OPERATING MANUAL 1920370 1615 EN A5 TIG Orbital System 75
CONTENTS 1.1 1.2 1.3 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................. 3 3.5.7 Calibrating weld power source current output ........................................... 17 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................. 3 About the product. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 operating manual and the safety instructions booklet carefully before using the equipment for the first time. For your own safety and that of your working environment, pay particular attention to the safety instructions in the manual.
OPERATING MANUAL 1.2 About the product TIG orbital welding is a semi-automatic welding method where the arc moves automatically and without interruption 360° around tubes or fitting components. Its pulse technology produces consistently high-quality welding seam. With this method, it is easy to produce high-quality joints even with low-level knowledge of welding. A5 TIG Orbital System 75 consists of a weld head, a controller unit, and an external TIG power source.
1.3 Weld head A B C D 15080 15030 15040 15060 Weight (kg) 3.2 5.0 6.4 8.2 10.0 Tube Diameter (mm) 3–25 6–51 9–75 12–102 50–152.4 A (mm) 124 175 202 231 297 B (mm) 62 83 96 110 144 C (mm) 43 43 43 43 43 D (mm) 19 19 19 19 19 W009315 15010 The weld head contains a U-shaped rotor gear that moves the tungsten electrode orbiting the non-moving tube. The head totally encloses the weld joint and allows the interior of the head to be flooded with shielding gas.
1.3.3 Collet frame and collets The collets mount in the weld head and are used to clamp the head on to the tube or fittings to be welded. • The collet frame swings open on a hinge and is held closed using two latches on 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 first clamped tube before it is clamped.
1.3.5 Extended collets / combination Figure: A pair of flush collets Figure: A pair of extended collets Figure: A combination of collets The outer surface of the collet pair is flush with the outer face of the collet frame. Flush collets are used for joints where there is very little straight length between the joint and an obstruction. Extended collet is thicker than flush collet, and it extends wider from the collet frame.
1.5 TIG power source 1.6 Tube preparation A5 TIG Orbital System 75 uses an external TIG power source. This allows using the same power source for tack welds. For successful autogenous welding, ensure that the tube ends (or fittings) are machined square relative to their axes. The two ends are butt tightly together. With Kemppi Master MLS 2300 AC/DC power source, Microtack® function allows easy and fast tacking.
2. INSTALLATION 2.1 Connecting the weld head G B 6 C D A - D. All connections are located on the controller unit: A. B. C. E Connect the weld head’s control cable to the connector marked with the weld head symbol. Connect the weld head’s gas hose to the Gas Out connector. Connect the hose from gas cylinder to the Gas In connector E. F. G. Connect the weld head current cables to the positive (red) and negative (black) connector.
2.3 Mounting the weld head The collets are designed to clamp firmly on the outside diameter (OD) of the tubing or fittings to be welded. The interior diameter (ID) of standard collets is oversize relative to the tube to be welded by .075 mm to allow for standard dimensional tolerances. The collet halves that make a pair are identical. They are engraved to show the tube OD or tube fitting ODs and type. 1. 2.
3. OPERATION 3.2 Tungsten electrode 3.1 Rotor gear ø 1.0 /1.6 / 2.4 mm You can use multiple tungsten electrode sizes in each weld head by changing the tungsten electrode holder. Tungsten electrodes and tungsten electrode holders are available in the following sizes: • 1.0 mm • 1.6 mm • 2.4 mm 20 – 30° Weld head contains a rotor gear that drives the electrode around the tube. Rotor gear is U-shaped to allow easy placement of the weld head on and off the tube.
3.2.3 Tungsten electrode geometry guidelines To install the tungsten electrode and holder, do the following: Tungsten electrode diameter Arc gap Use the smallest diameter 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. Recommended Tungsten electrode diameters for different tube wall thicknesses.
NEUTRIX OPERATING MANUAL 3.3 Electrode sharpeners Ultima – TIG – cut Use sharpener to sharpen the electrodes, to cut them to correct length, and to help gather and recycle welding dust. Desktop model (recommended) allows more precise lengths. It recycles dust into liquid instead of air. You can also use a hand-held model. You can also use a hand-held model. Only sharpening is possible with the hand-held model, not accurately cutting to length.
3.4 Weld head control panel 3.5 Controller unit control panel A 3.5.1 Quick guide to start welding 1 3 A C 0 1 5 W009315 D A. B. C. D. Stop: immediately terminate the weld cycle and all functions of the weld head. Start Weld: initiate the weld program. LED light beside the button is lit during the weld cycle. This is also a soft way to stop welding. Home position: welding can be started only when the rotor gear is in its home position.
3.5.2 Main/Home screen 3.5.3 Initial setup screen 3.5.4 Program storage (Library) OPERATING MANUAL A The A5 TIG Orbital System 75 controller unit stores the last ten (10) programs that have been created. These ten programs can be called up by using the Tool Box. in 1. 2. 3. 4. 5. 6. 7. 8. 9. Tube outer diameter Tube wall thickness Amperage corrections/fine tuning Tool box Gas purge Power supply Weld head Electrode length Weld head temperature 2 1 mm 1. 2. A in Press the toolbox icon.
Selected welding programs show on the top right corner of the screen. If a program is modified (for example, Program 2), it can run in modified state without changing the stored Program 2. As soon as the power is turned off, it stores the screen parameters and overwrites the original Program 2. When the same program is loaded from the memory (after unsaved modifications), the original saved program is restored.
3.5.7 Calibrating weld power source current output Calibration is used to correct manufacturing variations between different power sources. 1. 2. 3. On the Home screen, select a program or create a new program by entering correct tube O.D. and wall thickness. Go to Tool Box, and press Calibration. Press Amperage Calibration. The following screen appears. Arc ignites and welding occurs during calibration. The following screen indicates the time that the arc is on.
3.5.9 Pulsed/non-pulsed welding Select Pulsed/Non-Pulsed welding. Pulsed Current Non-Pulsed Current These alternate at each push of the button. If an error occurred during calibration, an error screen of below type appears. 7. Exit the screen by pressing Check Mark and repeat the sequence. 3.5.8 Selecting power source 1. 2. 3. Press the power source icon. Select your power source from the list. After pressing the power source icon the correct control panel setting is displayed on the screen.
3.5.10 Gas purge Gas purge fills the weld head with backing gas. Connect the gas hoses. Switch on the controller unit. Press Purge on the main menu. After purging, the purge icon turns green. The system is now ready for welding. OPERATING MANUAL 1. 2. 3. 4. 5. When using backing gas, make a branch to the gas hose after controller gas output. Then adjust the gas flow to both branches to the desired value (backing ca. 2–5 l/min and weld head 5–10 l/min).
3.5.11 Preparing welding – test weld 2. 3. Power On: Turn on the power of the power supply and the controller. Weld Head: Clamp the weld head on the workpiece Purging the Head: Purge the gas hose and chamber of the weld head by pressing the icon on the power supply. The icon changes from black to green when gas is flowing. Purge the weld head and gas line for approximately ten (10) minutes prior to the start of welding per shift. 4. Purge the tube ID in preparation for welding.
3.5.12 Icons and screens during welding A 1 3 2 4 1. Pre-purge Press Start Weld on the weld head to initiate the weld sequence. Purging of gas inlet hose and weld head with argon occur for a preprogrammed time in seconds. Remaining time is displayed. 2. Arc ignition and weld progress The electrode does not start to rotate immediately following arc ignition. This delay allows the arc to penetrate to the tube I.D. The delay time is determined by the tube wall thickness dimension.
3.7 Updating software To stop weld head and controller operation at any time: To check for software revisions: 1. 2. Press the Stop button on the weld head control panel, or Press the large red EQUIPMENT STOP button on the controller unit. This is a locking switch that disconnects power from the controller. The control circuits remain powered. 1. 2. Check the version displayed on the splash screen by pressing the Kemppi logo in the upper left corner of the Home screen.
ADDITIONAL DETAILS 4.2 Ordering information 4.1 Technical data Property Value Product name Product code Input power 90 – 240 VAC, 1A Product name Product code Welding positions all A5 TIG Orbital Controller 75 6204075 Auto-stop yes Weld head 7530 & 7540 Power source: MinarcTig EVO 200 Pipe outer diameter (O.D.) 9.5 – 101.6 mm See MinarcTig information External dimensions 330 x 420 x 170 mm Power source MasterTig MLS 2300 AC/DC See MasterTig information Weight 6.
4.2.2 Collets When ordering collets, it is important to specify the exact OD dimension of the tube or fitting. Because of the wide range of fitting manufacturers, it is necessary to specify the fitting manufacturer and type. If possible, include data sheet or drawing defining the specification for the fitting in the order. When ordering collets, it is important to specify the exact OD dimension of the tube or fitting.
Collet product codes for 7540 weld head Tube OD (inch) Collet, Extended Collet, Flush Tube OD (mm) Collet, Extended Collet, Flush Tube OD (inch) Collet, Extended Collet, Flush Tube OD (mm) Collet, Extended Collet, Flush 0.375 1001246-0.375 1001248-0.375 10 1001250-10 1001252-10 0.500 1001254-0.500 1001256-0.500 12.0 1001258-12 1001260-12 0.402 1001246-0.402 1001248-0.402 12.0 1001250-12 1001252-12 0.625 1001254-0.625 1001256-0.625 13.0 1001258-13 1001260-13 0.
4.2.3 Tungsten electrode material and ordering information Kemppi uses ceriated tungsten to increase electrode life, arc starting, and stability, and recommends this material for orbital use. 2% ceriated = no radiation risk OPERATING MANUAL These tungsten electrodes are commonly marked in grey color. Tungsten electrodes can be pre-cut and sharpened to certain lengths with Tungsten electrode sharpening and cutting devices.
Electrode lengths for different tube OD, 7530 weld head Electrode lengths for different tube OD, 7530 weld head... Tube OD [mm] Tube OD [inch] 9.5 0.375 10.0 electrode diameter 1.0 mm 1.6 mm 2.4 mm Tube OD [mm] Tube OD [inch] 1.0 mm 1.6 mm 2.4 mm length [mm] length [mm] length [mm] 49.1 48.5 48.0 41.0 1.614 length [mm] length [mm] length [mm] 33.4 32.8 32.3 0.394 48.9 48.3 47.8 42.4 1.669 32.7 32.1 31.6 10.2 0.402 12.0 0.472 48.8 48.2 47.7 47.9 47.3 46.8 44.
Electrode lengths for different tube OD, 7540 weld head Electrode lengths for different tube OD, 7540 weld head... Tube OD [mm] Tube OD [inch] 12.0 0.472 12.7 electrode diameter 1.0 mm 1.6 mm 2.4 mm Tube OD [mm] Tube OD [inch] 1.0 mm 1.6 mm 2.4 mm length [mm] length [mm] length [mm] 60.1 59.5 59.0 48.3 1.902 length [mm] length [mm] length [mm] 41.9 41.4 40.9 0.500 59.7 59.2 58,7 50.8 2.000 40.7 40.1 39.6 13.0 0.512 13.5 0.531 59.6 59.0 58.5 59.3 58.8 58.3 51.
5. TROUBLESHOOTING Should you experience a malfunction from your machine, please consult the troubleshooting sections below first, and complete some basic checks. Problem: Check the following: Machine won’t work • • • • • Check that mains plug is connected correctly. Check that mains power distribution is switched on. Check the mains fuse and or circuit breaker. Check that power source 0/I switch is ON.
5.2 Warnings and error messages Acknowledge program’s warning and error screens by pressing the Confirm button or by correcting the problem. Explanation Pipe wall thickness is incorrect with respect to selected tube OD (For example, wall thickness is greater than the tube OD). No gas, or gas flow is too low. This warning only appears when a program has been started. Power and work cables reversed. Arc outage. Arc failed to initiate at start of weld sequence or extinguished prior to weld completion.
5.3 Common weld defects Weld head too hot. The temperature limit of the head has been reached. Possible cause: duty cycle too high. Let head cool between welds, or install a water cooler. Problem Possible solution Excessive weld oxidation (blue color) or porosity • • • • • Melt-through during welding • Wall thickness less than programmed. Correct. • Tube ends not in tight contact during welding. Use tube-squaring tool. Completed weld not straight • Tube ends not square. Use tube-squaring tool. 6.
7. DISPOSAL Check at least every half year: Do not use compressed air for cleaning as there is a risk that the dirt will compact even more tightly into gaps of cooling profiles. Do not use pressure washing devices. Only an authorized trained electrician should carry out repairs to Kemppi machines. 6.
And you know.
