OPERATING MANUAL 1920860 1826 EN A3 A7 MIG Welder
CONTENTS Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................. 3 1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................. 3 2. 3. Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................. 4 System Overview. . .
1. INTRODUCTION 1.1 General This operating manual contains important information on the use, maintenance and safety of your Kemppi product. The technical specifications of the equipment can be found at the end of the manual. Please read the manual carefully before using the equipment for the first time. For your own safety and that of your working environment, pay attention to the safety instructions in the manual.
2. INSTALLATION The product is packed in specially designed transport cartons. However, always make sure the products have not been damaged during transportation prior to this. Product packaging material is recyclable. Detailed installation instructions and the technical information that is out of the scope of this manual are found in the A3 MIG Welder Integration guide. Operating environment Positioning the machines The machines included in the system are suitable for both indoor and outdoor use.
3. SYSTEM OVERVIEW A3 MIG Welder system 3.1 Power Source A3 MIG Welder is a welding system for welding automation that includes all welding devices needed in robot welding. A3 MIG Power Source 400 2 3 A3 Power Source 400 2 1 12 3 11 4 5 6 10 4 Figure 3.1 A3 MIG Welder system 1. Power Source 2. Wire feeder 3. MIG torch 4. Interconnection cable set 7 8 Figure 3.2 Power source, front and rear 1. Control panel 2. Main switch 3. Main power indicator light (ON/OFF) 4. Overheating indicator 5.
3.2 Control panel The control panel is used for controlling and monitoring the operation of the power source and the wire feeder. The buttons and knobs are used for adjusting functions. The displays and indicators reflect the operating modes of the machine. 1 3 OPERATING MANUAL 2 9 4 5 6 7 8 Figure 3.4 Control panel layout 1. Miscellaneous functions 2. Displays 3. System and welding setup 4. Synergic program selection 5. Welding process selection 6. Welding program setup 7. Memory channel setup 8.
3.3 DIP switches By default, all DIP switches are OFF. P1 ON P2 ON Panel P1 – DeviceNet configuration 1-2 Baud rate 125-500 kbps 3-8 Mac ID 0-63 Panel P2 – System configuration 1-2 Touch sensor voltage 50-200 V 3 Safety stop OFF/ON 4 Collision sensor OFF/ON 5 Collision sensor switch type OPENING/CLOSING 6 Byte order LITTLE-ENDIAN/BIG-ENDIAN 7 Watchdog OFF/ON 8 (Reserved) (Reserved) Figure 3.
3.4 Wire feeder A3 Wire Feeder 25, Power connector 1 2 4 5 7 7 4 3 5 3 6 Figure 4.10 Wire feeder with PowerPin connector, front and rear 1. Peripheral connector 2. Wire inch button 3. Gas outlet 4. PowerPin connector with welding cable joint 5. Wire feeder control cable connector 6. Wire liner connector 7. Gas inlet Figure 4.9 Wire feeder with Euro connector, front and rear 1. Peripheral connector 2. Wire inch button 3. Euro connector 4. Wire feeder control cable connector 5.
Threading the wire and adjusting tightness © Kemppi Oy 2018 9 OPERATING MANUAL When changing the welding wire, the pressure arms need to be released. Ensure that the groove of the feed rolls matches the diameter of filler wire used. Release the wire end and cut off any deformed section before pulling it out from the wire feeder. Straighten about 20 cm of the new filler wire and ensure the tip has no sharp edges.
DuraTorque™ 400, 4-wheel wire feed mechanism accessories Wire guide tubes Fe, Mc, Fc metal outlet tube middle tube inlet tube 0.6 SP007437 SP007429 SP007293 0.8 – 0.9 SP007438 SP007430 SP007294 1.0 SP007439 SP007431 SP007295 1.2 SP007440 SP007432 SP007296 1.4 SP007441 SP007433 SP007297 1.6 SP007442 SP007434 SP007298 2.0 SP007443 SP007435 SP007299 2.4 SP007444 SP007436 SP007300 0.8 – 0.9 SP007454 SP007465 SP007536 1.0 SP007455 SP007466 SP007537 1.
USING THE WELDER 4.2 Control panel 4.1 Basic controls 1 Main switch When you turn the on/off switch to position 1, the main power indicator is illuminated, and the welding system starts a power-up sequence. The system is ready for use when the control panel is ready. Always turn the machine on and off with the power source mains switch. Never use the mains plug as a switch.
Control knobs 1 and 2 The two displays of the control panel show adjustable operation parameters, their values, and the units of measure. During welding, display (1) shows the welding current value that is being used, while display (2) shows the welding voltage. The displays can show the following symbols. The left-hand control knob (1) allows the adjustment of the speed of wire feeding. The selected speed is shown on the display (1) on the left-hand side. Use values 1...
Selecting the welding process When you press the Wire inch button (4), the wire feeder engine starts feeding. The gas valve does not open, and the power source is not activated. The wire feed pace is 2 m/min for the first two seconds, and then 10 m/min. When the button is released, the wire feeding stops. The machine automatically goes back to the normal state after approximately 3 seconds from release of the button or immediately when you press the ESC button.
4.3 Standard MIG features The standard A3 MIG Welder delivery includes three MIG features that facilitate welding and improve weld quality. These features are creep start, hot start and crater fill. Crater fill (CrL) To use a MIG feature, press the feature selector button 8. Press the selector button repeatedly to use one or several features. Only the features allowed for the welding method you have chosen will be available.
4.4 Optional MIG features To use the optional features, enter a machine-specific activation code in the machine's control panel as shown below. To acquire an activation code, contact a Kemppi representative. If the code entry failed, the control panel display will show an error code. For more information on error codes, see "Troubleshooting". Activating optional features The operating instructions for optional features can be found in the documentation supplied with the feature. 1.
4.5 Memory channels Use the control panel memory channels to store welding parameters you use into the machine's memory for easy use later without the need to readjust all parameters. The control panel has 90 memory channels, numbered 0...89. If you want to change the welding parameters stored in a welding channel, go to the SET mode by pressing the MEMORY button. Now select the parameters you want and store them by pressing SAVE. Storing welding parameters in memory 1. Press the MEMORY button (9) twice.
4.6 Synergic 1-MIG, WiseThin, and WiseRoot welding The WiseThin and WiseRoot processes (advanced auto arc) are synergic welding processes developed for the special needs of robotic welding with welding characteristics optimised particularly for welding automation. Selecting a welding program 1. 2. 3. 4. 5.
1-MIG, Al group Program number Wire, mm Material Shielding gas Program number Wire, mm Material Shielding gas 201 0.8 SS-316 Ar+2%CO₂ 303 1.0 Al-5356 Ar 202 0.9 SS-316 Ar+2%CO₂ 304 1.2 Al-5356 Ar 203 1.0 SS-316 Ar+2%CO₂ 306 1.6 Al-5356 Ar 204 1.2 SS-316 Ar+2%CO₂ 313 1.0 AL-4043 Ar 206 1.6 SS-316 Ar+2%CO₂ 314 1.2 Al-4043 Ar 211 0.8 SS-316 Ar+30%He+1%O₂ 316 1.6 Al-4043 Ar 212 0.9 SS-316 Ar+30%He+1%O₂ 213 1.0 SS-316 Ar+30%He+1%O₂ 214 1.
WiseRoot, Fe group Program number Wire, mm Material Shielding gas Program number Wire, mm Material Shielding gas 701 0.8 Fe Ar+18%-25%CO₂ 802 0.9 Fe Ar+18%-25%CO₂ 702 0.9 Fe Ar+18%-25%CO₂ 803 1.0 Fe Ar+18%-25%CO₂ 703 1.0 Fe Ar+18%-25%CO₂ 804 1.2 Fe Ar+18%-25%CO₂ 704 1.2 Fe Ar+18%-25%CO₂ 812 0.9 Fe CO₂ 711 0.8 Fe CO₂ 813 1.0 Fe CO₂ 712 0.9 Fe CO₂ 814 1.2 Fe CO₂ 713 1.0 Fe CO₂ 714 1.
Quick setup To set the values of the functional parameters for MIG features, use the QUICK SETUP feature, which you can activate by briefly pressing the SETUP button (5). Select the parameter to adjust using the left-hand side control knob or the button (8) and then set the parameter value with the right-hand side control knob. The value you specified is instantly stored in the control panel memory. The following tables list the parameter values that can be specified for the MIG features.
Parameter Display Value range Factory setting Description Pre-gas time PrG 0.0 ... 9.9 s 0.0 s Pre-gas time in seconds Post gas time PoG 0.1 ... 9.9 s, aut (Aut) Aut Post gas time in seconds or automatically according to the welding current (Aut). Creep start level Cre 10 ... 170 % 50 % Percentage of wire feed speed: 10%-99% = slow start 100% = no creep start 101%-170% = accelerated start. Start power sta -9 … +9 0 Strength of start pulse Post current time PoC -9 ...
WiseRoot and WiseThin parameters Display Value range Factory setting Description Synergic start time fst -9 … 9 0 Start time in WiseRoot/WiseThin welding. Synergic start voltage ful -30 … 30 0 Voltage level in the beginning of the WiseRoot/WiseThin welding. OPERATING MANUAL Parameter WiseFusion parameters Parameter Display Value range Factory setting Description WiseFusion on fus off (Off ), on (On) na (N/A) Off Switch WiseFusion on/off (only in synergic processes). N/A = no license.
4.8 Touch sensor (seam search) The touch sensor is a specific functional system used in automated welding for finding workpiece’s accurate location and position. The touch sensor hardware and I/O are in the welding power source. A welding robot finds the edges of the workpiece by touching them either with a welding wire or a gas nozzle. Touches are detected by the touch sensor and the information is passed on to the robot controller.
The touch sensor device behaves as a software controllable power source. The power source can be switched on and off from the robot controller by using the digital robot interface. The touch sensor cannot be used when the welding cycle is on. Voltage source, levels and safety The touch sensor provides four selectable DC voltage levels. The voltage level can be configured by using the DIP switches 1 and 2 on the panel (2).
4.9 Collision sensor The collision sensor is a module mounted between a robot arm and a welding torch. It protects the torch neck from bending and breaking on a collision to an obstacle. The collision detection is usually based on micro switches or optical switches which act on the collision. The detection is passed to the robot that uses it to stop motion immediately to prevent any damage.
5. TROUBLESHOOTING The problems listed, and the possible causes are not definitive, but serve to suggest some standard and typical situations that may present during normal environmental use when using the MIG/MAG process with the A3 MIG Welder.
Code Description Measures 2 UNDERVOLTAGE Undervoltage in the mains supply (phase missing) Check the fuses. 3 OVERVOLTAGE Lengthy overvoltage in the mains supply. 4 OVERHEAT 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. Do not switch off the power source. Let the fans cool down the device. 101 NO WELDING PROGRAM Internal program error.
OPERATION DISTURBANCES Should you experience a malfunction from your machine, please consult the basic troubleshooting text above first, and complete some basic checks. If the machine malfunction cannot be corrected with these measures, contact your Kemppi maintenance service workshop. Operation of the overload protection Yellow thermal protection lamp is lit when the thermostat is operating, due to loading beyond the stated duty cycle.
7. MAINTENANCE When considering and planning routine maintenance, please consider the frequency of machine use and the working environment. Correct operation of the machine and regular maintenance will help you avoid unnecessary downtime and equipment failure. 7.1 Daily maintenance 7.2 Periodic maintenance Check the overall condition of the welding gun. Remove welding spatter from the contact tip and clean the gas nozzle. Replace worn or damaged parts. Only use original Kemppi spare parts. 7.
8. DISPOSAL 9.
10. TECHNICAL DATA A3 Power source 400 Power supply A3 Wire Feeder Supply voltage 3~ 50/60 Hz 400 V, -15 % … +20 % Operating voltage (safety voltage) Mains connection cable H07RN-F 4G6 (5 m) Rated power Maximum supply current 23 A Effective supply current 21 A Load capacity Fuse 35 A delayed Efficiency (100 % duty cycle) 87 % Power factor (at max. current) 0.9 Minimum short circuit power Ssc of supply network 4.
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