OPERATING MANUAL 1920390 1615 EN A7 TIG Orbital System 300
CONTENTS 1.1 1.2 1.3 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................. 4 3.2 General. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................. 4 About the product. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................. 5 Weld head.. . .. . . . . . .
Troubleshooting.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................................... 46 5.1 5.2 5.3 5.4 5.5 5.6 5.7 Operation problems.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................................... 46 Root-pass refinement for horizontal pipe (5G position)......................... 47 Common weld defects: identification and prevention........................... 48 Warnings/error messages . . . . . . . . . . . . .
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.
1.2 About the product With this method, it is easy to produce high-quality joints even with low-level knowledge of welding. A7 TIG Orbital System 300 consists of a controller unit, weld head, remote control, and interconnecting cables. The controller unit is a digital power source designed to be used with the 300-series of weld heads including a water cooler unit, internal memory, and a USB port for program transfer. The unit is operated by a remote pendant that contains all controls.
1.3.1 General specifications Axial clearance from the weld line to the rear of the machine is 21 6mm and from the weld line forward 10 mm. Travel Torch speed in the forward direction is adjustable from 0 to 250 mm/min. Wire The 300 series of weld heads has been designed to carry a 1 kg spool (100 mm) of 0.8 mm diameter welding wire with the feed rate adjustable from 0 to 2.54 m/min. Special spool is available to low profile applications. Torch and umbilical The water-cooled torch is rated at 200 amps.
1.4.1 Remote control A. R F B A C G D H E I J K L N O P Q All the functions of A7 TIG Orbital System 300 are accessible via one handheld device. The remote control includes an easy-to-use graphical user interface and clear colour display. You can create, modify and manage welding programs. Use adaptive auto programming for automatic calculation of welding parameters. You can fine-adjust welding values and electrode movements during welding.
The following -/+ perform multiple functions depending on the operating conditions: • During programming, these serve to directly input the desired parameter values. • During “Run Program” mode, these serve as JOG switches when no arc is present. • During welding, they serve as override switches for each function, within the pre-set limits of the % override screen. Current: decrease/increase welding current level in both programming and welding modes. J.
2. INSTALLATION 2.1 Controller connections A C B C E K B D G H I OPERATING MANUAL D A F J All controller connections are located on the rear of the controller unit: A. B. C. D. E. F. G. H. I. J. K.
2.2 Water cooler 2.2.1 Filling water cooler with coolant Cooling and heat-balancing requires that cooling water is pure. However, the degree of water purity as well as the temperature of the environment determine if you need to apply additives and/or otherwise take care of the water supply. You can fill the water tanks with normal tap water. 2.2.2 Operating the water flow The water flow switch has a factory pre-set trip point that is not adjustable.
2.3 Weld head set-up 2.3.1 Assemblies Machine package including: A. B. C. D. E. F. G. H.
If the pipe is either under or oversized, do one of the following: • Shorten the pads. • Use longer pads to maintain concentricity. • Substitute pads with alternate pads to allow a guide ring designed for a larger pipe size to be mounted concentrically on a smaller pipe size. Clamp the guide ring rigidly on the pipe using setscrew(s) on the other half of the ring. Guide rings for 8" and larger pipes are supplied as twopiece units that are bolted together by two recessed captive socket-head screws.
Roller chain and tensioner Roller chain and tensioner hold the 300-series weld head on the guide ring. Roller chain changes for each pipe size and is supplied as part of the guide ring kit with the link that improves the rigidity of the hinge. • The roller chain and tensioner assembly circles the guide ring reaching from the machine package to the tractor. • The latch/tensioner mechanism is located at the tractor end. • Rollers on the flexible chain minimize friction and facilitate motion around the pipe.
2.5 Mounting the weld head 1 4 6 5 2 4. 1. 2. 3. Place the weld head on top of the pipe. Aim the guide rollers over guide ring and leave the roller chain and tensioner hanging down to one side. Rock the machine lightly to ensure that drive sprocket is properly meshed with the chain. 5. 6. Hold the weld head in its position and pull the tensioner and latch assembly to the mating attachment. Check that all guide rollers and chain rollers are in place and the guide rollers are properly in place.
2.6 Wire spool 7 1 b 6 5 2 3 a Swing the wire spool mounting bracket away from the pipe to accommodate easy spool installation. 1. 2. Install the wire spool on the mounting bracket. a. Be sure to align anti-rotation pin in the sleeve with the slot in the nylon nut. b. Tighten the knurled knob to prevent accidental unwinding. Swing the mounting bracket back to its original position. 3. 4. Push the wire through the guide tube and insert into groove on the lower feed roll.
2.7 Electrode Almost all welding can be done with the tungsten electrode ground to a 30° included angle. The tungsten electrode should have a 0.15 mm flat to avoid tungsten "spitting". The greater the included angle of the tungsten, the greater the penetration capability. Changing the included angle also affects weld bead width. Oscillation width needs to be changed accordingly. See recommended tungsten electrode geometry. 0.1 mm 30° inc. both ends 0.15 mm 1. 2. 3.
1. 2. 3. 4. 5. 6. 7. 8. 2.9 Mechanical adjustments Centre torch weaving over the weld joint. a) Rotate the Cross-Seam Adjustment Encoder to the centre position. b) Ensure that the electrode is centered on the pipe joint. If necessary, loosen the clamp on the weaving shaft and move the torch and AGC mechanism to adjust the electrode position. Use Wire inch button to run the wire until its end is just beyond the electrode.
3. OPERATION 3.1 Welding settings 3.1.2 Pulsillation (synchronized pulsed current/ oscillation mode) 3.1.1 Setting current level Carbon steel 1.3 amps per .025 mm of material to penetrate. Stainless steel 1.0 amps per .025 mm of material to penetrate. High alloy steel 0.75 amps per .025 mm of material to penetrate. Above guidelines do not take into consideration filler wire addition, bevel geometry, or tungsten geometry.
3.1.5 Hot-pass procedure 3.1.4 Root-pass procedure Filler wire to tungsten electrode gap should be approximately 1.5 mm (rule of thumb is 2/3 the diameter of the electrode). When welding a "J" prep, the wire entry into the weld puddle is correct when it appears that the wire is standing still. Wire should feed smoothly into the front edge of the weld puddle. There should be no drip or drag of the wire. When welding a 37.5 degree bevel, the wire should push slightly into the work.
The choice of a torch oscillation (weave) or stringer bead technique is affected by a number of factors, as both techniques have positive and negative features.
3.1.7 Shield gas effects 3.2.1 Groove preparation 3.2.2 Joint design and fit-up tolerance 100 % argon is normally used for TIG welding. In certain cases it may be a good idea to use a mixed gas, such as 95 % argon and 5 % hydrogen. • Use mixed gas for better control of the weld puddle and lower heat input. • Add hydrogen or helium to increase the arc voltage and create a "stiffer" more focused arc column.
1. 2. 3. 4. Ensure that the tube ends (or fittings) are machined square-relative to their axis. The two ends are very tightly together. Ensure there is no gap between tube ends resulting from lack of squareness or burrs left from the machining process. Once the tube end is faced off, check for burrs. Carefully remove any burrs with a hand de-burring tool. If the tube wall thickness variation exceeds 10 %, create a 5° chamfer cut on the inside of the tube ends.
3.3 Controller unit menus When the controller unit is first turned on, the main display remains off except for backlighting. After approximately 12 seconds the model, S/N, software release date, and last calibration date appear on the display. The main menu options of A7 TIG Orbital System are Library, Help, Menu, and New.
3.3.1.2 Help Pre-Purge The A7 TIG Orbital System 300 contains a context-sensitive help that shows information and instructions about the screen and line currently selected. This view provides explanation or assistance on an item highlighted by the cursor. Upslope These screens will change with the start of each new level and pass according to the program used.
3.3.2 Maintenance Menu Copy Welds (power source internal memory) 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. The Copy function allows you to copy a weld program within the power source’s internal memory.
1. 2. 3. 4. 5. 6. 7. On the Maintenance Menu, select Print Welds. Select Weld To Print. Using the control knob, enter the weld number to print. 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.
3.3.3 Options Menu Setting the weld counter At completion of each weld, the system stores the actual parameters run and related weld ID number, operator name, and time and date to print out if necessary. The weld number sequentially increases by one digit per weld. You can set/reset the weld counter at any specific number using the control knob. Setting the password Press Enter. Password screen appears. Press Enter. An alphanumeric pop‐up field appears.
3.3.5 Calibrate head The 300-series TIG orbital controller can use a 300-series weld head. You can also use 150-series closed weld heads with an adapter cable. To calibrate the weld head, press Menu in the Main menu to enter the Maintenance menu. Once in the Calibrate Head menu, do the following: 1. 2. 3. 4. 5. 6. 7. 8. 9. Select the model of the weld head to be calibrated. Use Up/Down to navigate within the menu and Enter to make a selection.
3.3.6 300-head guide ring speed factors 2. Use torch rotation speeds of 6 to 9 cm/min for most welding applications. Select torch rotation speed as the first parameter. Carriage speed refers to the speed at which the weld head moves around the guide ring. The weld head rotates on the guide ring, not the pipe surface, and the tungsten electrode is extended inward to the pipe surface. 3. Actual tungsten electrode speed is slower than carriage speed.
3.3.8 Autotack 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. the weld head control cable is damaged or not connected). Advanced Help provides assistance for the operator as well as for a competent electric repair technician. Tack welding is useful when welding larger diameter tubes, for which Autotack automatically generates a tack-welding program. Select 4 or 8 equally spaced tacks.
Autoprogram for 300-series weld heads always uses position-based programming. Each pass is divided into six levels. Certain defaults are automatically selected (for example, Prepurge is always 5 seconds). To change these defaults, edit the weld program after it has been generated. To create a new program using Autoprogram: 1. Select Yes. (If password protection has been applied, you will be asked for your password to continue.
Weld Notes Use cursor to select line, control knob to modify. Completion of programming Certain items have been previously selected and cannot be changed (e.g. Weld No, Data, OD). The cursor will pass these items. Autoprogram for the 150-series weld heads operates similarly to the 300-series weld heads. The main difference is that programming is time-based and each program is created on 4 levels. Program Notes 1. 2. 3. 4. Use cursor to select the line for additional notes.
3.5 Manual programming Use the floating keyboard. The keyboard is accessible any time the currently highlighted line requires keyboard input; such as the Password Entry screen, the Program Notes screen, or any other text entry line. The left (shown as <<) and right (shown as >>) keys move the highlighted character to the left or right along the line. • To replace a letter, move the highlighted character (cursor) to the letter and use the control knob and Enter.
Pass Screen Select the functions to be used during this pass for all levels. This screen will appear before each new pass. • AGC Step: Arc gap control step function indexes operation with pulsed current. When off, the function is operational during both high and low pulse periods. When on, the function operates during high pulse and is disabled during low pulse time period. • LP Amps: low pulse current, shown as a percentage of high pulse current (peak).
Pass 1, level 1 Move the cursor and enter values with the control knob. • Amps: current at each level (using pulsed current, this is high pulse current). • Wire: Filler Wire Feed Rate (in IPM or CM per minute, function not available). • RPM: Rotation Speed • LP Amps: Low Pulse Amperage, shown as percentage of high pulse current. • HPT: High Pulse Time Period, in seconds. • LPT: Low Pulse Time Period, in seconds. • HP RPM: rotation speed on high current pulse (shown only when RPM STEP is turned ON).
• Auto Rewind: if “switched on” (by selecting Yes on the display), the weld head automatically rewinds at completion of a weld and comes to a halt at the starting rotational position. Post‐purge occurs simultaneously with auto rewind. • AGC Stop Delay: AGC operation normally turns off at the initiation of downslope. This feature delays the termination of AGC for an adjustable period (seconds) after downslope as been initiated. Move the cursor and enter values with the control knob. Press Next when complete.
3.6 Prepurge – Upslope 3.7 Programmed oscillation width (without striking an arc) a) Move the cursor and enter values with the control knob. Press Next when finished. • Prepurge: Time period gas flows at weld start before arc ignition (seconds). • Upslope: Time period in seconds that weld current ramps up from start amps value to level 1 value. • Travel Delay: Period (seconds) beginning at end of upslope before rotation begins. Used to establish penetration.
To select weld number to edit: 1. Move cursor to Edit. Press Select. 2. Edit weld parameters. Use cursor to select an item. Modify with the control knob. To add/remove a pass: To scale a weld: In Edit mode, proceed to the final pass/level. The next screen allows a pass to be added or removed anywhere in the program. Welds may be edited by scaling current or travel speed up/down by a percentage of programmed speed. This will scale programmed values in all passes and levels.
3.11 Welding 3.12 Travel speed correction Press Main to exit to Main Menu. Press Run to immediately weld with new program. Compared with the electrode tip, the weld head rotates further away from the pipe surface. This makes the actual rotation speed of the electrode tip slower than that of the weld head. • Correction factor = the weld head rotation diameter divided by the electrode tip rotation diameter Editing a weld program • Move cursor to Edit. Press Select. • Use the cursor to select an item.
3.13 Shielding gas 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. Use a higher purity grade for high quality welds on easily oxidizable alloys.
The purpose of purging is to replace unwanted air and other vapor contaminants from the root pass by a gas that prevents oxidation during welding. Oxidation can produce a variety of problems, such as root oxidation (sugar), incomplete fusion, porosity and changes in weld chemistry, which can affect weld mechanical and corrosion resistance properties adversely. Purging is recommended when welding stainless steel, nickel alloys, and most nonferrous base metals. Argon is commonly used. 1. 2. 3. 4. 5.
ADDITIONAL DETAILS 4.2 Weld head technical data 4.1 Controller technical data Property Value Property Value Mains connection voltage 230 VAC ± 10 % Application Multi-pass orbital GTAW pipe-to-pipe, pipe-to-fitting Fuse (delayed) 16 A Pipe outer diameter (OD) 25–355 mm (1 – 14”) Maximum output current 220 A @ 40 %, 170 A @ 100 % Cable length 7.6 m standard; extension cables available Weld heads 300 series Carriage clamping Ring for each pipe size Weight 33.
4.3 Ordering information Kemppi uses ceriated tungsten which increases electrode life, arc starting, and stability. We recommend this for orbital use. 2% ceriated involves no radiation risk. These tungsten electrodes are commonly marked in grey color. Product code Product name Product code 10 pcs. 1.0 mm diameter, 175 mm long 9873531 A7 TIG Orbital Controller 300 6204300 10 pcs. 1.6 mm diameter, 175 mm long 9873532 A7 TIG remote control (pendant) 6204301 10 pcs. 2.
Product code Guide ring kit ordering codes Extension cable kit, 300 series weld head, 15 m SP800689 Ordering code Item name Extension cable kit, 300 series weld head, 7.5 m SP800690 size [inch] Cable assembly, remote control, Ethernet, 15 m SP800691 1.750” 103854-1750 GUIDE RING KIT, 300 (44.5 MM) 1.900” 103854-1900 GUIDE RING KIT, 300 (48.3 MM) Double flow meter gas regulator SP800680 2.000” 103854-2000 GUIDE RING KIT, 300 (50.
Ordering code Item name 102222-012 GUIDE RING INSERTION KIT (0.30 MM) 102222-350 GUIDE RING INSERTION KIT (8.89 MM) 102222-781 GUIDE RING INSERTION KIT (19.84 MM) 102222-031 GUIDE RING INSERTION KIT (0.79 MM) 102222-359 GUIDE RING INSERTION KIT (9.12 MM) 102222-781-L GUIDE RING INSERTION KIT (19.84 MM) 102222-045 GUIDE RING INSERTION KIT (1.14 MM) 102222-375 GUIDE RING INSERTION KIT (9.53 MM) 102222-809 GUIDE RING INSERTION KIT (20.55 MM) 102222-050 GUIDE RING INSERTION KIT (1.
5. TROUBLESHOOTING 5.1 Operation problems Should you experience a malfunction from your machine, please consult the troubleshooting sections below first, and complete some basic checks. If the machine malfunction cannot be corrected with these measures, contact your Kemppi maintenance service workshop. 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.
5.2 Root-pass refinement for horizontal pipe (5G position) Problem Possible solution Excessive reinforcement from 2 o’clock to 11 o’clock • Increase wire speed 50 mm/min (2 inches/min) maximum increments at a time. • Increase travel speed 3 mm/min (0.125 inches/min) maximum increment at a time. • Decrease high pulse current if pulse technique is used alternately. • Decrease low pulse current (% of high pulse current) or increase low pulse time to 0.2 seconds maximum.
Problem Possible solution High frequency but no weld current Check for broken electrode or ground cable in the weld head, handle, or in the cable.
5.4 Warnings/error messages Certain internal and external problems will result in error messages and in some cases further actions. For example: • If you attempt to start a weld without the flow of shielding gas, pressing the start weld switch will result in an error message. The weld start sequence will be terminated. • If gas flow is interrupted during the weld sequence, welding will be terminated and the indicated error message will say: “Weld Aborted: Check Gas Supply”. Message during welding 1.
Comment: creating or editing weld program Comment: XXX or ### is the maximum speed allowed for the selected weld head. 11. Autotack Failure Wall thickness and OD must be greater than zero. 18. New Weld Creation 12. Autotack Failure Wall thickness must be less than pipe radius. 13. New Weld Creation Amperage must be less or equal to 200. AGC must be less than 15. Comment: If in AVC mode, message is ”AVC must be less than 20”. AGC must be greater than 1.
Comment: xxx/### is maximum OSC speed for the selected weld head. Comment: travel or wire calibration, code ECA02 for backup file 25. New Weld Creation 32. Program Failure Comment: xxx/### is maximum OSC speed for the selected weld head. Comment: teach mode, save weld. 26. Copying Weld Failure 33. Not applicable Weld on USB can’t copied to protection zone directly. 34. Operating Mode Change Fail Comment: user sets protection zone for the weld program. 27.
Comment: add and delete pass. Comment: wrong format weld program; old weld program Last pass cannot be deleted. 39. Weld Number xxx Pass Maintenance Error No more passes to add 45. Load failure Go to library, review and resave weld. Comment: because of old weld program. 40. File Exists, unable to copy 46. Load Failure Error, time out to get response ###e-4 Comment: copy weld program Comment: ### is a weld program number 41. File Copy Failed, file exists? 47. Load Failure Failure to send weld.
5.5 Checking machine setup during booting 1. Master RCM3209 Set Fail Master Rabbit is RCM3200 in controller; change and try again. 2. Master RCM3200 Set Fail Master Rabbit is RCM3209 in controller; change and try again. 3. Not applicable 5. Wrong S2 BEMF Driver board Remote configuration is BEMF & ENCODER; change and try again. 6. Wrong S2 BEMF Driver board Remote configuration is ENCODER; change and try again. 7.
5.6 Machine system messages 1. Disk full warning The space available on the disk is too small; download printed weld or QC file! 2. Update Failure Memory stick is not ready; check and update again. 3. Update Failure Wrong memory stick for the USB; check USB stick and update again. OPERATING MANUAL 5.7 Controller unit fault conditions Certain fault conditions will cause the arc to be immediately terminated or prevent arc strike during weld initiation.
6. 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. 6.2 Periodic maintenance 6.1 Preventing tungsten electrode rotation not concentric to tube OD Periodic maintenance should only be carried out by a suitably qualified person.
6.3 Weld head maintenance Consult the factory if any apparent internal machine package problem develops. While field maintenance, such as motor replacement, is possible with standard hand tools, some complex sequences, techniques, and adjustments may require specific procedures. Contact Kemppi to provide rapid turn-around service for all equipment. 6.3.1 External maintenance The roller chain uses sealed, permanently lubricated roller bearings, and no lubrication is required.
6.3.6 Maintenance of torch components • Flush the radiator-type water cooler used with this system periodically. • Use algaecide to prevent growth occurring in the tank (in areas, where this is found problematic). You can usually remove a blockage by reversing the inlet and outlet fittings of the torch cable and flushing the torch cable. The normal flow rate of water through a new torch cable is 0.6 l/min.
6.3.8 Internal arcing Clean 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.
6.5 Service Workshop maintenance The printer is mounted in the front panel of the controller unit allowing program parameters and other data to be printed. The printouts will remain stable for five (5) years, and they are suitable for archival purposes if they are suitably stored. This printer uses Thermal Paper SP800692. Kemppi Service Workshops complete maintenance according to their Kemppi service agreement. 6.4.1 Installing paper in the printer To install paper in the printer, do the following: 1. 2.
7. 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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