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A7 MIG Welder

A7 MIG Welder

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Содержание Kemppi A7 MIG Welder 350

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 65: ...And you know...

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