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Kemppi A7 TIG Orbital System 300, Operating Instructions Manual, Page: 41 / 48

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41

A7 TIG Orbital System 150

© Kemppi Oy 2016

1615

OPERA

TING M

ANU

AL

Collet product codes for 15060 weld head

Tube OD 

(inch)

Collet, 

Extended

Collet, Flush

Tube OD 

(mm)

Collet, 

Extended

Collet, Flush

2.000

1001262-2.000

1001264-2.000

6.0

1001266-51

1001268-51

2.500

1001262-2.500

1001264-2.500

8.0

1001266-52

1001268-52

3.000

1001262-3.00

1001264-3.00

10

1001266-53

1001268-53

3.500

1001262-3.500

1001264-3.500

12.0

1001266-54

1001268-54

4.000

1001262-4.000

1001264-4.000

13.0

1001266-60.3

1001268-60.3

4.500

1001262-4.500

1001264-4.500

13.5

1001266-70

1001268-70

5.000

1001262-5.000

1001264-5.000

16.0

1001266-76.1

1001268-76.1

5.500

1001262-5.500

1001264-5.500

18.0

1001266-85

1001268-85

6.000

1001262-6.000

1001264-6.000

19.0

1001266-104

1001268-104

 

 

 

20.0

1001266-108

1001268-108

 

 

 

22.0

1001266-127

1001268-127

 

 

 

23.0

1001266-129

1001268-129

5.1.2  Tungsten electrode material

Kemppi uses ceriated tungsten to increase electrode life, 

arc starting, and stability, and recommends this material 

for orbital use. 

2% ceriated = no radiation risk

These tungsten electrodes are commonly marked in grey 

color.

Ordering codes for standard length (175 mm) tungsten 

electrodes and sharpening / cutting machines:

9873531

10 pcs. 1.0 mm diameter, 175 mm long

9873532

10 pcs. 1.6 mm diameter, 175 mm long

9873533

10 pcs. 2.4 mm diameter, 175 mm long

6270001

Ultima – TIG – cut, tungsten electrode cutting/sharpening machine

6270002

Neutrix, portable, tungsten electrode sharpening machine

6270003

Auto Grind, Tungsten electrode automated grinder.

Summary of Contents for A7 TIG Orbital System 300

Page 1: ...150 1920380 1615 A7 TIG Orbital System EN OPERATING MANUAL...

Page 2: ...water cooler with coolant 14 3 5 Preparing for welding 15 3 5 1 Preparing the workpiece 15 3 5 2 Shielding and backing gas 16 3 6 Instructions for welding 16 3 7 Weld head control panel 17 3 8 Control...

Page 3: ...ance 44 7 1 Periodic maintenance 44 7 1 1 Factory and field calibration 44 7 2 Weld head maintenance 44 7 2 1 Calibrating the weld head 44 7 2 2 Cleaning the weld head 45 7 2 3 Internal arcing 45 7 3...

Page 4: ...authorized Kemppi dealer or visit the Kemppi website at www kemppi com The specifications presented in this manual are subject to change without prior notice Important notes Items in the manual that r...

Page 5: ...t includes an integrated TIG power source and a cooling unit You can create and save up to 100 welding programs and select the most suitable for each welding object by using the unit s graphic interfa...

Page 6: ...ty cycles Control panel is in the handle and assembly to the controller is provided by a 7 5 metre hose longer cables are available The weld head is clamped on tubes by changeable collets It includes...

Page 7: ...n either side of the head Both sides of the collet frame open and close independently This allows one tube or fitting to be clamped in place and the second tube or fitting to be butted tightly to the...

Page 8: ...e used for joints where there is very little straight length between the joint and an obstruction Advantages Enables welding in tight places where there is not much room for clamping for example when...

Page 9: ...quipped with a gas flow sensor that is factory preset Shielding gas must be flowing to the weld head to initiate a welding arc If gas flow is insufficient pressing the Start Weld button will not initi...

Page 10: ...2 2 Connecting the weld head A B C D All connections are located on the rear of the controller unit Do the following A Connect the weld head s control cable to the connector marked with the weld head...

Page 11: ...ight over closure of the collet frame Compliance and preload are provided by the collet frame adjustable latch mechanism The latch lever provides very high clamping loads with minimal effort After adj...

Page 12: ...actly the correct arc gap Pre grinded and cut to length electrodes are available 3 2 1 Diameter and length You can use multiple tungsten electrode sizes in each weld head by changing the tungsten elec...

Page 13: ...tungsten electrode suitable for the weld current range for positive arc ignition and a stable arc Thicker diameters handle high currents and have a greater life at the expense of arc starting Electro...

Page 14: ...watertankswithnormaltapwater However the degree of water purity as well as the temperature of the environment determine if you need to apply additives and or otherwise take care of the water supply Wh...

Page 15: ...xidation or contaminated from machining operations primarily lubricants 6 At the completion of the weld the auto rewind function rotates the rotor into open throat position to allow the weld head to b...

Page 16: ...ss steel nickel alloys and most nonferrous base metals Argon is commonly used The chamber created around the tube joint by the installation of the weld head is flooded with inert gas that both protect...

Page 17: ...either direction when welding arc is not on This is useful when mounting or replacing the electrode or checking its condition 3 8 Controller unit control panel D E B C A F G I H A Color LCD display s...

Page 18: ...tion 4 New to create a new weld program Library Programs are listed Use the up down cursor to scroll through programs Select program with Select soft key Library displays the following choices Weld Nu...

Page 19: ...s QC Set up Options New Create procedures using either the Auto program or standard manual entry Navigating Select and proceed through a task using four soft keys see Main screen Menu The selected ite...

Page 20: ...umber using the control knob 4 Press Next when finished 5 Use Back to move to previous screen 1 Use the cursor to select each line highlighted in red 2 Use the control knob to select Head Model and Ma...

Page 21: ...knob to modify 3 8 5 Program information 1 Use cursor to select item the control knob to modify Certain items have been previously selected and cannot be changed i e Weld No Data OD etc The cursor wil...

Page 22: ...key Use cursor to select item Modify with the control knob Certain items may not be modified The cursor will bypass these items Choose Next to move through levels and edit as you go The edited weld w...

Page 23: ...er to insert selected on the line Arrow keys move the highlighted character to the left or right along the line You can replace a typed character by moving the highlighted cursor on it and using the c...

Page 24: ...if necessary using the control knob 4 Press Next 3 8 8 Pulsing levels You can select pulsed or non pulsed current Move the cursor and use the control knob to change selections Pulsing varies the curre...

Page 25: ...eed LP Amps Low Pulse Amperage shown as percentage of high pulse current HPT High Pulse Time Period in seconds LPT Low Pulse Time Period in seconds HP RPM rotation speed on high current pulse shown on...

Page 26: ...nto Level 5 Therefore note any other changes that are occurring in subsequent levels within the pass before modifying any parameter in that pass This is only true for Level parameters within any given...

Page 27: ...l level If this function is turned ON with the control knob program downslope will begin exactly as Home position is actuated If starting from Home position this will be one 360 revolution then downsl...

Page 28: ...10 assuming no program number 10 exists The program will not be deleted from weld number 2 two copies of the program now exist When performing a Copy or Transfer to a destination program of the same n...

Page 29: ...d with sequencing through the weld program and simultaneous rotation of the weld head By using this function You can observe the rotation of the tungsten electrode while changing the various levels of...

Page 30: ...ation weld then press Copy For weld programs 100 and above indicate a program to be stored or presently stored on the stick When performing a copy or transfer to a destination program of the same numb...

Page 31: ...e been changed on the Maintenance Print Weld Files screen press Save Memory Internal memory Print Transfer files for printing to integrated printer or transfer to memory stick for printing using a PC...

Page 32: ...determine the optimum cut length for the tungsten electrode refer to this screen For 800 series weld heads tungsten electrode length is calculated based on tube OD 3 8 20 Advanced Help Advanced Help a...

Page 33: ...mperature 20 40 C 5 ORDERING INFORMATION The chart below shows the products and options required A complete orbital welding system requires an orbital controller a weld head of suitable size collets f...

Page 34: ...ng sharpening machine 6270001 Neutrix portable tungsten electrode sharpening machine 6270002 Auto grind tungsten electrode automated grinder 6270003 Purge plug kit 10 100 mm 6206009 Oxygen content met...

Page 35: ...5 0 531 34 5 34 0 33 5 15 9 0 625 33 3 32 8 32 3 16 0 0 630 33 3 32 7 32 2 17 2 0 677 32 7 32 1 31 6 18 0 0 709 32 3 31 7 31 2 19 0 0 748 31 8 31 2 30 7 19 1 0 750 31 8 31 2 30 7 20 0 0 787 31 3 30 7...

Page 36: ...42 8 21 3 0 839 43 2 42 7 42 2 22 0 0 866 42 9 42 3 41 8 23 0 0 906 42 4 41 8 41 3 Tube OD Tube OD electrode diameter 1 0 mm 1 6 mm 2 4 mm mm inch length mm length mm length mm 25 4 1 000 41 2 40 6 40...

Page 37: ...53 5 25 4 1 000 53 4 52 8 52 3 26 9 1 059 52 6 52 1 51 6 28 0 1 102 52 1 51 5 51 0 29 0 1 142 51 6 51 0 50 5 30 0 1 181 51 1 50 5 50 0 33 7 1 327 49 2 48 7 48 2 35 0 1 378 48 6 48 0 47 5 38 1 1 500 47...

Page 38: ...42 7 42 1 41 6 127 0 5 000 36 3 35 8 35 3 129 0 5 079 35 3 34 8 34 3 139 7 5 500 30 0 29 4 28 9 152 4 6 000 23 6 23 1 22 6 5 1 1 Collets When ordering collets it is important to specify the exact OD...

Page 39: ...OD inch Collet Extended Collet Flush Tube OD mm Collet Extended Collet Flush 0 250 1001238 0 250 1001240 0 250 6 0 1001242 6 1001244 6 0 375 1001238 0 375 1001240 0 375 8 0 1001242 8 1001244 8 0 402 1...

Page 40: ...53 1001252 53 54 0 1001250 54 1001252 54 60 3 1001250 60 3 1001252 60 3 70 0 1001250 70 1001252 70 76 1 1001250 76 1 1001252 76 1 Collet product codes for 15040 weld head Tube OD inch Collet Extended...

Page 41: ...5 500 18 0 1001266 85 1001268 85 6 000 1001262 6 000 1001264 6 000 19 0 1001266 104 1001268 104 20 0 1001266 108 1001268 108 22 0 1001266 127 1001268 127 23 0 1001266 129 1001268 129 5 1 2 Tungsten el...

Page 42: ...set gas flow rate Check that correct welding program is selected Check correct selection on the control panel Variable welding performance Check welding parameter settings 6 2 Tungsten electrode rotat...

Page 43: ...soon increase time at last level or use Start position to initiate downslope Concavity suck back or excessive penetration All ID locations Weld current too high Rotation speed too low Tubes not tight...

Page 44: ...are available with traceable calibration Contact the factory if necessary 7 2 Weld head maintenance 7 2 1 Calibrating the weld head The 150 series controller software allows users to calibrate the tra...

Page 45: ...irt and impurities in the weld head may cause internal arcing It is a situation where the arc jumps from the tungsten electrode to the collet frame and the welding arc fails to ignite 7 2 3 Internal a...

Page 46: ...r 7 4 Updating software The 150 series controller allows complete software upgrade via memory stick or thumb drive This software canbedownloadedfromtheKemppidatastoreasanemail attachment Please contac...

Page 47: ...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...

Page 48: ...And you know...

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