Kemppi Kemppi A7 MIG Welder 350 Page 1 Operating Manual Download

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A7 MIG Welder

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Summary of Contents for Kemppi A7 MIG Welder 350

Page 1: ...350 450 1920300 1735 A7 MIG Welder A7 MIG Welder EN OPERATING MANUAL...

Page 2: ...ge PIN 34 4 3 9 Settings Fieldbus 35 4 3 10Settings Network 35 4 3 11Settings Backup restore and reset 36 4 3 12Settings Licenses 36 4 4 User identification 37 4 4 1 Overview 37 4 4 2 Turning user ide...

Page 3: ...problems 54 5 2 Error codes 55 5 2 1 Power source errors 55 5 2 2 Cooling unit errors 56 5 2 3 Wire feeder errors 57 5 2 4 Welding curve errors 57 5 2 5 Robot interface errors 58 5 2 6 I O device erro...

Page 4: ...in order to minimize damage and harm are indicated by the symbols below Read these sections carefully and follow their instructions Note Gives the user a useful piece of information Caution Describes...

Page 5: ...ironment The machines included in the system are suitable for both indoor and outdoor use Always make sure that the air flow to the machine is unrestricted The recommended operating temperature range...

Page 6: ...5 6 3 4 Figure 3 2 Power source front and rear 1 Setup panel 2 Main switch 3 Main power indicator light ON OFF 4 Overheating indicator 5 Welding cable connection negative pole 6 Welding cable connecti...

Page 7: ...Gate door switch input 7 Wire feeder control cable connection The robot interface unit on top of the power source handles the communication with a robot and contains all necessary connections to integ...

Page 8: ...Web user interface for details 3 3 User interfaces The A7 MIG Welder system has two integrated user interfaces with system setup and control capability a setup panel and a web user interface The web...

Page 9: ...nsparent lid 7 Wire feeder control cable connection 8 Compressed air inlet 9 Shielding gas inlet 10 Arc measurement cable connector for the power source 11 Arc measurement cable connector for the work...

Page 10: ...3 9 Interconnection cable set A Measurement cable B Cooling hose red incoming from gun C Cooling hose blue outgoing to gun D Shielding gas hose E Welding cable F Control cable The cooling hoses B and...

Page 11: ...lding using inert gases MIG or active gases MAG This model is water cooled and can be used in all welding positions Robot mounts The A7 MIG Gun 500 w and 500 g are mounted to the welding robot using s...

Page 12: ...7 MIG Gun 500 w Operation manual 3 6 Cooling unit A7 Cooler 1 3 2 5 4 6 7 Figure 3 15 Cooling unit 1 Test switch 2 Filling hole in the side plate 3 Overheat control indicator 4 Power supply cable 5 Co...

Page 13: ...evice that can be used to control external devices such as a torch cleaning station It is capable of driving 24 V logic signals relays and valves and reading logic states switches and digital sensors...

Page 14: ...itched on When the orange warning indicator light is on the machine is overheated This is due to a higher than regular working load exceeding the rated duty cycle The cooling fan continues to cool the...

Page 15: ...ntry button Enter the main menu by pressing this button Up down arrows Navigate in the menus up and down by pressing these buttons Control knob Adjust values and settings of menu parameters by turning...

Page 16: ...enu item Value range Description Select channel Edit channel 0 199 Select which memory channel to edit create or delete The text below the selection shows whether the channel is empty or not New chann...

Page 17: ...rs Select welding parameters like wire feed speed and fine tuning The list of the available welding parameters depends on the selected welding process 3 6 Welding functions Select welding functions li...

Page 18: ...nd higher value to rougher arc These are system limits Actual limits come from the selected welding curve Welding parameters for 1 MIG process Edit channel 2 6 Menu item Value range Default value Desc...

Page 19: ...ing curve Welding parameters for Double Pulse MIG process Edit channel 2 6 Menu item Value range Default value Description 1 10 WFSpeed WFS min WFS max From curve Set the wire feed speed in 0 05 m min...

Page 20: ...mits Actual limits come from the selected welding curve Welding parameters for WiseThin process Edit channel 2 6 Menu item Value range Default value Description 1 7 WFSpeed WFS min WFS max From curve...

Page 21: ...ll 7 10 CraterTime 0 0 10 0 s 1 0 s Set the crater fill slope time 8 10 Creep start 10 99 OFF CURVE CURVE Set the creep start off adjust the creep start level or select the value of the welding curve...

Page 22: ...ssing OK soft button See section 4 4 User identification for more information 4 2 5 Welding system settings System config menu Main menu 4 8 Menu item Value range Factory value Description 1 20 Water...

Page 23: ...gas time 0 0 9 9 s CURVE CURVE Override the post gas time of the welding curve or let the system use the curve value 12 20 Control USER PANEL REMOTE GUN USER Select which remote control is used or let...

Page 24: ...of the subfeeder for arc voltage calculation 21 21 Gas sensor menu Enabled ON OFF OFF Set gas sensor unit on and off Level 5 0 20 0 l min 10 0 l min Set gas flow detection level Gas mixture menu Ar 0...

Page 25: ...d The filler wire is driven backwards by accelerating to the selected speed The test is stopped when the button is released Speed 0 5 25 0 m min 5 0 m min Set the wire feed speed in 0 05 m min steps f...

Page 26: ...losing Opening Select the type of the electrical switch used in the signal line The opening type switch opens the electrical circuit of the signal line and the closing type switch closes the circuit 7...

Page 27: ...ctness of the gas flow measurement 11 12 Gun menu Configure the welding torch connected to the A7 MIG Wire Feeder Gun type 0 Normal 1 Binzel MasterPull 2 Binzel WHPP 3 Binzel WHPPi 4 Dinse MEP 200E 0...

Page 28: ...to show and hide the side bar The menu items are shown according to the access level of the current user See Section 4 4 User identification for more information Current user User logout Clicking the...

Page 29: ...ending on the process the fine tuning voltage dynamics pulse current double pulse amplitude and double pulse frequency values during welding Saving the changes will affect the arc behavior immediately...

Page 30: ...ng memory channels A memory channel contains configuration of the welding process program parameters and functions There are up to 200 memory channels available in the system To create a new memory ch...

Page 31: ...program Forsomeprocesses there are several available welding programs The drop down list of the welding programs can be filtered to make the selection easier by using material group wire wire diameter...

Page 32: ...ater fill step level Crater fill end level and Crater fill time by using the sliders select Creep start option CURVE or SET VALUE and set Creep start level by using the sliders select Start power leve...

Page 33: ...NOZZLE or SELECT AT ROBOT by clicking on the buttons select Fast output polarity LOW ACTIVE or HIGH ACTIVE by clicking on the buttons In the Collision sensor settings menu you can select Collision sen...

Page 34: ...t User identification ON and OFF by clicking on the buttons change Role for a user by clicking the orange arrow and clicking on the WELDER SUPERVISOR or ADMINISTRATOR button create a new user by typin...

Page 35: ...formation Accessing this view requires administrator or service supervisor rights Changing the fieldbus settings affects the communication between the welder system and the robot 4 3 10 Settings Netwo...

Page 36: ...Network options the desired items to restore and then press the Restore button reset all welding system settings and memory channels by clicking on the Factory reset button clear the logbook by clicki...

Page 37: ...ther users The user identification system requires at least one existing administrator level user account in order to work correctly The system prevents deleting or changing an administrator user acco...

Page 38: ...ss the User settings menu Go to the User activation and select a user number from the USER1 USER10 until the text Disabled appears under the username This means that the particular user account is not...

Page 39: ...press the Set button to save the settings Web user interface Go to the Settings Users page The user identification system must be turned on to access user settings Press the orange arrow to left of t...

Page 40: ...anel The setup panel displays User logged off text when no user is logged in To log in press the F2 button select a user provide a valid PIN code and press OK You are now logged in To log out press F2...

Page 41: ...connected to a welding minus The positive pole of the sensor is connected either to a welding plus or a gas nozzle The target for the positive pole can be changed by a user A relay in the touch sensor...

Page 42: ...bus Digital robot interface 6 Arc measurement cables 7 Peripheral connector 8 Touch tool welding wire or gas nozzle 9 Touch detection 10 Welding minus touch sensor ground On Off control The touch sens...

Page 43: ...ool and when the arc measurement cables are connected The measurement system does not influence touch sensing when the gas nozzle is used as the touch tool The touch sensing is influenced when the arc...

Page 44: ...used as touching tool 4 5 3 Fast status output The fast status output is a direct hardware output for systems where the latency between the sensing and the detection status reception is an issue The...

Page 45: ...ead see Figure 4 23 Weaving the welding head during TAST and measuring the arc length The seam tracking provides precise welds in setups where the workpiece position within repetitive tasks varies or...

Page 46: ...he Error 53 Collision detected in the welding system When the error occurs the power source stops welding immediately Fieldbus 1 3 5 4 2 Figure 4 25 Collision sensing system 1 Collision sensor 2 Field...

Page 47: ...e by turning the control knob on the Switch type parameter Press the Save button to save the settings Web user interface Go to the Welding settings Welding system Collision sensor settings and select...

Page 48: ...question If the button is pressed the light flashes three times to indicate a prohibited function The indicated function is not carried out A light is on The indicated function is available All lights...

Page 49: ...e guide tube ensuring that the mounting direction is correct the arrow on the bottom of the middle wire guide tube indicates wire s direction of travel towards the torch 6 Mount the lower feed rolls e...

Page 50: ...SP011451 108 SP007276 33 1 6 SP011452 108 SP007275 33 2 0 SP011453 108 SP007274 33 2 4 SP011454 108 SP007273 33 GT04 T Dinse plastic Al Ss Fe Mc Fc 0 8 0 9 SP011443 112 SP007279 33 1 0 SP011445 112 SP...

Page 51: ...57 W001058 1 2 W001059 W001060 1 4 1 6 W001061 W001062 2 0 W001063 W001064 2 4 W001065 W001066 Al Fc Mc Ss Fe U groove 1 0 W001067 W001068 1 2 W001069 W001070 1 6 W001071 W001072 Table 4 23 Metal wire...

Page 52: ...easurement setup and calibration refer to the A7 MIG Welder Integration guide 4 9 2 Display The arc voltage current and power can be displayed in the setup panel and in the web user interface The setu...

Page 53: ...means of manual control or during welding The indication is reported 3 seconds after the gas valve has been opened The status is monitored in the welding display of the web user interface and is pass...

Page 54: ...heck shielding gas supply Check and set gas flow rate Check gas type for application Check gun electrode polarity Check correct welding program selected Check correct channel number selected on wire f...

Page 55: ...ERHEAT ALARM The overheat detector of the power source has gone off during welding Welding has continued for too long without interruption or the ambient temperature is too high Minor error Do not swi...

Page 56: ...d MMA TIG power source whose pole is connected to the weld piece is connected to the MIG MAG power source outputs at the same time as MIG MAG is used or the arc fed power source is defective Serious e...

Page 57: ...e an optional accessory welding program or a specific setting for welding that has not been activated using a license code Error Acquire a license for the optional function you want from the device pr...

Page 58: ...s card slot or the contact is defective The system can be used normally but log entries cannot be recorded Warning Check that the microSD memory chip is correctly connected 136 THE LOGBOOK MEMORY CARD...

Page 59: ...he A7 MIG Welder Integration guide for more information on the input configuration 202 INPUT 2 ERROR Input 2 reported an error Error 203 INPUT 3 ERROR Input 3 reported an error Error 204 INPUT 4 ERROR...

Page 60: ...the machine provides protection for auxiliary devices Use the same type and rating of fuse as marked beside the fuse adapter Damage caused by incorrect fuse selection is not covered by the guarantee...

Page 61: ...mains socket and wait about 2 minutes capacitor charge before removing the cover plate Check at least every half year the electric connectors of the machine clean any oxidized parts and tighten loose...

Page 62: ...air cooled 6260460 ROBOT 70 10 WH CABLE SHOE Interconnection cable set 10 meters water cooled 6260480 ROBOT 70 20 GH CABLE SHOE Interconnection cable set 20 meters air cooled 6260481 ROBOT 70 20 WH CA...

Page 63: ...sions LxWxH 610 x 240 x 520 mm 610 x 240 x 520 mm Weight no mains connection cable 40 2 kg 40 2 kg Weight with mains connection cable 42 6 kg 42 6 kg Degree of protection IP23S IP23S Efficiency 100 du...

Page 64: ...IP44 Storage temperature range 40 C 60 C EMC class A Input voltage rating 24 V DC Input current rating 100 mA Output voltage rating 24 V DC Output current rating 100 mA Operating voltage safety voltag...

Page 65: ...And you know...

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