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A7 MIG Gun 500-g

© Kemppi Oy 2016

1616

OPERA

TING M

ANU

AL

3.  IDENTIFICATION

The welding gun system Kemppi A7 MIG Gun 500-g is used 

in industry and in the trade for welding using inert gases 

(MIG) or active gases (MAG). This model is gas-cooled 

and can be used in all welding positions. These operating 

instructions describe only the welding gun system A7 MIG 

Gun 500-g. The welding gun system may only be operated 

as supplied or with authentic Kemppi spare parts.

Figure 1: Kemppi A7 MIG Gun 500-g

4.  CE MARKING

This device fulfils the requirements of the following EU 

directives:

•  The Machinery Directive, 2006/42/EC

•  The EMC Directive, 2004/108/EC

•  The RoHS Directive, 2011/65/EU

5.  SAFETY

Read and follow the additional safety instructions 

enclosed.

5.1  Designated use

The gas-cooled welding gun system A7 MIG Gun 500-

g must be used for robot and automatic application as 

described in this manual. Designated use also includes 

complying with the prescribed operation, maintenance, 

and servicing conditions.

Any use other than that described under “Designated use” 

is considered contrary to the intended use. 

Unauthorized conversions or power-increasing modifi- 

cations are not allowed.

The warranty does not cover wear parts and damage due 

to overloading or improper use.

5.2  Responsibilities of the user

•  Keep the operating instructions within easy reach 

in the location of the device for reference, and 

include the operating instructions when handing 

over the product.

•  Installation, operation, and maintenance work 

may only be carried out by qualified personnel. 

Qualified personnel are persons who, on account 

of their special training, knowledge, experience, 

and familiarity with the relevant standards, are 

able to assess the tasks assigned to them and 

identify possible dangers.

•  Keep all other persons out of the work area.

•  Follow the accident prevention regulations of the 

relevant country.

•  Ensure good lighting of the work area, and keep 

the area clean.

•  Observe the following standards and guidelines 

in particular: 

•  89/391/EEC: Directive on the introduction 

of measures to encourage improvements in 

the safety and health of workers at work

•  2009/104/EC: Directive concerning the 

minimum safety and health requirements 

for the use of work equipment by workers 

at work

•  2004/108/EC: Directive on the 

harmonization of the laws of the Member 

States relating to electromagnetic 

compatibility The occupational health and 

safety regulations of the country in question 

•  Regulations on occupational safety and 

accident prevention

5.3  Personal protective equipment

To avoid danger to the user, using personal protective 

equipment (PPE) is recommended in these instructions. 

PPE consists of the following:

•  Protective clothing

•  Safety goggles

•  A class-P3 respiratory mask

•  Gloves

•  Safety shoes

Summary of Contents for A7 MIG Gun 500-g

Page 1: ...500 g 1920330 1616 A7 MIG gun EN OPERATING MANUAL...

Page 2: ...al description 9 10 1 The neck 9 10 2 The connection module 9 10 3 The mount 9 10 4 The hose assembly 9 11 Installing the robot gun 10 11 1 Assembling the A7 MIG Gun 500 g neck 10 11 2 Connecting the...

Page 3: ...can be found in the chapter Technical data and at the end of this manual Please read the manual carefully before using the equipment for the first time For your own safety and that of your work envir...

Page 4: ...e user Keep the operating instructions within easy reach in the location of the device for reference and include the operating instructions when handing over the product Installation operation and mai...

Page 5: ...ing the machine The welding arc and spatter The welding arc harms unprotected eyes Be careful also with reflecting flashes from the arc The welding arc and spatter burn unprotected skin Wear safety gl...

Page 6: ...led bridged or otherwise bypassed During welding work outdoors use suitable protection against the weather conditions Check the electrical device for any damage and for proper functioning in accordanc...

Page 7: ...id out in EN 60974 7 Type Type of cooling Load ED Wire Gas flow Weight CO2 M21 A7 MIG G A A mm l min 500 g gas 500 40 100 0 8 1 6 10 30 900 For pulse arc operation the load figures are reduced by up t...

Page 8: ...re a setting device It must be ordered separately and depends on the configuration The contact information for consulting and ordering can be found on the Internet at www kemppi com 8 TRANSPORT The co...

Page 9: ...n system A7 MIG Gun 500 g all the way to the contact tip The contact tip transmits the welding current to the welding wire producing an arc between the welding wire and work piece The light arc and th...

Page 10: ...escribes how to assemble the A7 MIG Gun 500 g neck Figure 5 A7 MIG Gun 500 g neck assembly 2 3 4 7 8 6 5 1 1 Gas nozzle 2 Contact tip 3 Tip adapter 4 Gun neck 5 Neck liner connection module 6 Allen ke...

Page 11: ...gun 9 Lay the hose assembly 7 straight and attach it to the connection module 1 on the gun neck side 10 Slide the ready to use wire guide from the central plug 5 up to the stop in the changeable body...

Page 12: ...ntity The type and quantity of the shielding gas depend on the welding task and the gas nozzle geometry To prevent the shielding gas supply from becoming clogged by impurities the cylinder valve must...

Page 13: ...e work pieces to cool down after welding Before performing welding work fasten the ground clamp properly to the work piece or the welding table Dazzling of the eyes The arc produced by welding may dam...

Page 14: ...ues and assume single shift operation Maintenance and cleaning work may only be carried out by qualified and trained specialists Always wear your personal protective clothing when performing maintenan...

Page 15: ...5 Cut off the protruding wire liner 6 The liner must be even with the support sleeve 1 6 Screw the collet chuck 4 onto the spiral liner 6 as far as it will go The position of the wire guide can be che...

Page 16: ...air Wire burned solid in the contact tip Wrong parameters set Check or correct the setting s Contact tip worn out Replace Irregular wire feed Guide spiral liner PA liner clogged Clean in both directio...

Page 17: ...body mount robot mount and gun neck 14 1 Disposal Fordisposal thelocallyapplicableregulations laws provisions standards andguidelines must be observed For the welding torch system to be properly disp...

Page 18: ...ntact tip holder CONTACT TIP ADAPTER M8 G500 copper SP600629 Contact tip Life Wire Hole 0 8 0 9 W007919 0 9 1 05 W007920 1 0 1 15 W006826 1 2 1 6 W006518 1 4 1 8 W007921 Gas nozzle Gas nozzle bottle f...

Page 19: ...And you know...

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