OPERATING MANUAL 1920380 1615 EN A7 TIG Orbital System 150
CONTENTS 1.1 1.2 1.3 1.4 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................. 4 3.7 3.8 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................. 4 About the product. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................. 5 Weld head.. . .. . .
6. Troubleshooting.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................................... 42 6.1 6.2 Operation problems.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................................... 42 Tungsten electrode rotation not concentric to tube O.D... ..................... 42 7. Maintenance.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...............................................
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.
A7 TIG Orbital System 150 is used for TIG orbital welding. It is a semi-automatic welding method where the arc moves automatically and without interruption 360° around tubes or fitting components. The system consists of a weld head and a controller unit. The controller unit includes an integrated TIG power source and a cooling unit. The system offers a wide operating range and good reach and is suitable for • tube-to-tube • tube-angle • tube-to-fitting welding.
1.3 Weld head A B C D 15020 15030 15040 15060 Weight (kg) 3.2 5.0 6.4 8.2 10.0 Tube Diameter (mm) 3–25 6–51 9–76 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.
1.4 Controller unit 1.4.1 Front panel 1.4.3 Water cooler The water flow function is factory calibrated. Interruption or insufficient water flow (less than 0.5 LPM) results in termination of welding and a warning message on the display. A7 TIG Orbital System 150 power source and cooling unit are integrated inside the controller unit. This unit also involves a printer to print welding parameters on paper. The parameters can be saved on a memory stick through the USB port.
INSTALLATION 2.2 Connecting the weld head 2.1 Controller unit connectors A A B E B C D C E F G All connections are located on the rear of the controller unit: A. B. C. D. E. F. G. F D Power ON/OFF Resettable fuses TRVL = Travel motor, (WIRE = Wire feed motor, not available) Weld head control cable Gas Out (to weld head) Gas In (from cylinder) Welding power connector ( – ) Earth return connector ( + ) All connections are located on the rear of the controller unit. Do the following: A. B. C. D.
2.4 Mounting the weld head The collets are designed to clamp firmly on the outside diameter (OD) of the tube 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 OD and type. 1. 2.
3. OPERATION 3.2 Tungsten electrode 3.1 Rotor gear 3.2.1 Diameter and length ø 1.0 /1.6 / 2.4 mm Order the tungsten electrodes or cut them to a precise length by yourself. When the tungsten is inserted into the holder and bottomed, it will create the desired tip-towork distance without the need for adjustment. 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 Geometry guidelines To install the tungsten electrode and holder, do the following: 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. The tungsten electrode tip-to-work distance, the arc length is kept to a minimum and produces a more stable arc and deeper penetration.
Ultima – TIG – cut 3.4 Filling water cooler with coolant NEUTRIX 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. Only sharpening is possible with the hand-held model, not accurately cutting to length.
1. 2. 3. 4. 5. Turn the power supply ON. Clamp the weld head on the workpiece. Purge the gas hose and chamber of the weld head using the purge button on the power supply. Purge the weld head and gas line for approximately ten (10) minutes prior to the start of welding each shift. Purge the tube ID in preparation for welding with backing gas. Load the appropriate weld program number as described in the power supply manual. The red LED on the handle next to the Home position ignites.
3.6 Instructions for welding 3.5.2 Shielding and backing gas Use the following 5-step procedure to start welding: 100% argon is normally used for TIG welding. In certain cases, you can benefit from using a mixed gas, such as 95% argon, 5% hydrogen. This mixed gas gives better control of the weld puddle and lower heat input. Adding hydrogen or helium increases the arc voltage and creates a "stiffer", more focused arc column. Industrial grade inert gas is sufficient for most stainless steel welds.
3.7 Weld head control panel 3.8 Controller unit control panel A E B F B H D A G C I A. D B. W009315 C. 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. It also allows easy installation and removal of the workpiece. 1.
When the control is first turned on the main display will remain off except for backlighting. After approximately 12 seconds the model, S/N, software release date, and last calibration date appear on the display. 3.8.2 Main screen/Menu Four soft keys on the main screen allow access to: 1. 2. 3. 4. Library of existing procedures Help with detailed explanation of highlighted item Menu that provides access to various functions and system configuration New to create a new weld program.
2. Press Start Weld to initiate weld or press Purge to pull in gas solenoid if you want to use a longer purge time. (For example, to purge gas lines when first connecting the weld head to the power source.) 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 item is highlighted in red.
3.8.3 Using Auto program Use cursor to select line and the control knob to modify Next Weld to Run. You have two choices: 1. 2. 1. 2. 1. 2. 3. 4. 5. Select Yes with the control knob. Press Next. If Password Protection has been applied, you will be asked for your password to continue. Select Weld Number using the control knob. Press Next when finished. Use Back to move to previous screen. 3. 4. Repeat the weld program.
3.8.5 Program information You may override any of the pre-programmed values, but only within the limits defined during programming. The percentage of override limits can be individually programmed for each parameter between 0–100% of the programmed value. You can gain sufficient override capacity to compensate for tube fit variations, for example, but avoid to modify the original program outside of specified heat input limitations.
The edited weld will overwrite the original program if the same weld number is selected. To create a new program, select an unused program number. 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. © Kemppi Oy 2016 22 A7 TIG Orbital System 150 OPERATING MANUAL Editing a weld program Move cursor to edit. Press Select (soft key).
3.8.7 Manual programming Entering text Using the floating keyboard The keyboard is accessible when a highlighted line requires keyboard input; such as in the Password Entry or Program Notes screen or on any other text entry line. Use the cursor to select the item to be labeled. 1. 2. 3. Press Enter on a text entry line to display the floating keyboard. Use the control knob to select a character. Press Enter to insert selected on the line.
2. 3. 4. 3.8.9 RPM Step You can select pulsed or non-pulsed current. Move the cursor and use the control knob to change selections. Pulsing varies the current between high and low values. RPM Step can be turned on/off. This function indexes tungsten electrode rotation with pulsed current. Tungsten electrode will rotate during low current pulse and stop on high current pulse (or be set to run at a percentage of low current speed). Press Next.
3.8.11 Pass level screens Move the cursor and enter values with the control knob. Press Next when finished. • Pre-purge: the time period when gas flows at weld start before arc ignition (seconds). • Upslope: the time period in seconds that the weld current ramps up from start amps value to level 1 value. • Travel Delay: the period (seconds) beginning at end of upslope before rotation begins. Used to establish penetration. • Start Amps: current level at which arc is initiated.
Pass 1, Level 3 to Final Level Continue moving through the screens for each level and change parameters as needed OPERATING MANUAL Example You wish to change the amperage originally programmed in Level 4 of a one pass weld. However, other parameter changes occur in a subsequent level, such as level 5 or 6. If you make the change in amperage in Level 4 and press Next, you will automatically copy all of the Program Level 4 values into Level 5.
3.8.13 Override Limit function Downslope Screen: move the cursor and enter values with the control knob. Press Next when complete. Downslope Delay: downslope of weld current will occur immediately at the tie‐in of the start location. If you want an overlap of the weld, set the desired seconds of Downslope Delay. Downslope: downslope or current taper time period in seconds. Pulsing Downslope: choice of pulse current or steady state current during downslope period (Yes or No).
3.8.15 Options Menu In the Main Menu screen, press Menu. This will open the Maintenance Menu screen. Most functions are passwordprotected if this option is selected. You may want copy an existing weld program as a starting point for creating a new weld program for a different tube size using the editing feature. 1. 2. In the Maintenance Menu screen, select Copy Welds and press Enter. Enter the program numbers for source weld and destination weld, then press Copy.
Entering operator’s name Enter operator’s name using the technique described in section Alphanumeric labeling. Setting date and time Press Enter to select the Date/Time field and set date and time. Setting the language Use the control knob to scroll through the alternatives. Using the test mode If you need to use the test mode, use the control knob to select Yes. This mode allows simulation of an actual weld with sequencing through the weld program and simultaneous rotation of the weld head.
3.8.17 Deleting welds (*These are the actual weld programs, not print files. They are special file types formatted for the welding control system, not human-readable files.) The Delete function is used to remove unwanted programs from memory. 1. 2. To transfer a weld program from internal memory to a memory stick or vice versa, place the stick in the USB port on the front of the power source.
3.8.18 Printing welds 1. 2. 3. 6. 7. Select Print or Store File. Use the control knob to select: Memory, Printer, or Both. Select Short Form (parameters only) or Long Form (parameters, as well as all procedure information and notes). To save the settings that have been changed on the Maintenance / Print Weld Files screen, press Save. On the Maintenance Menu, select Print Welds. 3.8.20.
5. If no stick is installed or it has not yet finished initializing, an error message displays. Press Dnload to download all stored print files to the stick. 3.8.20 Advanced Help To 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. Advanced Help allows you to diagnose problems which may result from an external situation (e.g. an empty gas bottle) or an internal situation (e.g.
ADDITIONAL DETAILS 5. 4.1 Technical data 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 for the weld head (extended or flush) and cut-to-length tungsten electrodes. There are several additional pieces of equipment available as listed below to complete a productive orbital welding environment.
Product ordering codes: Product code A5 TIG Orbital Controller 150 6204150 Electrode lengths for different tube OD, 15010 weld head Electrode diameter Tube OD Tube OD 1.0 mm 1.6 mm 2.4 mm 15010 Orbital weld head 6206002 mm inch length [mm] length [mm] length [mm] 15020 Orbital weld head 6206003 3.17 0.125 26.4 25.8 25.3 15030 Orbital weld head 6206004 6 0.236 25.0 24.4 23.9 15040 Orbital weld head 6206005 6.35 0.250 24.8 24.2 23.7 15060 Orbital weld head 6206006 8 0.
Electrode lengths for different tube OD, 15020 weld head Tube OD Electrode diameter 1.0 mm 1.6 mm 2.4 mm mm inch length [mm] length [mm] length [mm] 6.0 0.236 38.3 37.7 37.2 35.0 1.378 23.8 23.2 22.7 6.4 0.250 38.1 37.6 37.1 38.1 1.500 22.2 21.7 21.2 8.0 0.315 37.3 36.7 36.2 40.0 1.575 21.3 20.7 20.2 9.5 0.375 36.5 36.0 35.5 41.0 1.614 20.8 20.2 19.7 10.0 0.394 36.3 35.7 35.2 42.4 1.669 20.1 19.5 19.0 10.2 0.402 36.2 35.6 35.1 44.5 1.752 19.
Electrode lengths for different tube OD, 15030 weld head Tube OD Tube OD Electrode diameter 1.0 mm 1.6 mm 2.4 mm Tube OD electrode diameter 1.0 mm 1.6 mm 2.4 mm mm inch length [mm] length [mm] length [mm] mm inch length [mm] length [mm] length [mm] 9.5 0.375 49.1 48.5 48.0 25.4 1.000 41.2 40.6 40.1 1.059 40.4 39.9 39.4 10.0 0.394 48.9 48.3 47.8 26.9 10.2 0.402 48.8 48.2 47.7 28.0 1.102 39.9 39.3 38.8 12.0 0.472 47.9 47.3 46.8 29.0 1.142 39.4 38.8 38.
Electrode lengths for different tube OD, 15040 weld head Tube OD electrode diameter Tube OD 1.0 mm 1.6 mm 2.4 mm Tube OD electrode diameter 1.0 mm 1.6 mm 2.4 mm mm inch length [mm] length [mm] length [mm] mm inch length [mm] length [mm] length [mm] 12.0 0.472 60.1 59.5 59.0 48.3 1.902 41.9 41.4 40.9 12.7 0.500 59.7 59.2 58.7 50.8 2.000 40.7 40.1 39.6 13.0 0.512 59.6 59.0 58.5 51.0 2.008 40.6 40.0 39.5 13.5 0.531 59.3 58.8 58.3 52.0 2.047 40.1 39.
5.1.1 Collets Tube OD Tube OD electrode diameter 1.0 mm 1.6 mm 2.4 mm mm inch length [mm] length [mm] length [mm] 50.8 2.000 74.4 73.9 73.4 51.0 2.008 74.3 73.8 73.3 52.0 2.047 73.8 73.3 72.8 53.0 2.087 73.3 72.8 72.3 54.0 2.126 72.8 72.3 71.8 60.3 2.374 69.7 69.1 68.6 63.5 2.500 68.1 67.5 67.0 70.0 2.756 64.8 64.3 63.8 76.1 2.996 61.8 61.2 60.7 76.2 3.000 61.7 61.2 60.7 85.0 3.346 57.3 56.8 56.3 88.9 3.500 55.4 54.8 54.3 101.6 4.
Collet product codes for 15020 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 0.125 1001227-0.125 1001232-0.125 6.0 1001234-6 1001236-6 0.250 1001238-0.250 1001240-0.250 6.0 1001242-6 1001244-6 0.250 1001227-0.25 1001232-0.25 8.0 1001234-8 1001236-8 0.375 1001238-0.375 1001240-0.375 8.0 1001242-8 1001244-8 0.375 1001227-0.
Collet product codes for 15030 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.
5.1.2 Tungsten electrode material 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.
TROUBLESHOOTING 6.1 Operation problems 6.2 Tungsten electrode rotation not concentric to tube O.D. Should you experience a malfunction from your machine, please consult the troubleshooting sections below first, and complete some basic checks. The tungsten electrode should maintain an equal gap ±0.1mm (±0.005") Total Indicated Runout (T.I.R.) as it rotates around the workpiece. Variations of arc gap outside this tolerance will cause inconsistent penetration and weld bead width.
Problem Possible solution Arcing within the weld head (see Maintenance section) Contaminated eroded or improper length tungsten electrode. • Improperly cleaned tube surface or poor contact between collets and tube may cause arcing between tube/pipe collets. • Metal debris on the inside surface of the weld head. • Arc-starting amperage too low. High frequency but no Check for broken electrode or ground cable in the weld head, handle, weld current or in the cable.
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. Disconnect the machine from the mains before handling the electrical cables. 7.1 Periodic maintenance Periodic maintenance should only be carried out by a suitably qualified person.
7.2.3 Internal arcing Clean the weld head periodically to maintain maximum operating efficiency. Keep the unit free of moisture, debris, and other contaminants (oil, water, abrasives, etc.) that can affect normal operation and weld consistency. • Clean insulating components with a soft brush and a fast drying solvent, such as acetone or denatured alcohol. • Clean drive gear assemblies using a fine wire brush and solvent.
7.4 Updating software The printer is mounted in the front panel of the control unit to print program parameters and other data. The printouts remain stable for five (5) years, and they can be archived if suitably stored. This printer uses Thermal Paper P/N SP800692. The 150 series controller allows complete software upgrade via memory stick or thumb‐drive. This software can be downloaded from the Kemppi datastore as an email attachment. Please contact Kemppi’s service department for upgrade information.
8. DISPOSAL Do not dispose of electrical equipment with normal waste! OPERATING MANUAL In observance of European Directive 2002/96/EC on waste electrical and electronic equipment, and its implementation in 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.
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