Page 1
1920860
1826
A7 MIG WelderA3 MIG Welder
EN
OPERATING MANUAL
Page 2
2
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
CONTENTS
1. Introduction ..........................................................................................3
1.1 General ......................................................................................................3
2. Installation .............................................................................................4
3. System Overview ................................................................................5
3.1 Power Source .............................................................................................5
3.2 Control panel .............................................................................................6
3.3 DIP switches ..............................................................................................7
3.4 Wire feeder ................................................................................................8
4. Using the welder ...............................................................................11
4.1 Basic controls ...........................................................................................11
4.2 Control panel ...........................................................................................11
4.3 Standard MIG features ............................................................................14
4.4 Optional MIG features .............................................................................15
4.5 Memory channels ....................................................................................16
4.6 Synergic 1-MIG, WiseThin, and WiseRoot welding .................................17
4.7 Welding and system setup ......................................................................20
4.8 Touch sensor (seam search) ....................................................................23
4.9 Collision sensor .......................................................................................25
5. Troubleshooting ................................................................................26
5.1 Typical problems .....................................................................................26
5.2 Error codes ...............................................................................................27
6. Operation disturbances ..................................................................28
7. Maintenance .......................................................................................29
7.1 Daily maintenance ..................................................................................29
7.2 Periodic maintenance .............................................................................29
7.3 Service Workshop maintenance .............................................................29
8. Disposal ................................................................................................30
9. Ordering numbers ............................................................................30
10. Technical data ....................................................................................31
Page 3
3
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
1. INTRODUCTION
1.1 General
Congratulations on choosing the A3 MIG Welder system.
When used correctly, Kemppi products can signicantly
increase the productivity of your welding and provide
years of economical service.
This operating manual contains important information
on the use, maintenance and safety of your Kemppi product. The technical specications of the equipment can be
found at the end of the manual.
Please read the manual carefully before using the equipment for the rst time. For your own safety and that of
your working environment, pay attention to the safety
instructions in the manual.
For more information on Kemppi products, contact
Kemppi Oy, consult an authorized Kemppi dealer, or visit
the Kemppi web site at www.kemppi.com.
The specications presented in this manual are subject to
change without prior notice.
Important notes
Items in the manual that require attention 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 a situation that may result in
damage to the equipment or system.
Warning: Describes a potentially dangerous situation.
If not avoided, it will result in personal damage or fatal
injury.
Disclaimer
While every eort has been made to ensure that the information contained in this guide is accurate and complete,
no liability can be accepted for any errors or omissions.
Kemppi reserves the right to change the specication of
the product described at any time without prior notice.
Do not copy, record, reproduce or transmit the contents
of this guide without prior permission from Kemppi.
Page 4
4
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING 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.
When moving the welding machine, never pull it
from the welding gun or other cables. For lifting the power
source, use the handles on top of the power source.
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
The machines included in the system are suitable for both
indoor and outdoor use. Always make sure that the air
ow to the machine is unrestricted. The recommended
operating temperature range is -20…+40°C.
Positioning the machines
Place the machine on a sturdy, level surface that is dry
and will not allow dust or other impurities to enter the
machine´s cooling air ow. Preferably, situate the machine in a suitable carriage unit so it is above oor level.
• The surface inclination may not exceed
15 degrees.
• Ensure the free circulation of the cooling air.
There must be at least 20 cm of free space in
front of and behind the machine for cooling-air
circulation.
• Protect the machine against heavy rain and
direct sunshine.
Do not operate the machine in the rain.
Never aim the spray of sparks from a grinding
machine toward the equipment.
Page 5
5
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
3. SYSTEM OVERVIEW
A3 MIG Welder system
A3 MIG Welder is a welding system for welding automation that includes all welding devices needed in robot
welding.
2
3
4
A3 Power Source 400
1
Figure 3.1 A3 MIG Welder system
1. Power Source
2. Wire feeder
3. MIG torch
4. Interconnection cable set
3.1 Power Source
A3 MIG Power Source 400
1
12
10
11
9
2
7
6
5
8
3
4
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. System conguration DIP switches
6. Control cable connection
7. Welding cable connection, negative pole ( – )
8. Welding cable connection, positive pole ( + ),
front and rear
9. DeviceNet and safety stop connection
10. Wire feeder connection
11. Fuse (6.3 A, delayed)
12. Mains power cable
The A3 Power Source 400 is designed for demanding professional use. The power
source is suitable for MIG/MAG, 1-MIG, WiseRoot and WiseThin processes. It supports also WiseFusion function. The Wise processes and functions are optional and
can be activated by licenses.
Page 6
6
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
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 reect the operating modes of the machine.
1
765 8
4
3
9
2
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. Robot control indicator
9. Control knobs
Page 7
7
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
3.3 DIP switches
The A3 Power Source comprises two DIP switch panels
on the right side of the power source. The switches can
be accessed through a hole in the cover plate. The hole is
covered by a rubber plug. The rst panel (P1) congures
DeviceNet baud rate and Mac ID. The second panel (P2)
congures the touch sensor, safety stop, collision sensor,
eldbus byte order, and watchdog.
By default, all DIP switches are OFF.
ON
1 2 3 4 5 6 7 8
P1
ON
1 2 3 4 5 6 7 8
P2
Figure 3.5 DIP switches in the power source
Panel P1 – DeviceNet conguration
1-2 Baud rate 125-500 kbps
3-8 Mac ID 0-63
Panel P2 – System conguration
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 3.6: Quick guide for DIP switch conguration
3 4 5 6 7 8 Mac ID
OFF OFF OFF OFF OFF OFF 0
OFF OFF OFF OFF OFF ON 1
OFF OFF OFF OFF ON OFF 2
OFF OFF OFF OFF ON ON 3
...
ON ON ON ON OFF OFF 60
ON ON ON ON OFF ON 61
ON ON ON ON ON OF 62
ON ON ON ON ON ON 63
1 2 Baud rate
OFF OFF 125 kbps
OFF OFF 250 kbps
ON OFF 500 kbps
ON ON (Reserved)
1 2 Voltage
OFF OFF 50 V
OFF ON 80 V
ON OFF 110 V
ON ON 200 V
Page 8
8
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
3.4 Wire feeder
A3 Wire Feeder 25, Euro connector
1 2
3
7
4
5 6
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. Wire liner connector
6. Welding cable connector
7. Gas inlet
A3 Wire Feeder 25, Power connector
1 2
3
4
5
6
7
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
Page 9
9
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
Threading the wire and adjusting tightness
When changing the welding wire, the pressure arms need to be released. Ensure that the
groove of the feed rolls matches the diameter of ller wire used. Release the wire end
and cut o any deformed section before pulling it out from the wire feeder. Straighten
about 20 cm of the new ller wire and ensure the tip has no sharp edges. File if necessary,
as a sharp wire edge may damage the wire gun liner – particularly softer plastic liners.
Present the ller wire tip to the back of the wire feed rolls and press the wire inch button
on the wire feed front panel. Feed the wire to the gun contact tip and prepare to weld.
Page 10
10
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
Wire feed rolls, metal
ø mm lower upper
Fe, Ss,
(Al, Mc, Fc)
V-groove
0.8 – 0.9 W006074 W006075
1.0 W006076 W006077
1.2 W004754 W004753
1.4 W006078 W006079
Fc, Mc, (Fe)
V-groove, knurled
1.0 W006080 W006081
1.2 W006082 W006083
1.4 – 1.6 W006084 W006085
2.0 W006086 W006087
Al, (Fc, Mc, Ss, Fe)
U-groove
1.0 W006088 W006089
1.2 W006090 W006091
1.6 W006092 W006093
Mount the lower feed roll, ensuring that the pin on the shaft ts in the cut on the
feed roll.
DuraTorque™ 400, 4-wheel wire feed mechanism accessories
Wire guide tubes
ø mm outlet tube middle tube inlet tube
Ss, Al,
(Fe, Mc, Fc)
plastic
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
Fe, Mc, Fc
metal
0.8 –
0.9
SP007454 SP007465 SP007536
1.0 SP007455 SP007466 SP007537
1.2 SP007456 SP007467 SP007538
1.4 –
1.6
SP007458 SP007469 SP007539
2.0 SP007459 SP007470 SP007540
2.4 SP007460 SP007471 SP007541
Page 11
11
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
4. USING THE WELDER
4.1 Basic controls
Main switch
When you turn the on/o 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 o with the power source mains switch. Never use
the mains plug as a switch.
Indicator lights
The indicator lights of the machine report its operational
state: When the green main power indicator is on, it indicates that the machine is switched 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 machine down. When the light goes o the machine
is ready to weld again.
Cooling fans
The A3 Power Source incorporates two simultaneously
operating cooling fans. The fans will start during welding as the machine reaches operational temperature, and
they will run for 1 to 10 minutes after welding, depending
on the heat eect of the completed cycle.
4.2 Control panel
31 2 4
9 10 1187
6
5
1
2
21
Figure 4.1 Control panel buttons, displays and knobs
1. Left display
2. Right display
1. Left selection/adjustment k nob
2. Right selection/adjustment knob
1. Escape/Back button
2. Dynamics button
3. Gas test button
4. Wire inch button
5. System setup button
6. Synergic program selection button
7. Welding process selection button
8. Synergic feature setup button
9. Memor y channel edit mode selection
button
10. Memory channel selection button
11. Memory channel save button
Page 12
12
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
Displays 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.
Symbol Character Symbol Character
a
A
s
S
b
B
t
T
c
C
u
U
d
D
v
V
e
E
w
W
f
F
x
X
g
G
y
Y
h
H
z
Z
i
I
1
1
j
J
2
2
k
K
3
3
l
L
4
4
m
M
5
5
n
N
6
6
o
O
7
7
p
P
8
8
q
Q
9
9
r
R
0
0
Control knobs 1 and 2
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.
The right-hand side control knob (2) allows for controlling the welding voltage in MIG and 1-MIG processes, in
which case the selected voltage is shown on the righthand side display (2).
These control knobs are also used for specifying the operating parameters. A parameter for adjustment is selected
with the left-hand knob, while the value of the parameter
is selected with the right-hand knob.
Adjusting MIG dynamics (Arc Force)
When you press button (2), you can adjust the MIG welding dynamics of the machine by means of the knob (2).
When using the MIG or 1-MIG welding process, the welding dynamics setting aects the features of the welding
arc and the amount of welding spatter as shown below:
The value 0 is the recommended basic setting.
Use values -1...-9 if you want a softer arc and less spatter.
Use values 1...9 if you want a rougher and more stable
arc. This setting is useful when you are using 100% CO
shielding gas when welding steel.
Gas test
The gas test button (3) opens the gas valve without activating the wire feed or power source. By default, gas ows
for 20 seconds. The remaining gas ow time is shown on
the display.
The right-hand knob allows you to set the default gas
ow time, between 10 and 60 seconds, and store the new
default value in the machine’s memory. To stop the gas
test, press the ESC button (1).
Page 13
13
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
Wire feed test
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 rst 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.
Retrieving weld data
The weld data function allows you to return to the welding current and voltage used during the previous session,
with the weld data feature. To use the feature, press buttons 3 and 4 simultaneously.
Selecting the welding process
The welding process selection button (7) allows you to select the welding process you want to use. You can select
one of the following processes:
• regular MIG welding
• 1-MIG welding
• WiseThin & WiseRoot (optional)
In regular MIG welding, the wire feed speed and welding voltage are adjusted separately. Unlike the above,
the 1-MIG, WiseThin and WiseRoot processes are synergic
welding processes where the welding voltage and other
welding parameters are interconnected so that the welding power and arc length are adjusted to attain optimal
welding values.
The WiseThin and WiseRoot processes are optional
features intended for welding automation. They must
be acquired separately by licenses and are therefore not
available in all congurations.
Page 14
14
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
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 ll.
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.
Creep start (CrE)
The purpose of the creep start feature is to make controlled weld start easier and smoothen the initial stage of
welding, for example when welding with high wire feed
speeds. At the beginning, the machine will use a slow
wire feed speed until the wire touches the work piece and
the current starts owing.
Creep start is available for both the regular MIG welding
and the synergic 1-MIG welding.
Hot start (Hot)
The purpose of hot start is to reduce start faults, for example when welding aluminium or other materials with
particularly good thermal conductivity. In this scenario,
there is a xed pre-gas time at the beginning of the welding, after which the welding power briey rises above the
specied power level. The power and time parameters for
hot start can be specied in the SETUP settings.
Hot start is available for synergic 1-MIG welding.
Crater ll (CrL)
Welding Level
Crater Fill Start Level
Crater Fill Time
Crater Fill End Level
Figure 4.2 Crater ll
The purpose of crater ll is to facilitate controlled nishing of welding and to reduce the welding faults caused
by the nal crater. When you press the welding gun trigger completely down at the end of welding, the welding
power is reduced to a pre-set crater ll level. To end the
crater ll stage, release the gun trigger. The crater ll parameters can be specied in the SETUP settings.
Crater ll is available for synergic 1-MIG welding.
Page 15
15
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
4.4 Optional MIG features
In addition to the standard MIG features, it is also possible to acquire optional features
that further enhance the welding.
To use the optional features, enter a machine-specic ac tivation code in the machine's
control panel as shown below. To acquire an activation code, contact a Kemppi representative.
Activating optional features
1. Press and hold down the SETUP button (5) for at least 5 seconds. The
SETUP settings menu appears on the display.
2.
Select the Cod (cod) alternative with the left-hand side control knob
in the control panel and then select the value Ent (ent) using the
right-hand side control knob.
3. Briey press the SAVE button (11).
4. When the display on the left-hand side reads 1 (1), enter the rst value
of the activation code using the right-hand side control knob. The value
you have entered is shown in the right-hand side display.
5. Select the entry of the next value using the left-hand side control knob.
6. Enter the value corresponding to the value shown in the left-hand side
display using the right-hand side control knob.
7. Repeat steps 5 and 6 until you have entered all values of the activation
code.
8. Finally, press the SAVE button (11) briey.
The control panel will read Suc cEs (success) to indicate that the activation code
has been entered correctly and the optional feature is available. You can exit the code
entry mode at any time by briey pressing ESC.
If the code entry failed, the control panel display will show an error code. For more
information on error codes, see "Troubleshooting".
The operating instructions for optional features can be found in the documentation
supplied with the feature.
Page 16
16
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
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.
You can store the welding parameters you use, i.e., the wire feed speed and the welding
voltage. You can also store MIG feature settings, such as creep start or crater ll settings.
Storing welding parameters in memory
1. Press the MEMORY button (9) twice. If a memory channel is free, the SET
indicator starts ashing. In other cases, it will be turned on constantly. (If
the memory is empty, one push of the button is enough.)
2. Select the memory channel you want using the CH button (10).
3. Specify the welding settings you want and store the selections by
pressing SAVE button (11).
4. Press the MEMORY button (9) twice. The ON indicator light will turn on
and the welding parameters you selected are activated.
5. Start welding.
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.
You can also store the welding parameters with the SET button when the memory feature is in the OFF state, i.e., when the MEMORY indicators are not on.
To clear the data in a memory channel, press the MEMORY and CH buttons simultaneously when the control panel is in the SET mode (the SET indicator is on).
Using stored welding parameters
1. Press the MEMORY button to turn on the ON indicator.
2. Select the memory channel you want from the robot.
3. Star t welding.
Page 17
17
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
4.6 Synergic 1-MIG, WiseThin, and WiseRoot welding
In synergic 1-MIG welding, the machine selects the optimal welding parameters suitable
to the ller wire and shielding gas using the programs, or synergic curves, stored in the
control panel. The welder controls the welding by adjusting the welding power and arc
length.
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. Before you start welding, nd the welding program suitable to your ller
wire and shield gas in the tables below and then activate the program as
follows:
2.
Select the welding process (1-MIG or Wise) with button (7).
3. Press the SYNERGIC PROGRAM button (6) for more than 1 second. This
will activate program selection and the control panel displays start
ashing.
4. Select the material group with the left-hand side control knob and
the welding program for the material group with the right-hand side
control knob according to the tables below. The program you selected is
immediately recorded in the memory.
5. Press ESC button (1) or the SYNERGIC PROGRAM button (6) to exit the
menu.
MIG programs in the A3 MIG Welder machine
Please note with the aluminium and special alloy programs that the A3 MIG Welder
system doesn’t support push-pull guns.
WiseRoot and WiseThin programs are enabled by licenses.
1-MIG, Fe group
Program number Wire, mm Material Shielding gas
101 0.8 Fe Ar+18%-25%CO
102 0.9 Fe Ar+18%-25%CO
103 1.0 Fe Ar+18%-25%CO
104 1.2 Fe Ar+18%-25%CO
106 1.6 Fe Ar+18%-25%CO
111 0.8 Fe CO
112 0.9 Fe CO
113 1.0 Fe CO
114 1.2 Fe CO
116 1.6 Fe CO
121 0.8 Fe Ar+8%CO
122 0.9 Fe Ar+8%CO
123 1.0 Fe Ar+8%CO
124 1.2 Fe Ar+8%CO
126 1.6 Fe Ar+8%CO
152 0.9 FEMC Ar+18%-25%CO
154 1.2 FEMC Ar+18%-25%CO
164 1.2 FEMC CO
174 1.2 FEFC rutile Ar+18%-25%CO
184 1.2 FEFC rutile CO
194 1.2 FEFC basic Ar+18%-25%CO
Page 18
18
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
1-MIG, SS group
Program number Wire, mm Material Shielding gas
201 0.8 SS-316 Ar+2%CO
202 0.9 SS-316 Ar+2%CO
203 1.0 SS-316 Ar+2%CO
204 1.2 SS-316 Ar+2%CO
206 1.6 SS-316 Ar+2%CO
211 0.8 SS-316 Ar+30%He+1%O
212 0.9 SS-316 Ar+30%He+1%O
213 1.0 SS-316 Ar+30%He+1%O
214 1.2 SS-316 Ar+30%He+1%O
216 1.6 SS-316 Ar+30%He+1%O
221 0.8 SS-309 Ar+2%CO
222 0.9 SS-309 Ar+2%CO
223 1.0 SS-309 Ar+2%CO
224 1.2 SS-309 Ar+2%CO
231 0.8 SS-309 Ar+30%He+1%O
232 0.9 SS-309 Ar+30%He+1%O
233 1.0 SS-309 Ar+30%He+1%O
234 1.2 SS-309 Ar+30%He+1%O
242 0.9 FC-316 Ar+18%-25%CO
244 1.2 FC-316 Ar+18%-25%CO
252 0.9 FC-316 CO
254 1.2 FC-309L Ar+18%-25%CO
1-MIG, Al group
Program number Wire, mm Material Shielding gas
303 1.0 Al-5356 Ar
304 1.2 Al-5356 Ar
306 1.6 Al-5356 Ar
313 1.0 AL-4043 Ar
314 1.2 Al-4043 Ar
316 1.6 Al-4043 Ar
1-MIG, SPE group
Program number Wire, mm Material Shielding gas
401 0,8 CuSi 3 Ar
402 0.9 CuSi 3 Ar
403 1.0 CuSi 3 Ar
404 1.2 CuSi 3 Ar
411 0.8 CuSi 3 Ar+2% CO
412 0.9 CuSi 3 Ar+2% CO
413 1.0 CuSi 3 Ar+2% CO
421 0.8 CuAl 8 Ar
423 1.0 CuAl 8 Ar
424 1.2 CuAl 8 Ar
Page 19
19
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
WiseThin, Fe group
Program number Wire, mm Material Shielding gas
701 0.8 Fe Ar+18%-25%CO
702 0.9 Fe Ar+18%-25%CO
703 1.0 Fe Ar+18%-25%CO
704 1.2 Fe Ar+18%-25%CO
711 0.8 Fe CO
712 0.9 Fe CO
713 1.0 Fe CO
714 1.2 Fe CO
WiseThin, SS group
Program number Wire, mm Material Shielding gas
721 0.8 SS-316 Ar+2%CO
722 0.9 SS-316 Ar+2%CO
723 1.0 SS-316 Ar+2%CO
724 1.2 SS-316 Ar+2%CO
WiseThin, SPE group
Program number Wire, mm Material Shielding gas
743 1.0 CuSi 3 Ar
753 1.0 CuAl 8 Ar
WiseRoot, Fe group
Program number Wire, mm Material Shielding gas
802 0.9 Fe Ar+18%-25%CO
803 1.0 Fe Ar+18%-25%CO
804 1.2 Fe Ar+18%-25%CO
812 0.9 Fe CO
813 1.0 Fe CO
814 1.2 Fe CO
WiseRoot, SS group
Program number Wire, mm Material Shielding gas
822 0.9 SS-316 Ar+2%CO
823 1.0 SS-316 Ar+2%CO
824 1.2 SS-316 Ar+2%CO
832 0.9 SS-316 Ar+30%He+1%O
833 1.0 SS-316 Ar+30%He+1%O
834 1.2 SS-316 Ar+30%He+1%O
Page 20
20
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
4.7 Welding and system setup
Quick setup
To set the values of the functional parameters for MIG features, use the QUICK SETUP
feature, which you can activate by briey 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
specied is instantly stored in the control panel memory. The following tables list the
parameter values that can be specied for the MIG features.
QUICK SETUP, MIG
Parameter Display Value range Factory
setting
Description
Creep start
level
Cre
10 ... 170 % 50 % Percent of wire feed speed default
10% refers to slow start,
170% refers to fast start
QUICK SETUP, 1-MIG, WiseThin, WiseRoot
Parameter Display Value range Factory
setting
Description
Creep start
level
Cre
10 ... 170 % 50 % Percent of wire feed speed default
10% refers to slow start,
170% refers to fast start
Hot start
level
Hot
-50 ... 75 % 30 % Percent of welding power:
-50% refers to cold start
+75% refers to hot start
Hot start time
H2t
0 ... 9.9 s 1.2 s The duration of the hot start in seconds.
Crater ll
start level
CrS
Crater ll
end level ...
250 %
90 % The welding power at the beginning of
the crater ll stage as a percentage of
the welding power pre-set value.
Crater ll end
level
CrL
10 ... Crater
ll start level
30 % The welding power at the end of the
crater ll stage as a percentage of the
welding power pre-set value.
Crater ll
time
Crt
0 ... 9.9 s 2 s The duration of the crater ll stage in
seconds.
All setup parameters
The machine has several parameters, whose settings can be specied with the control
panel's SETUP function as follows:
1. Press and hold down the SETUP button (5) for at least 5 seconds.
2. Select the parameter to adjust using the left-hand side control knob. The parameter
name is shown in display left-hand display.
3. Specify the parameter value with the right-hand side control knob. The selected
value is shown in the right-hand display. The parameter’s value is immediately
stored in the memory.
4. Exit the SETUP mode by pressing and holding down the SETUP button again for at
least 5 seconds or by briey pressing the ESC button.
All welding processes have their own setup parameters. For example, adjusting the postcurrent for synergic MIG welding does not aect the post-current of normal MIG welding.
The tables below show the features available in this welding machine and their possible
values.
Page 21
21
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
Regular MIG welding parameters
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 ... +9 0 Post-welding current time
Synergic MIG welding parameters
Parameter Display Value range Factory
setting
Description
Pre-gas time
PrG
0.0 ... 9.9 s,
syn (Syn)
Syn Pre-gas time in seconds or
automatically according to the synergic
welding program (Syn).
Post gas time
PoG
0.1 ... 9.9 s,
syn (Syn)
Syn Post gas time in seconds or
automatically according to the synergic
welding program (Syn).
Creep start
level
Cre
10 ... 170% 50 % Percentage of wire feed speed:
10%-99% = slow start
100% = no creep start
101%-170% = accelerated start.
Hot start
level
Hot
-50 ... 75 % 30 % Percent of welding power: -50% refers
to cold start and +75% to hot start.
Hot start time
h2t
0.0 … 9.9 s 1.2 s The duration of the hot start in
seconds.
Crater ll
start level
crs
Crater ll
end level …
250 %
90 % The welding power at the beginning of
the crater ll stage as a percentage of
the welding power pre-set value.
Crater ll end
level
CrL
10 % ... Crater
ll start level
30 % The welding power at the end of the
crater ll stage as a percentage of the
welding power pre-set value.
Crater ll
time
crt
0.0 … 9.9 s 2.0 s The duration of the crater ll stage in
seconds.
Start power
sta
-9 … +9 0 Strength of the star t pulse (not in
WiseRoot or WiseThin processes).
Post current
time
PoC
-9 ... +9 0 Post-welding current time
Synergic MIG
display units
Unl
m/min,
mm, A
m/min In 1-MIG and WiseRoot welding, the
parameter shown in the left-hand
side display: (wire feed speed (m/
min), sheet thickness (mm) or average
current (A).
Common system setup parameters
Parameter Display Value range Factory
setting
Description
Cable
compensation
CAL
-5.0 ... 9.0 V
/100 A
1.0 V/100 A Cable compensation (MIG) for
voltage losses.
Long system
mode
lsy off (O ),
on (On)
O Gives optimum welding
characteristics with long welding
cables. Recommended to be used
when the cable length exceeds 40 m.
Code entry
Cod ---, Ent
(Ent)
Entering license code manually. See
page 15 for details.
Scaling
SCA
0 ... 9999 0 A coecient with which the values
in the welding machine are scaled to
the scale used by the robot.
Restore factory
settings
FAC OFF (O ),
Pan (Pan),
All (All)
O Restores factory settings if you
select PAN or ALL and exit the menu.
PAN will reset the panel settings
and leave the memory channels
untouched. ALL restores the whole
system to the factory state.
Page 22
22
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
WiseRoot and WiseThin parameters
Parameter 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.
WiseFusion parameters
Parameter Display Value range Factory
setting
Description
WiseFusion on
fus off (O),
on (On)
na (N/A)
O Switch WiseFusion on/o (only in
synergic processes).
N/A = no license.
WiseFusion
Level
fup
10 … 60 %
na (N/A)
25 % Percentage of WiseFusion level (only
in synergic processes).
N/A = no license.
WiseRoot, WiseThin and WiseFusion are optional features. To acquire activation codes,
contact a Kemppi representative.
Page 23
23
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
4.8 Touch sensor (seam search)
The touch sensor is a specic functional system used in
automated welding for nding workpiece’s accurate location and position. The touch sensor hardware and I/O
are in the welding power source. A welding robot nds
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 generates a sensing voltage separately
from the welding power source. Touch is detected when
there is a short-circuit between the workpiece and the
sensing tool resulting in a voltage drop. The negative
pole of touch sensor’s voltage source is 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 device enables the conguration by a DIP
switch.
The touch sensor system consists of hardware and software. The hardware consists of a touch sensor device and
wiring in the wire feeder’s control cable for the gas nozzle
use (see Figure 4.4, “ Touch sensing system”). The software
enables conguration and control. The touch sensor is
congured by using DIP switches, and it is controlled by
the welding robot via the digital robot interface.
2
3
1
Figure 4.3 Touch sensor in the power source
1. Touch sensor device inside the welding power source
2. Wire feeder control cable connector (wiring for the gas
nozzle)
3. Fieldbus / Digital robot interface
Fieldbus
7
4
3
2
1
8
6
5
Figure 4.4 Touch sensing system
1. Conguration (DIP switches)
2. Welding plus (welding wire touch sensing)
3. Wire feeder control cable (gas nozzle touch
sensing)
4. Fieldbus / Digital robot interface
5. Peripheral connector
6. Touch tool (welding wire or gas nozzle)
7. Touch detection
8. Welding minus (touch sensor ground)
Page 24
24
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
On/O control
The touch sensor device behaves as a software controllable power source. The
power source can be switched on and o 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 congured by using the DIP switches 1 and 2 on the panel (2).
Panel (2) switches 1-2 Nominal Minimum Typical Maximum
ON
1 2 3 4 5 6 7 8
50 V
(default)
47.5 V 54.0 V 58.0 V
ON
1 2 3 4 5 6 7 8
80 V 76.0 V 80.0 V 84.0 V
ON
1 2 3 4 5 6 7 8
110 V 104.0 V 108.0 V 113.0 V
ON
1 2 3 4 5 6 7 8
200 V 190.0 V 200.0 V 210.0 V
All levels have limited continuous power supply to ensure human safety. The
200 V supply drops down under the 113 V level when loaded by a 5.6 kΩ resistor
which is the nominal DC resistance of the human body. In some cases, voltage levels
above 113 V can still cause minor harm, such as pain, to a person.
The power source and the touch sensing circuitry are galvanically isolated from the
other systems in the welding power source.
Touch tool
Two alternative touch tools can be used for touch sensing (see Figure 4.5, “Welding wire
used as touch tool” and Figure 4.6, “Gas nozzle used as touch tool”). The regular tool is
the welding wire (welding plus). Sometimes the welding wire is not accurate enough.
The tip of the welding wire can bend resulting in incorrect position information. In that
case the gas nozzle can be used instead. Using the gas nozzle requires extra wiring from
wire feeder’s 7-pin peripheral connector (pin C) to the gas nozzle. The touch tool can be
managed by the robot controller by using the digital robot interface.
Figure 4.21 Welding wire used as touching
tool
Figure 4.22 Gas nozzle used as touching tool
Page 25
25
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
4.9 Collision sensor
For information on connecting and conguring the
collision sensor, see the A3 MIG Welder Integration guide.
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.
In the A3 MIG Welder the collision sensor signal is read by
the power source, and the information is passed to the robot by the welding system. In addition, a collision causes
always the Error 146 Collision detected in the welding
system. When the error occurs, the power source stops
welding immediately.
Fieldbus
1
2
3
5
4
Figure 4.7 Collision sensing system
1. Collision sensor
2. Fieldbus / Digital robot interface
3. Wire feeder control cable
4. Peripheral connector
5. Conguration using DIP switches
The collision sensor is mounted to the robot arm, and it is
a mounting point for the welding torch.
2
3
4
5
1
Figure 4.8: Collision sensor mounting
1. Robot arm
2. Collision sensor
3. Collision signal cable
4. Torch suspension
5. Torch neck
There is a 7-pin peripheral connector in the front panel
of the wire feeder. The collision sensor signal is available
in the pin B, and the supply for the signal is in the pin A.
See the A3 MIG Welder Integration guide for more details.
Page 26
26
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
5. TROUBLESHOOTING
5.1 Typical problems
The problems listed, and the possible causes are not
denitive, 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.
Problem Check the following
Machine won’t work • Check mains plug is connected correctly
• Check mains power distribution is switched on
• Check the mains fuse and/or circuit breaker
• Check power source 0/1 switch is ON (1)
• Check interconnection cable set and connectors between the power source
and wire feed unit are correctly fastened. See the manual schematic
• Check earth return cable is connected
• Check control panels are switched on.
Dirty, poor quality weld • Check shielding gas supply
• Check and set gas ow rate
• Check gas type for application
• Check gun/electrode polarity
• Check correct welding program selected
• Check correct channel number selected on wire feeder control panel
• Check power supply – Phase down?
Variable welding
performance
• Check wire feed mechanism is correctly adjusted
• Check correct drive rolls are tted
• Check wire spool overrun tension is correctly adjusted
• Check gun liner is not blocked, replace if necessary
• Check correct gun liner is tted for the ller wire size and type
• Check contact tip for size, type and wear
• Check gun is not over heating in application
• Check cable connections and earth return clamp
• Check welding parameter settings.
Filler wire won’t feed • Check that pressure arms are closed and adjusted in wire feed mechanism
• Check welding gun switch function
• Check Euro gun collar is correctly fastened
• Check gun liner is not blocked
• Check contact tip, size, type, wear
• Check and try alternative gun.
Page 27
27
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
5.2 Error codes
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 o during welding.
Welding has continued for too long without interruption or the ambient
temperature is too high.
Do not switch o the power source. Let the fans cool down the device.
101 NO WELDING PROGRAM
Internal program error. The selected synergic welding curve was not found in
the memory. The system memory card is detached or defective.
Switch o and restart the power source. Contact the maintenance service if the
error is not resolved.
131 FIELDBUS INIT FAILED
Failed to initialize the eldbus during start-up.
Restart the device. Contact the maintenance service if the error is not resolved.
132 ROBOT COMMUNICATION ERROR
Communication to the robot has been lost. The eldbus cable has been
broken or detached, or there is a robot failure or shutdown. Welding is
interrupted when a lost connection is detected.
Check the eldbus cable. If the robot has been shut down, turn the robot on.
Switch o and restart the power source.
133 SAFETY STOP
The safety stop signal is activated by a user. Welding is immediately
interrupted.
Identify the reason for the safety stop. Do not release the safety stop signal before
the cause has been identied and resolved.
146 COLLISION DETECTED
The collision sensor has been activated. The welding torch mounted on
the arm of a welding robot has collided with the welding piece or another
obstacle.
Reverse the robot arm until the torch no longer touches the obstacle. Check the
torch in case of damages.
154 WIRE FEED MOTOR OVERCURRENT
Current limit is exceeded while the wire feed motor is running, and the motor
is stopped. The wire feeder rolls are too tight, the wire spool is too tight, or
the wire is stuck.
Check and replace the consumables in the wire feeder unit and the torch.
202 CURVE NOT ACTIVATED
An activated memory channel has not been congured properly.
Specify a welding curve for the memory channel.
### OTHER ERROR CODES Switch o and restart the power source. Contact the maintenance service if the
error is not resolved.
Page 28
28
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
6. OPERATION DISTURBANCES
Should you experience a malfunction from your machine,
please consult the basic troubleshooting text above rst,
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.
The thermostat will operate, if machine is continuously
loaded over rated values or cooling air circulation is
blocked.
Internal fans will cool the machine, and when the pilot
lamp is not lit the machine is automatically ready for
welding.
Control fuses
Fuse, 6.3 A delayed, on the rear wall of 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.
Under- and overvoltage in the mains supply
Primary circuits of the machine are protected against
sudden, transient overvoltage. The machine is designed
to withstand 3 x 440 V voltage continuously. Ensure that
voltage is kept within this permissible limit, especially
when the mains supply is provided by a combustion engine generator. If the mains have undervoltage (under
approx. 300 V) or overvoltage (over approx. 480 V) machine control stops operation automatically.
Loss of a phase in the mains supply
Loss of a mains power phase causes noticeably poor
welding properties. In some cases, the machine won’t
start at all. Loss of a phase can be due to following:
• Blowing of mains supply fuse
• Defective mains cable
• Bad connection of mains power cable on
machine terminal block or plug of machine.
Page 29
29
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
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.
Disconnect the machine from the mains before handling the electrical cables.
7.1 Daily 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.
Check the condition and connection of the welding circuit components: welding gun, earth return cable and
clamp, sockets and connectors.
Check the condition of the feed rolls, needle bearings
and shafts. Clean and lubricate bearings and shafts with a
small quantity of light machine oil if necessary. Assemble,
adjust and test function.
Check that the feed rolls are suitable for the ller wire you
are using, and that their pressure adjustment is correct.
7.2 Periodic maintenance
Periodic maintenance should only be carried out by
a suitably qualied person. Disconnect the plug of the
machine from the 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
connections.
You must know the correct tension torques values
before starting the reparation of the loose joints.
Clean the inner parts of the machine from dust and dirt
e.g. with a soft brush and vacuum cleaner. Also clean the
ventilation net behind the front grill.
Do not use compressed air, there is a risk that the dirt will
compact even more tightly into gaps of cooling proles.
Do not use pressure washing devices.
Only an authorized trained electrician should carry
out repairs to Kemppi machines.
7.3 Service Workshop maintenance
Kemppi Service Workshops complete maintenance according to their Kemppi service agreement.
The major points in the maintenance procedure are listed
as follows:
• Cleaning of the machine
• Checking and maintenance of the welding tools
• Checking of connectors, switches and
potentiometers
• Checking of electric connections
• Checking of mains cable and plug
• Damaged parts or parts in bad condition are
replaced by new ones
• Maintenance testing.
• Operation and performance values of the
machine are checked, and when necessary
adjusted by means of software and test
equipment.
Software loading
Kemppi Service Workshops can also test and load rmware and welding software.
Page 30
30
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
8. DISPOSAL
Do not dispose of electrical equipment with normal
waste!
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.
The owner of the equipment is obliged to deliver a decommissioned unit to a regional collection center, as per
the instructions of local authorities or a Kemppi representative. By applying this European Directive you will
improve the environment and human health.
9. ORDERING NUMBERS
Product Code
A3 Power Source 400 Welding power source, 400 A, DeviceNet 6201403
A3 Wire Feeder 25-RH-EUR Wire feeder, right handed, euro connector 6203403
A3 Wire Feeder 25-RH-PP Wire feeder, right handed, ower pin connector 6203413
INTERCONNECTION CABLE 70MM2 5M Interconnection cable set, 5 meters, air cooled,
for euro connector wire feeder
SP801064A
EARTH RETURN CABLE 70 MM2 5 M Earth return cable, 70 mm, 5 m SP801062A
A3 FIELDBUS BRANCHE CABLE 5M Branch cable set for DeviceNet and safety stop W015563
Page 31
31
A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
10. TECHNICAL DATA
A3 Power source 400
Power supply
Supply voltage 3~ 50/60 Hz 400 V, -15 % … +20 %
Mains connection cable H07RN-F 4G6 (5 m)
Maximum supply current 23 A
Eective supply current 21 A
Fuse 35 A delayed
Eciency (100 % duty cycle) 87 %
Power factor (at max. current) 0.9
Minimum short circuit power Ssc of
supply network
4.7 MVA
Idle power 25 W
Rated power 80 % ED 19.5 kVA
100 % ED 18.5 kVA
Primary current 50 % ED I1max 28 A
100 % ED I1 25.5 A
Welding characteristics
No-load voltage (peak) U0 = 85 V – 95 V
Open circuit voltage (average) 50 V
Welding voltage range 10 V - 46 V
Output capacity 40°C 80 % ED 400 A
100 % ED 380 A
Auxiliary device supply
Supply voltage 50 V DC
Fuse 6.3 A delayed
Environmental characteristics, dimensions and classication
Operating temperature range -20 °C … +40 °C
Storage temperature range -40 °C … +60 °C
External dimensions LxWxH 590 x 230 x 500 mm
Weight 36 kg
Degree of protection IP21S
EMC class A
A3 Wire Feeder 25
Electrical characteristics
Operating voltage (safety voltage) 50 V DC
Rated power 100 W
Load capacity 80 % ED 600 A
100 % ED 500 A
Wire feeder
Wire feed speed 0 … 25 m/min
Wire feed mechanism 4-roll, single motor
Gun connection Euro / PowerPin
Filler wires ø Fe, Ss 0.6 … 1.6 mm
ø Flux-cored wire 0.8 … 1.6 mm
ø Al 1.0 … 1.6 mm
ø CuSi 0.8 … 1.2 mm
Environmental characteristics, dimensions and classication
Operating temperature range -20 °C ... +40 °C
Storage temperature range -40 °C ... +60 °C
External dimensions LxWxH 269 x 175 x 169 mm
Weight 4.5 kg
Degree of protection IP21S
EMC class A
Page 32
And you know.
userdoc.kemppi.com
Declarations of Conformity – Overensstemmelseserklæringer – Konformitätserklärungen –
Declaraciones de conformidad – Vaatimustenmukaisuusvakuutuksia – Déclarations de conformité –
Dichiarazioni di conformità – Verklaringen van overeenstemming – Samsvarserklæringer – Deklaracje zgodności –
Declarações de conformidade – Заявления о соответствии – Försäkran om överensstämmelse – 符合性声明
Loading...