区宏达北路12号
创新大厦B座三区420室 (100176)
电话：[phone]6064
[phone]1282
传真：[phone]5259
[e-mail]
KEMPPI INDIA PVT LTD
LAKSHMITOWERS
NewNo.2/770,
FirstMainRoad,
KazuraGarden,
Neelankarai,
CHENNAI-600041
TAMILNADU
Tel[phone]1200
Telefax[phone]1234
[e-mail]
www.kemppi.com