Kemppi MMT 42C User manual

Operating manual
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MMT
42C

OPERATING MANUAL
English

EN
CONTENTS
1. Introduction ......................................................................................................................... 3
1.1 General ....................................................................................................................................... 3
1.2 Product Introduction ............................................................................................................ 3
1.3 Operation Safety..................................................................................................................... 4
2. Connecting the gun........................................................................................................ 5
3. Use and maintenance.................................................................................................... 7
4. Operation disturbances .............................................................................................10
5. Ordering numbers.........................................................................................................11
6. Technical data...................................................................................................................12
MMT 42C
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 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 Product Introduction
The MMT 42C is an air-cooled MIG/MAG welding gun for mechanised welding applications.
It is specially designed to be used with Kemppi welding carriages. This welding gun has a
straight neck and no trigger. Its operation is controlled by the welding equipment through the
data cable. This welding gun cannot be used for manual welding.
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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.
MMT 42C
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EN
2. CONNECTING THE GUN
Before connecting the gun to the welding machine, check wire liner and contact tip suit the
wire type and size used. For further information, please refer to consumables section later in
this document on page 11.
Dress the sharp ller wire. Improves wire loading and consumables life.
Connect the welding gun and hand tighten the collar.
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EN
ARC
ON
START
STOP
MagTrac F 61
SET
CH OFF
GAS TEST
WIRE INCH
WELD DATA
Load ller wire using the WIRE INCH button.
If you are using Kemppi MagTrac F 61 welding carriage, you can load the wire by selecting
Wire Inch option in the MagTrac control panel menu. For more information, see MagTrac F 61
operating manual.
FE 32
l/min
5
10
15
20
ARC
ON
START
STOP
MagTrac F 61
SET
CH OFF
GAS TEST
WIRE INCH
CYCLE WELD
Check gas ow rate and adjust to suit your application.
Trim excess ller wire at a slight angle, before welding. Improves ignition.
MMT 42C
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EN
Mount the welding gun to the welding carriage and connect the data cable connector to the
socket on the carriage.
Adjust the position of the gun in the carriage so that it points to the right spot and is in the
right angle and distance from the groove.
For more information, see welding carriage documentation.
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.
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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.
MMT 42C
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EN
If gun's neck gets too worn or damaged, you can replace it by unscrewing it from the gun
body and replacing with a new one.
NOTE! Check the tightness of the neck daily. A loose neck can cause voltage loss and excess heat in
the gun body.
If you wish to lock the neck in its position, open the torx screw under the rubber collar of the
bending support and remove one of the three washers.
NOTE! If the neck is locked, remember to loosen the torx screw before trying to unscrew the neck.
9
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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.
MMT 42C
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EN
5. ORDERING NUMBERS
MMT 42C: 6254205 (3 m), 6254207 (4.5 m)
NOTE! Orange part code colour denotes standard delivery specication.
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 SP006008 (includes4307070+4307030+9580124+4304600+
W004505+W004579)
Neck part 4302150 0.8–1.6mm Al
4302740 0.8–1.0mm Ss
4302750 1.2–1.6mm Ss
Wire liner 4188571 ø0.6–0.8mm 3m
4188581 0.9–1.2mm 3m
4188591 1.4–1.6mm 3m
4300840 0.8–1.6mm Al 3m
4302680 0.8–1.0mm Ss 3m
4302700 1.2–1.6mm Ss 3m
4188572 0.6–0.8mm 4.5m
4188582 0.9–1.2mm 4.5m
4188592 1.4–1.6mm 4.5m
4300850 0.8–1.6mm Al 4.5m
4302690 0.8–1.0mm Ss 4.5m
4302710 1.2–1.6mm Ss 4.5m
11
© Kemppi Oy / 1131
A
B
C

EN
6. TECHNICAL DATA
Gun Loading capacity Ar + CO₂Duty cycle (%) Wire diameters Type of cooling
MMT 42C 350A 100 0.8–1.6mm Air
MMT 42C 420A 70 0.8–1.6mm Air
Connection to MIG unit: Euro adapter
NOTE! Make sure that the gun selected is designed for the max. welding current needed.
Kemppi guns meet construction and safety requirements according to norm IEC / EN 60974-7.
MMT 42C
12

www.kemppi.com
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1131
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