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A7 MIG Welder 350
Operating Manual
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Kemppi A7 MIG Welder 350, Kemppi A7 MIG Welder 450 Operating Manual

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A7 MIG WelderA7 MIG Welder
EN
OPERATING MANUAL
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OPERATING MANUAL
CONTENTS
1. Introduction ..........................................................................................4
2. Installation .............................................................................................5
3. System Overview ................................................................................6
3.1 Power Source .............................................................................................6
3.2 Robot interface unit ..................................................................................7
3.3 User interfaces ...........................................................................................8
3.4 A7 MIG Wire Feeder 25 .............................................................................. 9
3.5 MIG Guns .................................................................................................11
3.6 Cooling unit .............................................................................................12
3.7 I/O device.................................................................................................13
4. Using the welder ...............................................................................14
4.1 Basic controls ...........................................................................................14
4.2 Setup panel .............................................................................................14
4.2.1 Button functions ..................................................................................15
4.2.2 Main menu ..........................................................................................16
4.2.3 Memory channel wizard ........................................................................16
4.2.4 User settings ........................................................................................22
4.2.5 Welding system settings ........................................................................22
4.2.6 System tests ........................................................................................25
4.2.7 Robot settings .....................................................................................26
4.3 Web user interface ..................................................................................28
4.3.1 Welding display....................................................................................29
4.3.2 Gas, air and wire inch ............................................................................29
4.3.3 Logbook .............................................................................................30
4.3.4 About .................................................................................................30
4.3.5 Welding settings – Memory channels .......................................................30
4.3.6 Settings – Language .............................................................................34
4.3.7 Settings – Users ....................................................................................34
4.3.8 Settings – Change PIN ...........................................................................34
4.3.9 Settings – Fieldbus................................................................................35
4.3.10 Settings – Network ...............................................................................35
4.3.11 Settings – Backup, restore and reset .........................................................36
4.3.12 Settings – Licenses ................................................................................36
4.4 User identication ...................................................................................37
4.4.1 Overview ............................................................................................37
4.4.2 Turning user identication system on .......................................................38
4.4.3 Creating new users ...............................................................................38
4.4.4 Deleting a user .....................................................................................39
4.4.5 Changing user role ...............................................................................39
4.4.6 Changing username ..............................................................................39
4.4.7 Changing PIN code ...............................................................................39
4.4.8 Resetting PIN code ...............................................................................40
4.4.9 Logging in and out, changing active user ..................................................40
4.5 Touch sensor............................................................................................41
4.5.1 Voltage source, levels and safety .............................................................43
4.5.2 Touch tool ...........................................................................................44
4.5.3 Fast status output .................................................................................44
4.5.4 Selecting output voltage .......................................................................44
4.5.5 Conguring touch tool ..........................................................................45
4.6 Through Arc Seam Tracking (TAST) ........................................................45
4.7 Collision sensor .......................................................................................46
4.7.1 Setting collision sensor on and o ...........................................................47
4.7.2 Selecting sensor type ............................................................................47
4.7.3 Selecting output polarity .......................................................................47
4.8 Wire feeder ..............................................................................................48
4.8.1 Loading the ller wire in
A7 MIG Wire Feeder 25 ...................................................................................48
4.9 Arc measurement ....................................................................................52
4.9.1 Setup and calibration ............................................................................52
4.9.2 Display ...............................................................................................52
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OPERATING MANUAL
4.10 Gas ow sensor .......................................................................................53
4.10.1 On/O control .....................................................................................53
4.10.2 Gas ow sensing level ...........................................................................53
4.10.3 Gas mixture setup ................................................................................53
5. Troubleshooting ................................................................................54
5.1 Typical problems .....................................................................................54
5.2 Error codes ...............................................................................................55
5.2.1 Power source errors ..............................................................................55
5.2.2 Cooling unit errors ................................................................................56
5.2.3 Wire feeder errors .................................................................................57
5.2.4 Welding curve errors .............................................................................57
5.2.5 Robot interface errors............................................................................58
5.2.6 I/O device errors ...................................................................................59
6. Operation disturbances ..................................................................60
7. Maintenance .......................................................................................61
7.1 Daily maintenance ..................................................................................61
7.2 Periodic maintenance .............................................................................61
7.3 Service shop maintenance ......................................................................61
8. Disposal ................................................................................................62
9. Ordering numbers ............................................................................62
10. Technical data ....................................................................................63
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OPERATING MANUAL
1. INTRODUCTION
Congratulations on choosing the A7 MIG Welder system. When used correctly, Kemppi products can signicantly 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 specications 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 particular 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 specications presented in this manual are subject to change without prior notice.
Important notes
Items in the manual that require particular 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 eort 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 specication 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.
The web user interface server, located in the robot interface unit, is meant to be used only in point-to-point connection with one authorized PC computer. For the sake of condentiality, it is not recommended to connect the A7 MIG Welder system to any public or internal network. Kemppi is not liable for errors or damages resulting from non-compliance of this recommendation.
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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 and the robot interface unit, use the recesses at the both ends of the robot interface unit.
Detailed installation instructions and the technical information that is out of the scope of this manual are found in the A7 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.
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OPERATING MANUAL
3. SYSTEM OVERVIEW
The A7 MIG Welder system
3
1
4
2
5
6
7
Figure 3.1 A7 MIG Welder system
1. Power Source
2. Robot interface unit
3. Wire feeder
4. MIG torch
5. Cooling unit (optional)
6. Interconnection cable set
7. I/O device (optional)
3.1 Power Source
A7 MIG Power Source 350/450
V
6,3A
1
12
8
10
11
9
2
7
5 6
3
4
Figure 3.2 Power source, front and rear
1. Setup panel
2. Main switch
3. Main power indicator light (ON/OFF)
4. Overheating indicator
5. Welding cable connection, negative pole ( – )
6. Welding cable connection, positive pole ( + )
7. Control cable connection
8. Fuse (6.3 A, delayed)
9. Control cable connection
10. Mains power cable
11. Measurement cable connection
12. Wire feeder cable connection
The A7 MIG Power Source 350/450 is designed for demanding professional use. The power source is suitable for pulsed MIG/MAG, 1-MIG, and also for WiseRoot+ and WiseThin+ processes.
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OPERATING MANUAL
3.2 Robot interface unit
A7 MIG Robot interface unit
1
2
5
6
7
3
4
Figure 3.3 Robot interface unit connections
1. Fieldbus module slot
2. Anybus CompactCom M30 module
3. Ethernet connection for the web user interface
4. Touch sensor fast output
5. Emergency stop input
6. Gate door switch input
7. Wire feeder control cable connection
The robot interface unit on top of the power source handles the communication with a robot and contains all necessary connections to integrate with a welding cell. The unit has an internal web server that provides a web user interface for easy control of welding and setup parameters via any device equipped with an internet browser including robot teach pendants.
For connecting the cables of the robot interface unit, see the A7 MIG Welder Integration guide.
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OPERATING MANUAL
Web user interface
1
2
4 5
6
3
Figure 3.5 Web user inter face layout overview
1. Side menu bar
2. Content frame
3. Current user / User logout
4. Setup parameters
5. Setup value controls
6. Pop-up bar (normally hidden)
The web user interface is a website that is located in a network server in the robot interface unit. It can be accessed by any internet browser that is capable of showing dynamic web pages. The web user interface can be used for controlling the welding system and all its setup parameters. See Section 4.3, “Web user inter face” for details.
3.3 User interfaces
The A7 MIG Welder system has two integrated user interfaces with system setup and control capability, a setup panel and a web user interface.
The web user interface is mandatory for conguring the eldbus. The eldbus conguration functionality is not available in the setup panel. The eldbus conguration is described in the A7 MIG Welder Integration guide.
Setup panel
2
4
5
1
7
8 83
6 66
Figure 14 Setup panel layout
1. Power button
2. Memory channel selector (-/+)
3. MENU entry button
4. Up / down arrows
5. Control knob
6. Menu shortcut keys
7. LCD display
8. Soft key buttons
The setup panel has a menu display, soft buttons and a control knob for easy navigation and control. See Section
4.2, “Setup panel ” for details.
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OPERATING MANUAL
3.4 A7 MIG Wire Feeder 25
A7 MIG Wire Feeder 25
21
3
4
Figure 3.6 Wire feeder – front
1. Euro connector for the welding gun
2. Compressed air outlet
3. Motor gun and peripheral connector
4. Welding current (+) input
5
6
7
12
10
9
8
11
Figure 3.7 Wire feeder – rear side
5. GT04T wire feed mechanism
6. Transparent lid
7. Wire feeder control cable connection
8. Compressed air inlet
9. Shielding gas inlet
10. Arc measurement cable connector for the power source
11. Arc measurement cable connector for the workpiece clamp
12. Wire liner connector
13 14
15 16
Figure 3.8 Wire feeder – cover
13. Gas test button
14. Air blow button
15. Wire retract button
16. Wire inch button
The A7 MIG Wire Feeder 25 is a durable and powerful wire feeding device for welding automation. For more information on using the wire feeder and its functions, see
Section 4.7, “Wire Feeder”.
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OPERATING MANUAL
Interconnection cable assembly for wire feeder
E
A
B
C
D
E
F
A
D
F
Figure 3.9 Interconnection cable set
A. Measurement cable B. Cooling hose (red, incoming from gun) C. Cooling hose (blue, outgoing to gun) D. Shielding gas hose E. Welding cable F. Control cable
The cooling hoses B and C run outside the wire feeder.
See the A7 Welder Integration guide for more detailed information on connecting the wire feeder.
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OPERATING MANUAL
3.5 MIG Guns
A7 MIG Gun 500-g
5
4
1
2
3
Figure 3.10 A7 MIG Gun 500-g
1. Torch neck
2. Connection module
3. Hose assembly
4. Welding gun connector
5. Robot mount
The A7 MIG Gun 500-g is used in gas welding using inert gases (MIG) or active gases (MAG). This model is gas­cooled and can be used in all welding positions.
A7 MIG Welding Gun 500-w
3
1
2
4
Figure 3.11 A7 MIG Gun 500-w
1. Torch neck
2. Hose assembly
3. Robot mount
4. Fastener
The A7 MIG Gun 500-w is used in gas welding using inert gases (MIG) or active gases (MAG). This model is water­cooled and can be used in all welding positions.
Robot mounts
The A7 MIG Gun 500-w and 500-g are mounted to the welding robot using special robot mounts. There are three types of robot mounts available: robot mount Type 1, Type 2 and Type 3.
Figure 3.12 Robot mount T1
The robot mount Type 1 serves for accommodating a welding gun in exact position. The mount is fastened to the robot with a cylinder head screws and a robot ange.
Figure 3.13 Robot mount T2
The robot mount Type 2 is used for connecting the robot and the welding gun. The device acts three-dimensionally and is adaptable to all types of robots and for handling machines via a robot ange.
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OPERATING MANUAL
Figure 3.14 Robot mount T3
The robot mount Type 3 is a gun seat without integrated collision protection. The collision protection or the switch­o of the robot is only possible via the robot control.
For assembly and installation of the A7 MIG guns, see A7
MIG Gun 500-g Operation manual, A7 MIG Gun 500-w Operation manual and A7 MIG Welder Integration guide.
For compatibility and selection table, see the separate
A7 MIG Gun 500-g Operation manual and A7 MIG Gun 500­w Operation manual.
3.6 Cooling unit
A7 Cooler
1
3
2
5
4
6
7
Figure 3.15 Cooling unit
1. Test switch
2. Filling hole (in the side plate)
3. O verheat control indicator
4. Power supply cable
5. Control cable
6. Coolant return connector
7. Coolant output connector
The cooling unit is designed for automatic and manual welding equipment and to be used for cooling of the liquid-cooled welding gun. See the A7 Cooler Operating
manual for more information on the installation.
This unit is equipped with a lter and a ow switch in the return channel to ensure uninterrupted cooling operation. The operation is controlled by software. See the A7
MIG Welder Integration guide for system conguration options.
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OPERATING MANUAL
3.7 I/O device
A7 I/O Device 4/4
1
2 3 4
Figure 3.16 I/O device
1. Aluminum case (IP44)
2. Four holes for I/O cabling, strain reliefs included
3. Control cable connector
4. Indicator light
A7 I/O Extension Card 8/8
1 2
3
Figure 3.17 I/O Extension card
1. Input connectors
2. Output connectors
3. Flat band cable for main card
The A7 I/O Device 4/4 is a general-purpose digital input and output device that can be used to control external devices, such as a torch cleaning station. It is capable of driving +24 V logic signals, relays, and valves, and reading logic states, switches, and digital sensors. Inputs are read and outputs written by a robot.
The A7 I/O Device 4/4 has 4 inputs and 4 outputs by default. It can be extended by A7 I/O Extension Card 8/8 that is available separately. The extension card has additional 4 inputs and 4 outputs, resulting in the total of 8 inputs and 8 outputs when equipped.
See the A7 MIG Welder Integration guide for electrical characteristics and more detailed information on the I/O device connection and conguration.
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OPERATING MANUAL
4. USING THE WELDER
4.1 Basic controls
Main switch
When you turn the on/o switch into position 1, the main power indicator is illuminated and the welder system starts a power-up sequence. The system is ready for use when the setup 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 A7 MIG 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 eect of the completed cycle.
4.2 Setup panel
1
2
4
5
7
8 83
6 66
Figure 4.1 Setup panel layout
1. Power button
2. Memory channel selector (-/+)
3. MENU entr y button
4. Up / down arrows
5. Control knob
6. Menu shortcut keys
7. LCD display
8. Soft key buttons
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OPERATING MANUAL
4.2.1 Button functions
Power button
You can log OFF the current user by pressing on the power button for approximately 5 seconds. The user identication system has to be on and a user logged in for this function. If the user identication system is o, the long press has no eect.
Pressing this button anywhere in the menu returns to the memory channel information display. Possible unsaved changes are lost.
Memory channel selector
There are up to 200 memory channels available in the system starting from number 0 and ending to number
199. The plus and minus buttons can be used to navigate between the memory channels in the information display. If the selected channel is empty, a soft button with text NEW is shown allowing direct entering to a channel editor.
MENU entry button
Enter the main menu by pressing this button.
Up/down arrows
Navigate in the menus up and down by pressing these buttons.
Control knob
Adjust values and settings of menu parameters by turning the control knob.
Menu shortcut keys
Press the F1 to view additional information on the current memory channel. Multiple presses show more information pages. Pressing this button in the menu returns to the channel information display.
Press the F2 to log a user in when the user identication system is turned on and all users are logged o. Pressing this button when a user has logged in redirects you to the user settings menu.
Press the F3 to select another wire feeder. The selection is allowed if there is multiple wire feeders connected into the welding system.
Soft key buttons
The function of the soft key buttons depends on the current menu location and the operation being performed in that location. The function is indicated by a text in the LCD display just above the buttons, for example BACK, EXIT, SELECT, OK, SAVE or NEW.
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OPERATING MANUAL
4.2.2 Main menu
Main menu list
Menu item Description
1/8 Edit channel Open a memory channel wizard and create, modify and delete
memory channels.
2/8 User settings Select, add, edit and delete users (requires login). See Section 4.4 ”User
identication” for more information.
3/8 Weld data Check the values of the last weld.
4/8 System cong
menu
Congure the welding system and view device information.
5/8 Language Select the menu language.
6/8 Select feeder
(WF#)
Select another parallel wire feeder for setup.
7/8 Test menu Test system devices.
8/8 Robot menu Congure the robot interface and devices for automated welding.
4.2.3 Memory channel wizard
For further information about the available welding programs, modied processes, Match™ functions and the special enhanced arc performance solution, see the wire feeder's operating manual or the Kemppi website at www.kemppi.com.
Edit channel (Main menu 1/8)
Menu item Value range Description
Select channel
Edit channel 0 - 199 Select which memory channel to edit,
create or delete. The text below the selection shows whether the channel is empty or not.
New channel (displayed when the selected channel is empty)
Menu item Value range Description
1/2 Create new Create a new memory channel by
selecting the welding curve and specifying welding functions and welding parameters. After saving the curve selection, the welding parameter setup is opened automatically.
1. Choose process MIG, 1-MIG, Pulse MIG, Double pulse MIG, WiseRoot+, WiseThin+, Curve number list
Select one of the processes for step-by­step curve selection, or go to the curve number list to select the welding curve directly by its number. In the step-by­step selection the curve list is ltered by each selection to make the curve selection easier.
2. Choose group * Select the group of the base material.
3. Choose material * Select the base material.
4. Choose diameter * Select the ller wire diameter.
5. Choose gas * Select the shielding gas type.
Choose curve * Choose the curve from the list ltered by
the process, material, wire diameter and shielding gas selections.
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OPERATING MANUAL
2/2 Copy from CH… Create a new memory channel by
making a copy from an existing one.
Copy from CH 0 - 199 Select the channel where to make the
copy from.
* The content of the list depends on the available curves and the selections in the
previous steps.
Edit channel (displayed when the selected channel is not empty)
Menu item Value range Description
1/6 Select weld cur ve Change the weld curve. The curve
selection follows the same method as when creating a new channel.
2/6 Welding parameters * Select welding parameters, like wire feed
speed and ne tuning. The list of the available welding parameters depends on the selected welding process.
3/6 Welding functions * Select welding functions, like hot start,
creep start and crater ll.
4/6 Advanced functions * Select advanced welding functions, like
WiseFusion and WisePenetration.
5/6 Copy channel to… Make a copy from this memory channel to
another channel.
Copy channel to 0 - 199 Select the channel number where to make
the copy. Note that making the copy to a non-empty channel overwrites the channel data without conrmation.
6/6 Erase channel Make this channel empty by erasing all
data from the channel.
* See the tables Welding parameters and Welding functions for more information.
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OPERATING MANUAL
Welding parameters
Welding parameters for MIG process (Edit channel 2/6)
Menu item Value range Default value Description
1/7 WFSpeed WFS min -
WFS max
From curve Set the wire feed speed in
0.05 m/min steps from 0.5 to
5.0 m/min and in 0.1 m/min steps above 5.0 m/min.
2/7 WFS max 0.7 - 25.0 m/min * From curve Set the upper limit for the
WFSpeed value.
3/7 WFS min 0.7 - 25.0 m/min * From curve Set the lower limit for the
WFSpeed value.
4/7 Voltage Voltage min -
Voltage max
From curve Set the welding voltage (arc
length).
5/7 Voltage max 8.0 - 50.0 V * From curve Set the upper limit for the
Voltage value.
6/7 Voltage min 8.0 - 50.0 V * From curve Set the lower limit for the
Voltage value.
7/7 Dynamics -9 … +9 0 Control the arc behavior in
short circuit. Lower value results to softer and higher value to rougher arc.
* These are system limits. Actual limits come from the selected welding curve.
Welding parameters for 1-MIG process (Edit channel 2/6)
Menu item Value range Default value Description
1/7 WFSpeed WFS min -
WFS max
From curve Set the wire feed speed
in 0.05 m/min steps from
0.5 to 5.0 m/min and in
0.1 m/min steps above 5.0 m/min.
2/7 WFS max 0.7 - 25.0 m/min * From curve Set the upper limit for the
WFSpeed value.
3/7 WFS min 0.7 - 25.0 m/min * From curve Set the lower limit for the
WFSpeed value.
4/7 FineTuning FineTuningMin -
FineTuningMax
0 Adjust the welding
voltage (arc length) of the welding curve up and down (0 = no adjustment).
5/7 FineTuningMax -9.0 … +9.0 +9.0 Set the upper limit for the
FineTuning value.
6/7 FineTuningMin -9.0 … +9.0 -9.0 Set the lower limit for the
FineTuning value.
7/7 Dynamics -9 … +9 0 Control the arc behavior
in short circuit. A lower value results in a softer arc and a higher value results in a rougher arc.
* These are system limits. Actual limits come from the selected welding curve.
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OPERATING MANUAL
Welding parameters for Pulse MIG process (Edit channel 2/6)
Menu item Value range Default value Description
1/8 WFSpeed WFS min -
WFS max
From curve Set the wire feed speed in
0.05 m/min steps from 0.5 to
5.0 m/min and in 0.1 m/min steps above 5.0 m/min.
2/8 WFS max 0.7 - 25.0 m/min * From curve Set the upper limit for the
WFSpeed value.
3/8 WFS min 0.7 - 25.0 m/min * From curve Set the lower limit for the
WFSpeed value.
4/8 FineTuning FineTuningMin
FineTuningMax-
0 Adjust the welding voltage
(arc length) of the welding curve up and down (0 = no adjustment).
5/8 FineTuningMax -9.0 … +9.0 +9.0 Set the upper limit for the
FineTuning value.
6/8 FineTuningMin -9.0 … +9.0 -9.0 Set the lower limit for the
FineTuning value.
7/8 Dynamics -9 … +9 0 Control the arc behavior in
short circuit. A lower value results in a softer arc and a higher value results in a rougher arc.
8/8 Pulse current -10 … +15 % 0 % Adjust the pulse current up
and down.
* These are system limits. Actual limits come from the selected welding curve.
Welding parameters for Double Pulse MIG process (Edit channel 2/6)
Menu item Value range Default value Description
1/10 WFSpeed WFS min -
WFS max
From curve Set the wire feed speed in
0.05 m/min steps from 0.5 to 5.0 m/min and in 0.1 m/ min steps above 5.0 m/min.
2/10 WFS max 0.7 - 25.0 m/min * From curve Set the upper limit for the
WFSpeed value.
3/10 WFS min 0.7 - 25.0 m/min * From curve Set the lower limit for the
WFSpeed value.
4/10 FineTuning FineTuningMin -
FineTuningMax
0 Adjust the welding voltage
(arc length) of the welding curve up and down (0 = no adjustment).
5/10 FineTuningMax -9.0 … +9.0 +9.0 Set the upper limit for the
FineTuning value.
6/10 FineTuningMin -9.0 … +9.0 -9.0 Set the lower limit for the
FineTuning value.
7/10 Dynamics -9 … +9 0 Control the arc behavior in
short circuit. Lower value results to softer and higher value to rougher arc.
8/10 Pulse current -10 … +15 % 0 % Adjust the pulse current up
and down.
9/10 DPulseAmp 0.1 - 3.0, CURVE CURVE Adjust the amplitude of
the wire feed speed, or use the value from the welding curve.
10/10 DPulseFreq 0.4 - 8.0 Hz, CURVE CURVE Adjust the frequency of
the double pulse, or use the value from the welding curve.
* These are system limits. Actual limits come from the selected welding curve.
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OPERATING MANUAL
Welding parameters for WiseRoot+ process (Edit channel 2/6)
Menu item Value range Default value Description
1/6 WFSpeed WFS min -
WFS max
From curve Set the wire feed speed in
0.05 m/min steps from 0.5 to 5.0 m/min and in 0.1 m/ min steps above 5.0 m/min.
2/6 WFS max 1.2 - 11.0 m/min * From curve Set the upper limit for the
WFSpeed value.
3/6 WFS min 1.2 - 11.0 m/min * From curve Set the lower limit for the
WFSpeed value.
4/6 FineTuning FineTuningMin -
FineTuningMax
0 Adjust the base current (arc
heat) of the curve up and down (0 = no adjustment).
5/6 FineTuningMax -9.0 … +9.0 +9.0 Set the upper limit for the
FineTuning value.
6/6 FineTuningMin -9.0 … +9.0 -9.0 Set the lower limit for the
FineTuning value.
* These are system limits. Actual limits come from the selected welding curve.
Welding parameters for WiseThin+ process (Edit channel 2/6)
Menu item Value range Default value Description
1/7 WFSpeed WFS min -
WFS max
From curve Set the wire feed speed
in 0.05 m/min steps from
0.5 to 5.0 m/min and in
0.1 m/min steps above 5.0 m/min.
2/7 WFS max 0.7 - 25.0 m/min * From curve Set the upper limit for the
WFSpeed value.
3/7 WFS min 0.7 - 25.0 m/min * From curve Set the lower limit for the
WFSpeed value.
4/7 FineTuning FineTuningMin -
FineTuningMax
0 Adjust the base current
(arc heat) of the curve up and down (0 = no adjustment).
5/7 FineTuningMax -9.0 … +9.0 +9.0 Set the upper limit for the
FineTuning value.
6/7 FineTuningMin -9.0 … +9.0 -9.0 Set the lower limit for the
FineTuning value.
7/7 Dynamics -9 … +9 0 Control the arc behavior in
short circuit. A lower value results in a softer arc and a higher value results in a rougher arc.
* These are system limits. Actual limits come from the selected welding curve.
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Welding functions
Welding Functions (In Edit Channel menu 3/6)
Menu item Value range Default value Description
1/10 HotStart ON, OFF, USER USER Set the hot start on and o,
or let the user select it from a welding panel.
2/10 HotStartLevel -50 … +100 % 40 % Set the hot start level
related to the welding current level.
3/10 Hot 2T time 0.0 - 9.9 s 1.2 s Set the duration of the hot
start.
4/10 Crater ll ON, OFF, USER USER Set the crater ll on and o,
or let the user select it from a welding panel.
5/10 CraterStart 10 - 250 % 100 % Set the level of the curve
where the crater ll starts from.
6/10 CraterFillEnd 10 - 250 %, not
higher than CraterStart value
30 % Set the level of the curve at
the end of the crater ll.
7/10 CraterTime 0.0 - 10.0 s 1.0 s Set the crater ll slope time.
8/10 Creep start 10 - 99 %, OFF,
CURVE
CURVE Set the creep start o, adjust
the creep start level or select the value of the welding curve being used.
9/10 Start power -9 … 9 0 Adjust the arc ignition
power.
10/10 WiseIgnition ON, OFF OFF Set the touch sense ignition
on and o.
Advanced functions* (Edit channel 4/6)
Menu item Value range Default value Description
1/4 WisePenetration ON, OFF OFF Set the Wise penetration on
and o.
2/4 Penet%(123A) -30 … 30 % 0 % Set the level of the Wise
penetration.
3/4 WiseFusion ON, OFF OFF Set the Wise fusion on and
o.
4/4 WiseFusion% 20 - 60 %, CURVE CURVE The Wise fusion
functionality controls the amount of short circuits in the arc. Lower fusion value reduces the amount of the short circuits and higher value increases the amount.
* If the function is not allowed by the selected process or there is no license for the
function, the text 'NA' (not allowed) is displayed.
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4.2.4 User settings
User settings menu (Main menu 2/8) (login required)*
Menu item Value range Factory value Description
1/5 Change PIN
code
Change your PIN code.
New PIN code 0000 - 9999 0000 Specify a new PIN code.
2/5 User mode ON, OFF OFF Set the user identication mode
on and o.
3/5 Set the user
rights
Change the role for a user.
Select user USER1 - USER10 Select the user whose role you
want to change. Note! You cannot change your own role.
Level Welder,
Supervisor, Administrator
Select the role for the user.
4/5 User activation Create and delete users.
User activation USER1 - USER10 Select the user account that you
want to create /delete.
User Enabled,
Disabled
Create an account by setting the user Enabled, or delete the account by selecting Disabled.
5/5 Reset user PIN
code
Reset the PIN code of a user.
Select user USER1 - USER10 Select the user whose pin code
to reset. The reset value is 0000. Conrm the reset by pressing OK soft button.
* See section 4.4 User identication for more information.
4.2.5 Welding system settings
System cong menu (Main menu 4/8)
Menu item Value range Factory
value
Description
1/20 Water cooling OFF, ON, AUTO AUTO Set the water cooler on and
o, or let the system control the cooler (AUTO). In auto mode the water pump starts when welding starts and stops after a delay when welding stops.
2/20 Cable length 10 - 100 m 10 m Set the welding circuit length
for optimal arc control.
3/20 FineCalib 0 V - 10 V /
100 A
10 V / 100 A Set the compensation for
cable resistance variation.
4/20 System clock View and modify the system
time and date.
5/20 Device information Review the following device
information for each device in the system: DevSW: Unit software version. SysSW: System base software version. BootSW: Boot software version. SW Item: Software item number. Serial: Device serial number. Prog: Programmer name. Date: Programming date.
6/20 Restore settings
ROBOT All settings All memory channels (0-199)
are restored from backup. Setup settings remain as they are.
Restore to factory All memory channels and
their backups are removed. All settings are set to default factory values.
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7/20 License menu
License code Enter a license code
manually:
• Up and down arrows are used to select the code number index.
• Control knob is used to select the code number (0-255).
• ENTER soft button is used to activate the license code after all numbers have been entered.
License timers Check the remaining license
time of the time-based Wise features.
8/20 Weld data delay 1 - 60 s 20 s Specify how long the Weld
Data is displayed after welding stops. Weld Data display can be closed by turning the control knob or pressing any button.
9/20 Display delay 1 - 20 10 Specify how long any
textual information (like ”Settings saved”) is displayed on the screen. This is an approximate time value and the actual delay may vary depending on the system load.
10/20 Pre gas time 0.0 - 9.9 s,
CURVE
CURVE Override the pre gas time of
the welding curve, or let the system use the curve value.
11/20 Post gas time 0.0 - 9.9 s,
CURVE
CURVE Override the post gas time of
the welding curve, or let the system use the curve value.
12/20 Control * USER, PANEL,
REMOTE, GUN
USER Select which remote control
is used, or let the user choose the remote control freely.
13/20 RemoteAutoRecog * ON, OFF ON Set the automatic
recognition of the remote control unit on and o.
14/20 MIG CurrentDisp ON, OFF OFF Set the MIG current display
on and o. When the MIG current display is o, the wire feed speed is displayed instead.
15/20 WFMotorWarnLev 1.5 - 5.0 A 3.5 A Set the warning level of
the wire feeding motor current. The setting aects how sensitively the system detects issues in the wire feeding system.
16/20 WF end step ON, OFF OFF Set the wire feeding end
step on and o. When the setting is on, the ller wire steps forward at the end of the welding cycle. Otherwise the ller wire remains in the position where it was driven during the welding cycle.
17/20 AutoWireInch * ON, OFF ON Set the automatic
SuperSnake wire inch feature on and o. When the setting is on, the ller wire is driven automatically to the SuperSnake by pressing the wire inch button.
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18/20 Gas guard * ON, OFF OFF Set the gas guard on and o.
Using this feature requires the gas guard to be installed into the wire feeder. This setting does not aect the gas sensor in the A7 MIG Wire Feeder.
19/20 ArcVoltage ON, OFF OFF Set the arc voltage
measurement and calculation function on and o. When on, the arc voltage, current and power are displayed on the setup panel and Web UI during welding.
20/20 SubFeederLength * 10 - 25 m 10 m Set the length of the
subfeeder for arc voltage calculation.
21/21 Gas sensor menu
Enabled ON, OFF OFF Set gas sensor unit on and
o.
Level 5.0 – 20.0 l/min 10.0 l/min Set gas ow detection level.
Gas mixture menu
Ar (0 – 100 %) (100 %) Amount of Argon (Ar) in the
mixture. This value cannot be adjusted manually. The value is automatically decreased when the amount of other gases is increased, and vice versa.
CO2 0 – 100 % 0 % Set the amount of Carbon
Dioxide (CO2) in the mixture.
N2 0 – 100 % 0 % Set the amount of Nitrogen
(N2) in the mixture.
O2 0 – 100 % 0 % Set the amount of Oxygen
(O2) in the mixture.
H2 0 – 100 % 0 % Set the amount of Hydrogen
(H2) in the mixture.
He 0 – 100 % 0 % Set the amount of Helium
(He) in the mixture.
* This setting applies only to manual welding.
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4.2.6 System tests
Test menu (Main menu 7/8)
Menu item Value range Factory value Description
1/4 Wire inch Run the wire inch test by
pressing the START soft button and keeping it pressed. The ller wire is driven forward by accelerating to the selected speed. The test stops when the button is released.
Speed 0.5 - 25.0 m/min 5.0 m/min Select the wire feed speed in
0.05 m/min steps from 0.5 to
5.0 m/min and in 0.1 m/min steps above 5.0 m/min.
WF motor Displays the motor current
during the test.
2/4 Wire retract Run the wire retract test
by pressing the START soft button and keeping it pressed. The ller wire is driven backwards by accelerating to the selected speed. The test is stopped when the button is released.
Speed 0.5 - 25.0 m/min 5.0 m/min Set the wire feed speed in
0.05 m/min steps from 0.5 to
5.0 m/min and in 0.1 m/min steps above 5.0 m/min.
WF motor Displays the motor current
during the test.
3/4 Gas test Run the gas test by pressing
the START soft button once. The test is run until the test time goes o or until the STOP soft button is pressed (appears in the place of the START button).
Test time 1 - 60 s 20 s Set how long the gas test is
run for.
4/4 Air blow Run the compressed air blow
test by pressing the START soft button once. The test is run until the test time goes o or until the STOP soft button is pressed (appears in the place of the START button).
Test time 1 - 60 s 20 s Set how long the air blow test
is run for.
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4.2.7 Robot settings
Robot menu (Menu 8/8)
Menu item Value range Factory setting Description
1/12 Interface mode * 1 - 99 15 Select the robot I/O table for the eldbus communication.
2/12 Voltage scaling * 0 - 9999 0 (no scaling) Select the maximum value for welding voltage / ne tuning in scaled mode (1-9999), or switch scaled
mode o (0).
3/12 WFS scaling * 0 - 9999 0 (no scaling) Select the maximum value for wire feed speed in scaled mode (1-9999), or switch scaled mode o (0).
4/12 Current scaling * 0 - 9999 0 (no scaling) Select the maximum value for welding current in scaled mode (1-9999), or switch scaled mode o (0).
5/12 Simulation ON, OFF, USER OFF Select welding simulation on and o, or let the user of the robot to manage the simulation (USER).
6/12
Emergency stop menu *
Congure emergency stop functionality. The emergency stop circuitry is connected to the robot interface unit of the A7 MIG Welder.
Selection ON, OFF OFF Set the emergency stop input on and o.
Line level 0 V, 24 V 0 V Select the voltage level of the input line.
Switch type Opening, Closing Opening Select the type of the electrical switch used in the signal line. The opening type switch opens the
electrical circuit of the signal line and the closing type switch closes the circuit.
7/12
Door switch menu * Congure gate door functionality. The gate door circuitry is connected to the robot inter face unit of the
A7 MIG Welder.
Selection ON, OFF OFF Set the gate door input on and o.
Line level 0 V, 24 V 0 V Select the voltage level of the input line.
Switch type Opening, Closing Opening Select the type of the electrical switch used in the signal line. The opening type switch opens the
electrical circuit of the signal line and the closing type switch closes the circuit.
8/12
Touch sensor menu * Congure touch sensor.
Voltage 50 V, 80 V, 110 V, 160 V,
170 V, 180 V, 200 V
50 V Select the output voltage level for the touch sensor.
Tool USER, Welding wire, Gas
nozzle
USER Select the tool used for touch sensing (welding wire or gas nozzle), or let the user of the robot to
manage the tool selection (USER).
FastOutput Low-act, High-act Low-act Select the signal polarity of the fast hardware output. The low-active signal pulls the output to 0 V on
logical ’1’ state and the high-active signal releases the output on logical ’1’. The signal is pulled up to 24 V by a resistor when released.
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OPERATING MANUAL
9/12
Coll. sensor menu * Congure collision sensor. The collision sensor is an optional external device connected to the A7 MIG
Wire Feeder.
Selection ON, OFF OFF Set the collision sensor on and o.
Switch type Opening, Closing Closing Select the type of the electrical switch used in the signal line. The opening type switch opens the
electrical circuit of the signal line and the closing type switch closes the circuit.
Output Low-act, High-act High-act Select the polarity of the output signal in the robot interface. The low-active signal is logically ’1’ when
the signal level is 0 V and the high-active signal is ’1’ when the signal level is 24 V.
10/12
Gas sensor menu * Congure gas sensor located in the A7 MIG Wire Feeder.
Enabled ON, OFF OFF Set the gas ow sensor on and o.
Level 5.0 - 20.0 l/min 5.0 l/min Set the gas ow detection level.
Gas type Unk nown, CO2, Argon,
AR18CO2
Unknown Select the shielding gas type used for welding. This selection aects the correctness of the gas ow
measurement.
11/12
Gun menu * Congure the welding torch connected to the A7 MIG Wire Feeder.
Gun type 0 (Normal),
1 (Binzel MasterPull), 2 (Binzel WHPP), 3 (Binzel WHPPi), 4 (Dinse MEP 200E)
0 (Normal) Select the type of the welding torch. Some torches have a push-pull motor, with or without a
tachometer. This selection enables use of certain push-pull torches.
12/12
Network settings * Congure web user interface server's network settings. The server is located in the robot interface unit
of the A7 MIG Welder.
DHCP enabled ON, OFF ON Switch the DHCP (dynamic host conguration protocol) client on for automatic IP settings or o for
manual (xed) settings.
IP address 0.0.0.0 - 255.255.255.254 0.0.0.0 View the current IP address when teh DHCP is on, or specify the IP address manually when the DHCP is
o.
Subnet mask 0.0.0.0 - 255.255.255.254 0.0.0.0 View the current subnet mask when the DHCP is on, or specify the subnet mask manually when the
DHCP is o.
Gateway 0.0.0.0 - 255.255.255.254 0.0.0.0 View the current gateway when the DHCP is on. The Web UI does not use the gateway address, so it is
not necessary to set up this value when the DHCP is o.
* For more information, see the A7 MIG Welder Integration guide.
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OPERATING MANUAL
4.3 Web user interface
To access the web user interface, make sure that the network settings of the web user interface server are correct and the network cable has been plugged in. The cable connection and the network conguration are described in the A7 MIG Welder Integration guide.
Open the web user interface with a web browser to by typing a proper IP address to the browser’s address eld. The IP address can be veried from the setup panel, Robot
Menu > Network settings > IP address.
The web user interface is used only for conguring robotic welding settings. If manual welding is used with the A7 MIG Welder, the conguration of the hand welding wire feeder is done using the setup panel.
1
2
4 5
6
3
Figure 4.2 Web user inter face layout overview
1. Side menu bar
2. Content frame
3. Current user / User logout
4. Setup parameters
5. Setup value controls
6. Pop-up bar (normally hidden)
Side menu bar
The side bar will be hidden if the width of the window is narrowed down. A side bar button appears in the top left corner of the window and can be used to show and hide the side bar.
The menu items are shown according to the access level of the current user. See Section 4.4 "User identication" for more information.
Current user / User logout
Clicking the current username opens a drop-down list with logout text. Clicking the text logs out the current user and redirects automatically to the login window.
Setup parameters and controls
Many of the menu items contain user congurable parameters. The setup parameters and their related controls are listed from top to bottom. They are ordered in functional groups to make system conguration easier.
Setup value controls
The controls allow you to change parameter values. Dierent types of parameter values have controls of types according to the parameter value range. The controls can be button bars, edit boxes, drop-down lists, sliders, and sliders with adjustable min and max limits. The slider value can be provided as a direct value input by clicking the current value and typing a new value.
Pop-up bar
The multi-function pop-up bar on the bottom of the window is normally hidden and appears when needed. The bar appears for error and warning notications and for save changes requests. It allows the user to take actions related to the notication and disappears after one of the buttons has been clicked.
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OPERATING MANUAL
4.3.1 Welding display
Figure 4.3 Welding display, main view
The Welding display view monitors the selected memory channel, the welding process data and the robot control state in real time. The display shows welding current, voltage, power, wire feed speed and gas ow rate. If arc measurement is set on, the measured arc voltage and arc power are also displayed.
You can view and change the welding parameters of the current memory channel by clicking on the memory channel info bar.
Figure 4.4 Welding display – editing welding parameters
Clicking on the memory channel info bar opens a sub view where you can change wire feed speed and, depending on the process, the ne tuning, voltage, dynamics, pulse current, double pulse amplitude and double pulse frequency values during welding. Saving the changes will aect the arc behavior immediately.
4.3.2 Gas, air and wire inch
Figure 4.5 Gas, air and wire inch view
In the Gas, air and wire inch view you can test shielding gas valve, compressed air valve, wire inch and wire retract.
To adjust the duration of the gas and air test, use the slider bars. Then click on the Run gas or Run air button. The test stops automatically after the specied time. Clicking the test button again during the test stops the test immediately.
To adjust the wire feed speed for wire inch and wire retract use the slider bar. Then click either on Run wire backward or Run wire forward button to start the test. The button has to be kept pressed down throughout the whole test. Releasing the button stops the test.
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OPERATING MANUAL
4.3.3 Logbook
Figure 4.6 Logbook view
In the Logbook view, you can scroll to see status messages, warnings, errors and other event information stored into the logbook. Clicking an item opens a dialog box showing more information about the event in a pop-up window.
You can also download the logbook information as a JSON (JavaScript Object Notation) le and store it on your hard disk by clicking the Download button. The JSON le contains the logbook entries that are shown in the current view.
4.3.5 Welding settings – Memory channels
Figure 4.8 Memory channels view
In the Memory channels view you can edit, save and clear welding memory channels. A memory channel contains conguration of the welding process, program, parameters and functions. There are up to 200 memory channels available in the system.
To create a new memory channel, click on the name eld of an empty memory channel and enter a name for the channel. A sub-view with a welding program selector, welding parameters and welding functions will open. Provide all required parameters and hit the Save button in the pop-up bar below.
To view the settings of a memory channel, click on the channel in the list.
To delete a channel, click on the channel name. A delete button will appear on the right side of the name box. Click on the button and conrm delete in a pop-up window.
4.3.4 About
Figure 4.7 About view
The About view shows the software version of the web user interface, the internal serial number of the power source and copyright notices.
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OPERATING MANUAL
Welding program selection
Figure 4.9 Memory channel editing – Welding program view
In the Welding program view you can select the desired welding process and welding program. For some processes there are several available welding programs. The drop­down list of the welding programs can be ltered to make the selection easier by using material group, wire, wire diameter and shielding gas.
Table 4.17: Welding process symbols
Icon Description
!
MIG welding process
*
WiseThin+ welding process
,
WiseRoot+ welding process
#
1-MIG welding process
%
Pulse welding process
'
Double pulse welding process
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OPERATING MANUAL
Welding parameters and functions
Figure 4.10 Memory channel editing – Welding parameters and functions view
In the Welding parameters view you can, depending on the selected welding process,
• set the min, max and initial values for Wire feed speed.
• set the min, max and initial values for Fine tuning or Voltage.
• set the value for the Dynamics and Pulse current.
• set the value manually or from the curve for Double pulse amplitude and
Double pulse frequency.
In the Welding functions menu you can, depending on the selected welding process,
• select Wise functions on and o and set up their eectiveness.
• select Hot start option OFF, ALWAYS ON or USER SETS ON/OFF and set Hot
start level and Hot start time by using the sliders.
• select Crater ll option OFF, ALWAYS ON or USER SETS ON/OFF and set Crater
ll step level, Crater ll end level and Crater ll time by using the sliders.
• select Creep start option CURVE or SET VALUE and set Creep start level by using the sliders.
• select Start power level by using the slider.
• select Touch sense ignition option OFF or ON
Welding settings – Welding system
Figure 4.11 Welding system settings view
In the Welding system view you can modify all settings related to the behavior and function of the welding system.
In the General settings menu you can
• turn Water cooling ON, OFF and AUTO by clicking on the buttons.
• adjust Welding cable length by using the slider bar.
• select Fine tuning calibration point by using the slider bar.
• select Arc voltage measurement ON and OFF by clicking on the button.
In the Wire feed settings menu you can
• adjust Wire feed motor current warning level by using the slider bar.
• select Wire feed end step ON and OFF by using the buttons.
In the Gas settings menu you can
• select Pre gas time and Post gas time CURVE or SET VALUE and adjusting the value by using the slider bar.
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OPERATING MANUAL
In the Gas sensor settings menu you can
• select Gas sensor ON and OFF.
• adjust Gas ow sensing level by using the slider bar.
• select Gas type.
• select Gas valve type from the drop-down menu.
• select Argon, Carbon Dioxide, Nitrogen, Oxygen, Hydrogen and Helium concentration in a Gas mixture.
In the General robot settings menu you can
• select Interface mode for the digital robot interface in the selection box.
• adjust Voltage scaling by using the slider bar.
• adjust Wire feed speed scaling by using the slider bar.
• adjust Current scaling by using the slider bar.
• select Simulation mode by OFF, ON or SELECT AT ROBOT by clicking on the buttons.
• select Gun type from the drop-down menu.
In the Touch sensor settings menu you can
• select Output voltage from the drop-down menu.
• select Touch tool WELDING WIRE, GAS NOZZLE or SELECT AT ROBOT by clicking on the buttons.
• select Fast output polarity LOW-ACTIVE or HIGH-ACTIVE by clicking on the buttons.
In the Collision sensor settings menu you can
• select Collision sensor ON and OFF by clicking on the buttons.
• select Switch type OPENING or CLOSING by clicking on the buttons.
• select Output polarity LOW-ACTIVE or HIGH-ACTIVE by clicking on the buttons.
In the Emergency stop settings menu you can
• select Emergency stop ON and OFF by clicking on the buttons.
• select Gate door switch ON and OFF by clicking on the buttons.
• select Switch type for the emergency stop and the gate door switch by clicking on the buttons.
• select Line level for the emergency stop and the gate door switch by clicking on the buttons.
In the Welding system time menu you can set the welding system time and date automatically or manually by clicking on the buttons.
• Set automatically: The current time and date of the web browser are used.
• Set manually: Before clicking on the button, specify the date and time in the
Welding system time edit box.
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OPERATING MANUAL
4.3.6 Settings – Language
Figure 4.12 Settings – Language view
In the Language view you can select the desired language for the web user interface by clicking on the drop-down menu. If available, the same language is used in the setup panel. If the setup panel is not capable of showing the selected language (for example Chinese) it uses English as the default.
4.3.7 Settings – Users
Figure 4.13 Settings – Users view
Accessing this view requires administrator or service
supervisor rights.
In the Users view you can
• select User identication ON and OFF by clicking on the buttons.
• change Role for a user by clicking the orange arrow and clicking on the WELDER, SUPERVISOR or ADMINISTRATOR button.
• create a new user by typing a name for an unused user account and selecting Role for the user.
• delete a user by clicking on the user’s DELETE button and conrming the delete in the pop-up dialog.
• reset PIN code to 0000 by clicking on the user’s RESET PIN button.
See Section 4.4 "User identication" for more information.
4.3.8 Settings – Change PIN
Figure 4.14 Settings – Change PIN view
In the Change PIN view the current user can change the PIN code by typing the required information in the elds and clicking on the CHANGE PIN button.
See Section 4.4 "User identication" for more information.
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OPERATING MANUAL
4.3.9 Settings – Fieldbus
Figure 4.15 Settings – Fieldbus view
In the Fieldbus view you can identify the eldbus, view the eldbus specic information and set the conguration values. The available information and configuration parameters depend on the eldbus type. See the A7 MIG
Welder Integration guide for more information.
Accessing this view requires administrator or service
supervisor rights.
Changing the eldbus settings aects the
communication between the welder system and the robot.
4.3.10 Settings – Network
Figure 4.16 Settings – Network view
In the Network menu you can congure the network settings of the web user interface server. See the A7 MIG
Welder Integration guide for more information about the
network conguration.
Accessing this view requires administrator or service
supervisor rights.
Changing the network settings aects your access to
the web user interface.
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OPERATING MANUAL
4.3.11 Settings – Backup, restore and reset
Figure 4.17 Settings – Backup, restore and reset view
In the Backup, restore and reset menu you can
• - create a backup le from memory channels and welding system settings by clicking on the
Backup button.
• restore settings from a backup le by clicking on the Choose le button, browsing for the le, selecting from the Memory channels, Welding
system, Users and Network options the desired
items to restore and then press the Restore button.
• reset all welding system settings and memory channels by clicking on the Factory reset button.
• clear the logbook by clicking on the Logbook
reset button and conrming the operation in the
pop-up dialog.
4.3.12 Settings – Licenses
Figure 4.18 Settings – Licenses view
In the Licenses menu you can view the current software licenses.
As an administrator or a supervisor you can add new software licenses. See further information about the available welding programs, modied processes, Match™ functions and special enhanced arc performance solutions on Kemppi's web site at www.kemppi.com.
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OPERATING MANUAL
4.4 User identification
4.4.1 Overview
The user identication system enables access control of individual users. The feature is optional and can be turned on when needed. Initially, the user identication system is turned o. The welding system is in the initial state when it is taken into use for the rst time or after a factory reset.
System conguration, control and monitoring functions are divided into three access levels. The lowest level (level
0) covers the smallest subset of functions. The middle level (level 1) covers a larger subset and the highest level (level 2) covers all the available functions. The access level is associated with a user account by specifying a role for the user. See Table 4.18 "User roles in the A7 MIG Welder
system" for descriptions of dierent user roles and the
associated access levels.
User accounts are protected from unauthorized use by a PIN code. The PIN code is a 4-digit numeric code that can have any value between 0000 and 9999. Each user can change their PIN code. Administrator level users can reset the PIN codes of other users. The user identication system requires at least one existing administrator level user account in order to work correctly. The system prevents deleting or changing an administrator user account when no other administrator account exists.
In the initial state, there is only one user account called “Admin” in the system. The PIN code of the Admin user is ‘0000’ (four zeroes) by default.
Table 4.18 User roles in the A7 MIG Welder system
Role Access level Description
Welder Level 0 A welder works on a robot cell changing workpieces and welding. The welder can
adjust welding values within the limits set by the supervisor. The welder cannot change system settings or memory channels.
Supervisor Level 1 A supervisor teaches the robot new works and prepares the system for welding. The
supervisor species welding value limits to be used by welders. The supervisor creates memory channels and deletes and modies them. The supervisor cannot change the system settings related to the cell conguration.
Administrator Level 2 An administrator builds and maintains the robot cell. The administrator species all
system settings related to the xed environment, for example, emergency stop or welding cable length. The administrator can create, modify and delete other users and set user identication system o if needed.
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4.4.2 Turning user identification system on
The user identication system can be turned on from either the web user interface or the setup panel.
Setup panel
Turning the user identication system on requires
administrator privileges in the setup panel. Go to
the Main menu > User settings and select a user with administrator privileges. Provide a valid PIN code to log in. In the User settings menu look for the User mode parameter and select the desired value (ON). Press the
Save button to save the settings.
Web user interface
In the web user interface the user identication system can be turned on without user login. Note that you still need to have a valid administrator PIN code available. The system requires user login immediately after the user identication system has been turned on and the user identication system cannot be turned o without administrator privileges. Go to the Settings > Users page and switch the User
identication parameter on. A pop-up dialog with Save
and Reset changes buttons will appear at the bottom. Press the Save button in the dialog to save the settings. The user interface will go to a login page automatically. Select an appropriate username and provide a PIN code to log in.
4.4.3 Creating new users
Creating a new user requires administrator privileges. Welders and supervisors cannot create users. There are up to ten user accounts available in the system. If all ten user accounts are in use, a new user cannot be created.
Setup panel
Go to the Main menu > User settings and provide your PIN code to access the User settings menu. Go to the
User activation and select a user number from the USER1
- USER10 until the text (Disabled) appears under the
username. This means that the particular user account is not in use. Click the Select button and switch the user to Enabled. Press the Set button. The new user is now created with welder privileges. In order to change the user privileges, see Subsection 4.4.5 "Changing user role".
You cannot congure usernames in the setup panel. In that case users are displayed by their system name (USER1, USER2...). Use the web user interface to congure the usernames.
TThe default PIN code for the new user account is 0000. To change the PIN code, the newly created user needs to be logged in. See Subsection 4.4.7 "Changing pin code" for more information.
Web user interface
Go to the Settings > Users page. In the web user interface the user identication system must be turned on to access user settings. Available unused user accounts are displayed in gray font. Click the text Click to create a new
user on the account you want to create and type a name
for the user. The user interface will make other options automatically available and a pop-up dialog with Save and Reset changes buttons appear at the bottom. Select the role for the user by clicking the Welder, Supervisor or
Administrator buttons. Click the Save button to save the
settings. The new user has been created with the default PIN code 0000. To change the PIN code, the newly created user needs to be logged in. See the Subsection 4.4.7
"Changing PIN code" for more information.
The Settings > Users selection in the side menu is not visible to welders and supervisors. If you cannot see the selection, you do not have the privileges to change user settings. Log out and log in using another account with administrator privileges.
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4.4.4 Deleting a user
Deleting a user requires administrator privileges. Welders and supervisors cannot delete users. At least one administrator account is required in the system. You cannot delete your own account.
Setup panel
Go to the Main menu > User settings and provide your PIN code to access the User settings menu. Go to the User
activation and select the user you want to delete. Switch
the user to Disabled and press the Set button. The user is now deleted and the account released for further use.
Web user interface
Go to the Settings > Users page. The user identication system must be turned on to access user settings. Users have a Delete button in their user account. Press the button to delete a user. A conrmation dialog with Delete and Cancel buttons appears. Press the Delete button on the dialog. The user is now deleted and the account released for new user.
4.4.5 Changing user role
When a new user is created in the web user interface, the user role is specied for the user in the same view. When a new user is created in the setup panel, the default role is Welder. The role can be changed afterwards. Changing a user role requires administrator privileges.
Setup panel
Go to the Main menu >User settings and provide your PIN code to access the User settings menu. Go to the Set
user rights and select the user whose role you want to
change.
You cannot change your own role.
Select the role and press the Set button to save the settings.
Web user interface
Go to the Settings > Users page. The user identication system must be turned on to access user settings. Press the orange arrow > to left of the user icon to see the user options. Select the role for the user by clicking on the
Welder, Supervisor or Administrator buttons. A pop-up
dialog with Save and Reset changes buttons will appear at the bottom. Click the Save button to save the settings.
4.4.6 Changing username
Usernames can be congured in the web user interface. The setup panel does not have this functionality. Changing a username requires administrator privileges. The user identication system must be turned on to access user settings.
Go to the Settings > Users page. Click on the username you want to change and retype the name. A pop-up dialog with Save and Reset changes buttons will appear at the bottom. Click the Save button to save the settings.
4.4.7 Changing PIN code
By default, the PIN code for each user is 0000 (four zeroes). Users can protect their user accounts by personalizing this code. In order to change the PIN code, the user identication system must be turned on.
Setup panel
Go to Main menu > User settings and provide your PIN code to access the User settings menu. Go to Change
PIN code and specify the new PIN code digit by digit. Go
to the next digit by pressing the Next button. After the fourth digit press the OK button to save the settings. The PIN code is now changed.
Web user interface
Go to the Settings > Change PIN page. On the page, enter the old PIN code in the rst box and the new PIN code twice in the boxes below. Press the Change PIN button. The PIN code is now changed.
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4.4.8 Resetting PIN code
The administrator can reset a PIN code to let the user redene it and access the system again. Resetting the PIN code requires administrator privileges.
Setup panel
Go to the Main menu > User settings and provide your PIN code to access the menu. Go to the Reset user PIN code and select the user whose PIN code you want to reset. Conrm reset by pressing the OK button.
Web user interface
Go to the Settings > Users page. The user identication system must be turned on to access users. Press the Reset
PIN button on the right side of the user whose PIN code
you want to reset. Please note that the reset operation is not conrmed – pressing the Reset PIN button will reset the PIN code immediately. A dialog with an OK button will appear indicating a successful operation.
4.4.9 Logging in and out, changing active user
Setup panel
The setup panel displays User logged o text when no user is logged in. To log in press the F2 button, select a user, provide a valid PIN code and press OK. You are now logged in.
To log out, press F2, select Log o and press Select. Alternatively, press the power button on the setup panel for ve seconds to log out.
When a user has already logged in, you can log in as an active user without logging out. To change you as the active user, press the F2 button, select your user account, provide a valid PIN code and press OK. You are now the active user and the other user account is logged out automatically.
Web user interface
The web user interface shows the login page when no user is logged in. To log in, select a user from the drop-down box, provide a valid PIN code and press the Login button.
To log out, locate your username in the right top right corner of the view. Press your name to open a drop-down list and select logout. The web user interface will redirect you to the login page.
When a user has already logged in, follow the logout and login instructions to change yourself as the active user.
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4.5 Touch sensor
The touch sensor is a specic functional system used in automated welding for finding workpiece’s accurate location and position. The touch sensor hardware and I/O is located in the robot interface unit. A welding robot nds the particular 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 shortcut 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 conguration by software.
The touch sensor system consists of hardware and software. The hardware consists of a touch sensor device, a fast status output connector and wiring in the wire feeder’s control cable for the gas nozzle use (see Figure 4.20 "Touch
sensing system"). The software enables conguration and
control. Conguration is available in the setup panel and in the web user interface. The touch sensor is controlled by the welding robot using the digital robot interface.
1
2
34
Figure 4.19 Touch sensor in the robot interface unit
1. Wire feeder control cable connector (wiring for the gas nozzle)
2. Touch sensor device inside the robot interface unit
3. Fast status output (direct hardware output)
4. Fieldbus / Digital robot interface
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Fieldbus
1
9
2
10
3
8
4
7
5
6
Figure 4.20 Touch sensing system
1. Conguration (web user interface or setup panel)
2. Welding plus (welding wire touch sensing)
3. Wire feeder control cable (gas nozzle touch sensing)
4. Fast status (direct hardware connection, optional)
5. Fieldbus / Digital robot interface
6. Arc measurement cables
7. Peripheral connector
8. Touch tool (welding wire or gas nozzle)
9. Touch detection
10. Welding minus (touch sensor ground)
On/O control
The touch sensor device behaves as a software controllable power source. The power source can be switched on or o from the robot controller by using the digital robot interface. The touch sensor cannot be put on or turned o from the setup panel or the web user interface.
The touch sensor cannot be used when the welding cycle is on.
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4.5.1 Voltage source, levels and safety
The touch sensor provides eight software selectable DC voltage levels (see Table 4.19,
“Voltage levels”). The voltage level can be congured in the web user interface or the
setup panel. See Subsection 4.5.5, “Selecting output voltage” for more information on the voltage level setup.
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. Use the gate door safety switch with touch sensor levels above 110 V.
The welder system features an arc measurement function which is performed between the welding plus and minus poles near the welding arc using specic cabling and a measurement circuitry. The measurement system inuences touch sensing when the welding wire is used as a touch tool and when the arc measurement cables are connected. The measurement system does not inuence touch sensing when the gas nozzle is used as the touch tool.
The touch sensing is inuenced when
• the arc measurement cable between the power source and the wire feeder (included in the cable set) is connected, but the arc measurement clamp from the wire feeder to the workpiece is disconnected.
• the clamp is also connected. This situation is more harmful because it causes false touch detection at certain voltage levels.
The Table 4.19, “Voltage levels” describes all setups and their relative voltage levels. The accuracy of all values in the table except the nominal voltage is ±5 %.
Table 4.19 Voltage levels
Nominal voltage
Voltage (gas nozzle)
Voltage (welding wire)
Voltage (welding wire + arc cable on)
Voltage (welding wire + arc clamp on)
50 V 55 V 54 V 54 V 50 V
80 V 80 V 80 V 77 V 74 V
110 V 110 V 110 V 105 V 87 V
150 V 150 V 150 V 130 V 89 V*
160 V 160 V 160 V 130 V 89 V*
170 V 170 V 170 V 130 V 89 V*
180 V 180 V 180 V 130 V 89 V*
200 V 200 V 200 V 130 V 89 V*
*Values cause false detection on touch sensor.
The power source and the touch sensing circuitry are galvanically isolated from the other systems in the robot interface unit.
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4.5.2 Touch tool
Two alternative touch tools can be used for touch sensing (see Figure 4.21, “Welding wire used as touch tool” and
Figure 4.22, “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 10-pole peripheral connector (pin F) to the gas nozzle.
The touch tool can be forced by the conguration in both the web user interface and the setup panel, or the selection can be allowed to be managed by the robot controller by using the digital robot interface. See Subsection 4.5.6,
“Conguring touch tool” for more information on these
alternatives.
Figure 4.21 Welding wire used as touching tool
Figure 4.22 Gas nozzle used as touching tool
4.5.3 Fast status output
The fast status output is a direct hardware output for systems where the latency between the sensing and the detection status reception is an issue. The normal latency is around 10 milliseconds through the eldbus. The response time of the fast output is about 1.5 milliseconds.
See the A7 Welder Integration guide for connecting and conguring the fast output.
4.5.4 Selecting output voltage
The output voltage of the touch sensor power source can be selected by using either the web user interface or the setup panel. Setting the voltage requires administrator
privileges.
Setup panel
Go to the Main menu > Robot menu > Touch sensor
menu and specify the desired output voltage value to the Voltage parameter by turning the control knob. Press the Save button to save the settings.
Web user interface
Go to the Welding settings > System settings > Touch
sensor settings and select the desired output voltage
from the Output voltage drop-down list. A pop-up bar with Save and Reset changes buttons will appear at the bottom. Press the Save button in the dialog to save the settings.
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4.5.5 Configuring touch tool
The touch tool can be congured from the web user interface or from the setup panel. The conguration requires administrator privileges. The touch tool can be forced either to the gas nozzle or the welding wire, or left to be controlled by the robot via the digital robot interface.
Setup panel
Go to the Main menu > Robot menu > Touch sensor
menu and turn the control knob on the Tool parameter to
congure the touch tool. Select the Welding wire or Gas
nozzle to force the tool, or USER to let the tool selection
control to the robot. Press the Save button to save the settings.
Web user interface
Go to the Welding settings > System settings > Touch
sensor settings and select the touch tool by clicking one
of the Touch tool buttons. Select the Welding wire or Gas
nozzle to force the tool, or Select at robot to let the tool
selection control to the robot. A pop-up bar with Save and
Reset changes buttons will appear at the bottom. Press
the Save button in the dialog to save the settings.
4.6 Through Arc Seam Tracking (TAST)
Through-Arc Seam Tracking ( TAST) is used in arc welding for following a welding groove automatically by weaving the welding head (see Figure 4.23, “Weaving the welding
head during TAST”) and measuring the arc length. The
seam tracking provides precise welds in setups where the workpiece position within repetitive tasks varies, or when the route of the groove is complicated.
Figure 4.23 Weaving the welding head during TAST
The arc length depends on the wire tip distance from the middle of the groove. Weaving the welding head between the edges of the groove generates a signal that is directly proportional to the arc length (see Figure 4.24, “TAST
signal waveform”). The generated signal is equivalent to
the welding current.
Arc length
Time
1 2 3
Figure 4.24 TAST signal waveform
1. Shor t arc (edge)
2. Long arc (middle)
3. Shor t arc (opposite edge)
The welding power source measures welding current as a contiguous value during welding. It lters the raw current value to generate a stable signal for the TAST. The TAST signal is valid for all MIG/MAG processes including Pulse MIG and Double Pulse MIG.
The TAST signal is passed to a welding robot as a numeric value using the digital robot interface. Using the TAST requires use of certain I/O tables containing a eld for the TAST value and the control signal. See the A7 MIG Welder
Integration guide for more information.
The TAST function is always available in the digital robot interface and therefor it does not have any conguration parameters in the web user interface or in the setup panel.
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4.7 Collision sensor
For information on connecting and conguring the collision sensor, see the A7 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 collision to an obstacle. The collision detection is usually based on micro switches or optical switches which act on the collision. The information about the detection is passed to the robot that uses it to stop motion immediately to prevent any damage.
In the A7 MIG Welder the collision sensor signal is read by the wire feeder and the information is passed to the robot by the welding system. In addition, a collision causes always the Error 53 Collision detected in the welding system. When the error occurs, the power source stops welding immediately.
Fieldbus
1
3
5
4
2
Figure 4.25 Collision sensing system
1. Collision sensor
2. Fieldbus / Digital robot interface
3. Wire feeder control cable
4. Conguration using web user interface or setup panel
5. Peripheral connector
The collision sensor is mounted to the robot arm, and it is a mounting point for the welding torch (see Figure 4.26, “Collision sensor mounting”).
1 2 3 4
5
Figure 4.26: Collision sensor mounting
1. Robot arm
2. Collision sensor
3. Collision signal cable
4. Torch suspension
5. Torch neck
The collision sensor input hardware is located in the wire feeder. There is a 10-pin peripheral connector in the front panel of the wire feeder. The collision sensor signal is available in the pin E, and the ground for the signal is in the pin H. See the A7 MIG Welder
Integration guide for more information about connecting the collision sensor.
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4.7.1 Setting collision sensor on and off
The collision sensor can be turned on and o by using either the web user interface or the setup panel. Setting sensor on and o requires administrator privileges.
The collision sensor should be turned o by software when there is no collision sensor installed in the system.
Setup panel
Go to the Main menu > Robot menu > Coll. sensor menu and turn the control knob on the Selection to set the sensor ON or OFF. Press the Save button to save the settings.
Web user interface
Go to the Welding settings >Welding system > Collision
sensor settings and select the collision sensor on or o by
clicking the ON or OFF button. A pop-up bar with Save and
Reset changes buttons will appear at the bottom. Press
the Save button in the dialog to save the settings. When turned on, additional settings appear.
4.7.2 Selecting sensor type
The sensor type can be selected by using either the web user interface or the setup panel. Setting the sensor type requires administrator privileges.
Setup panel
Go to the Main menu -> Robot menu -> Coll. sensor menu and select the switch type by turning the control knob on the Switch type parameter. Press the Save button to save the settings.
Web user interface
Go to the Welding settings > Welding system > Collision
sensor settings and select the switch type by clicking Opening or Closing button. The collision sensor must be
on in order to change the other settings. A pop-up bar with Save and Reset changes buttons will appear at the bottom. Press the Save button in the dialog to save the settings. When turned on, additional settings appear.
4.7.3 Selecting output polarity
The output polarity of the sensor aects to the polarity of the signal in the digital robot interface. If the polarity is low-active, the signal is 0 on collision and 1 otherwise. If the polarity is high-active, the signal is 1 on collision and 0 otherwise. Setting the output polarity requires administrator privileges.
Setup panel
Go to the Main menu > Robot menu > Coll. sensor menu, navigate to the Output parameter and turn the control knob on it to change the output polarity. Press the Save button to save the changes.
Web user interface
Go to the Welding settings > Welding system > Collision
sensor settings and select the output polarity by clicking
the Low-active or High-active button. A pop-up bar with
Save and Reset changes buttons will appear at the bottom.
Press the Save button in the dialog to save the settings.
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4.8 Wire feeder
The A7 MIG Wire Feeder can be manually operated in several alternative ways:
• By operating the wire feeder from the web user interface
• By operating the wire feeder from the setup panel
• By operating the wire feeder from the robot teach pendant through the digital robot interface
• By using the illuminated buttons on the wire feeder
1 2
3 4
Figure 4.27 Wire feeder buttons
1. Gas test button
2. Air blow button
3. Wire retract button
4. Wire inch button
The buttons on the wire feeder are illuminated.
All lights are o when:
• main power is o or
• user has not logged into the system (when log in is required) or
• during welding.
One of the lights is o:
• Function is not allowed at the moment (for example, no license for the function in question).
• If the button is pressed the light ashes three times to indicate a prohibited function. The indicated function is not carried out.
A light is on:
• The indicated function is available.
All lights are blinking:
• There is an error in the system that needs to be acknowledged in the setup panel, in the web user interface or from the robot teach pendant.
• Connection to the robot interface has been lost.
The system error cannot be acknowledged from the
wire feeder buttons.
4.8.1 Loading the filler wire in A7 MIG Wire Feeder 25
The ller liner is a consumable part which needs to be changed if it has been worn. To load a new ller liner, follow the following instructions.
Select the correct feed rolls and wire feed guide (wire guide tube and middle wire guide tube) according to the type of the ller wire. See Table 4.20, “Wire guide tubes
with Euro connector”, Table 4.21, “Wire guide tubes with Panasonic connector”, Table 4.22, “Plastic wire feed rolls”
and Table 4.23, “Metal wire feed rolls” for details.
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Mounting wire guide tubes and wire feed rolls to the wire feeder:
1. Open the pressure handle of the wire feed mechanism.
2. Remove the orange -colored fasteners from the motor shafts (lower shafts).
3. Remove the shafts of the auxiliary feed rolls by pulling from the orange-colored knobs.
4. Mount the outlet wire guide tube.
5. Mount the middle wire guide tube, ensuring that the mounting direction is correct (the arrow on the bottom of the middle wire guide tube indicates wire’s direction of travel -> towards the torch).
6. Mount the lower feed rolls, ensuring that the pin on the shaft ts in the cut on the feed rolls.
7. Mount the auxiliary feed rolls inside the pressure handle. While mounting the retainer shafts ensure that the niches of the orange knobs t into the tabs on the pressure handle.
8. Adjust the pressure of the feed rolls by using the adjustment screws.
1
3
2
8
7
6
4
5
Figure 4.28 Mounting wire guide tubes and wire feed rolls
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Figure 4.29 Wire guide tubes with Euro connector
Wire guide tubes with Euro connector
1 2
ø mm outlet tube mm middle tube mm
GT04 T Binzel metal
Fe, Mc, Fc
0.8 – 0.9 SP011460 108 SP007279 33
1.0 SP011461 108 SP007278 33
1.2 SP011462 108 SP007277 33
1.4 SP011768 108 SP007276 33
1.4 – 1.6 SP011463 108 SP007275 33
GT04 T Binzel plastic
Al, Ss (Fe, Mc, Fc)
0.8 – 0.9 SP011446 108 SP007279 33
1.0 SP011447 108 SP007278 33
1.2 SP011448 108 SP007277 33
1.4 SP011451 108 SP007276 33
1.6 SP011452 108 SP007275 33
2.0 SP011453 108 SP007274 33
2.4 SP011454 108 SP007273 33
GT04 T Dinse plastic
Al, Ss (Fe, Mc, Fc)
0.8 – 0.9 SP011443 112 SP007279 33
1.0 SP011445 112 SP007278 33
1.2 SP011769 112 SP007277 33
Table 4.20 Wire guide tubes with Panasonic connector
Wire guide tubes with Panasonic connector
1 2
ø mm outlet tube mm middle tube mm
GT04 T Binzel plastic
Al, Ss (Fe, Mc, Fc)
0.8 – 0.9 SP011770 117 SP007279 33
1.0 SP011771 117 SP007278 33
1.2 SP011772 117 SP007277 33
GT04 T Dinse plastic
Al, Ss (Fe, Mc, Fc)
0.8 – 0.9 SP011773 120 SP007279 33
1.0 SP011774 120 SP007278 33
1.2 SP011775 120 SP007277 33
Figure 4.29 Wire guide tubes
1
2
2
1
1. Outlet tube
2. M iddle tube
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Table 4.22 Plastic wire feed rolls
Wire feed rolls, plastic
ø mm lower upper
Fe, Ss, (Al, Mc, Fc) V-groove
0.6 W001045 W001046
0.8 – 0.9 W001047 W001048
1.0 W000675 W000676
1.2 W000960 W000961
1.4 W001049 W001050
1.6 W001051 W001052
2.0 W001053 W001054
2.4 W001055 W001056
Fc, Mc, (Fe) V-groove, knurled
1.0 W001057 W001058
1.2 W001059 W001060
1.4 – 1.6 W001061 W001062
2.0 W001063 W001064
2.4 W001065 W001066
Al, (Fc, Mc, Ss, Fe) U-groove
1.0 W001067 W001068
1.2 W001069 W001070
1.6 W001071 W001072
Table 4.23 Metal wire feed rolls
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
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4.9 Arc measurement
The welding system supports precise arc voltage, current, and power measurement for specic processes. Using this feature makes it unnecessary to concern about voltage losses in the welding cables. Measurement requires dedicated cables from the power source to the wire feeder (included in the interconnection cable set) and from the wire feeder to the workpiece (a separate cable with a clamp, included in the delivery). See Figure 4.30, “Arc measurement system” for details.
Fieldbus
1
3
2
4
Figure 4.30: Arc measurement system
1. Ear th cable: Cable and clamp for workpiece
2. Positive pole: Connection inside wire feeder
3. Arc measurement cable in the interconnection cable set
4. Setup and monitoring in setup panel and web user inter face
4.9.1 Setup and calibration
For the arc measurement setup and calibration, refer to the A7 MIG Welder Integration
guide.
4.9.2 Display
The arc voltage, current, and power can be displayed in the setup panel and in the web user interface. The setup panel displays a dot after the voltage value to indicate that the value is measured directly from the arc. In the weld data the text “AVol” is displayed for the same determination. In the web user interface, the arc values are displayed on the Welding
display page.
In order to display the values, the arc measurement has to be switched on by the means of the following instructions.
Setup panel
Go to the Main menu > System cong menu, navigate to the ArcVoltage parameter and turn the control knob on it to change the feature on. Press the Save button to save the changes.
Web user interface
Go to the Welding settings > Welding system > General settings and select the Arc voltage on by clicking the corresponding button. A pop-up bar with Save and Reset changes buttons will appear at the bottom. Press the Save button in the dialog to save the settings.
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4.10 Gas flow sensor
The welding system is equipped with a gas ow sensor that is located inside the wire feeder. The sensor is capable of sensing gas ow for any mixture of six base gases containing Argon (Ar), Carbon dioxide (CO₂), Nitrogen (N₂), Hydrogen (H₂), Oxygen (O₂) and Helium (He). The gas ow sensor provides both ow indication and ow rate outputs. The outputs can be monitored in the web user interface and in a robot pendant through the digital robot interface.
These instructions and specications apply to a gas ow sensor unit that is a standalone
device inside the wire feeder.
They do not apply to an integrated gas ow sensor that uses wire feeder hardware. To check the type of the gas sensor in use, go to setup panel’s Main menu > System cong
menu > Device information and navigate through the list. The standalone gas ow sensor
device appears in the list as “Gas sensor unit”. If that entry does not exist, the system uses the integrated gas ow sensor.
4.10.1 On/Off control
The gas ow sensor can be turned on and o. By default, it is o. When turned on, ow rate and status are monitored in web user interface’s welding display.
Setup panel
Go to the Main menu > System cong menu > Gas sensor menu, navigate to the Enabled parameter and turn the control knob on it to change the gas ow sensor on or o. Press the Save button to save the changes.
Web user interface
Go to the Welding settings > Welding system > Gas sensor settings and select the Gas
sensor on or o by clicking the corresponding button. A pop-up bar with Save and Reset changes buttons will appear at the bottom. Press the Save button in the dialog to save
the settings.
4.10.2 Gas flow sensing level
The welding system can indicate ow rate below sensing level. This feature is enabled when the gas ow sensor has been turned on, the gas ow sensing level has been set to greater than zero, and gas is owing by the means of manual control, or during welding. The indication is reported 3 seconds after the gas valve has been opened. The status is monitored in the welding display of the web user interface, and is passed to the robot via the digital robot interface as the GasFlowOk signal.
Setup panel
Go to the Main menu > System cong menu > Gas sensor menu, navigate to the Level parameter and turn the control knob on it to change the gas ow sensing level. Press the
Save button to save the changes.
Web user interface
Go to the Welding settings > Welding system > Gas sensor settings and adjust the Gas ow
sensing level parameter by using the slider, or by clicking on the value and typing a new
value. A pop-up bar with Save and Reset changes buttons will appear at the bottom. Press the Save button in the dialog to save the settings.
4.10.3 Gas mixture setup
Knowing the exact mixture of the shielding gas is necessary for precise gas ow measurement. The gas ow sensor unit supports ow measurement for any mixture of the six base gases, including pure base gases. The mixtures are set up by specifying the percentage of each gas in the mixture.
Recongure the mixture every time when the type of the shielding gas is changed.
The percentage of Argon is changed automatically when adjusting other gases, the total percentage being always 100 %. For example, if Carbon dioxide is increased from 0 to 18 %, Argon is changed automatically from 100 to 82 %. This applies for Ar+18CO₂ gas. If Carbon dioxide is increased to 100 %, Argon is decreased to 0 %. This applies for pure CO₂ gas, etc.
Setup panel
Go to the Main menu > System cong menu > Gas sensor menu > Gas mixture menu. Navigate through the gas parameters and adjust their percentage in the mixture by turning the control knob, according to the shielding gas in use. Press the Save button to save the changes.
Web user interface
Go to the Welding settings > Welding system > Gas sensor settings and adjust the gases by using sliders, or by clicking on the value and typing a new value. A pop-up bar with
Save and Reset changes buttons will appear at the bottom. Press the Save button in the
dialog to save the settings.
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5. TROUBLESHOOTING
5.1 Typical problems
The problems listed and the possible causes are not denitive, but serve to suggest some standard and typical situations that may present during normal environmental use when using the MIG/MAG process with the A7 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 ear th 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 tr y alternative gun.
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5.2 Error codes
Every incident is recorded in the logbook and
displayed to a user.
Severity Priority Description
Warning 1 Does not stop or prevent welding.
Minor error 2 Any welding operations are interrupted in a controlled manner
(involving downslope and crater lling, for instance).
Error 3 Any welding operations are immediately interrupted.
Requires user acknowledgement from the user interface.
Serious error 4 Any welding operations are immediately interrupted.
To acknowledge the error, the device has to be restarted.
Critical error 5 Any welding operations are immediately interrupted.
Turn the machine o, disconnect the power supply and contact the maintenance service.
5.2.1 Power source errors
Code Description Severity Measures
2 UNDERVOLTAGE ALARM
Undervoltage in the mains supply (phase missing).
Error Check the fuses.
3 OVERVOLTAGE ALARM
Lengthy overvoltage in the mains supply.
Error
4 OVERHEAT ALARM
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.
Minor error Do not switch o the power source. Let the fans cool down the device.
5 AUXILIARY VOLTAGE ALARM
Undervoltage in power source control card’s auxiliary voltage. The control card is defective.
Critical error Switch o and restart the power source. Contact the maintenance service if
the error is not resolved.
6 INTERNAL ERROR IN THE POWER SOURCE
A defective control card/connection, or set limit exceeded. Unable to measure auxiliary voltage or current/the set limit exceeded for overcurrent/auxiliary voltage.
Serious error Switch o and restart the power source. Contact the maintenance service if
the error is not resolved.
9 MEASUREMENT CABLE ERROR
Failed to measure welding voltage using a measurement cable. The earth return cable on the measurement cable is disconnected or defective.
Error Connect the earth return cable on the measurement cable to the welding
piece, check the connection of the intermediate cable, and if necessary, replace the intermediate cable.
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10 ILLEGAL PROCESS
The power source does not support the requested process. The welding process is unknown or from a dierent product range.
Error Replace the weld curve on the memory channel to one with a welding
process supported by the power source.
11 CUT-OFF CARD CONTROL ERROR
An error has occurred in the cur-o card control. The cut-o card connector is loose, or the card is defective.
Critical error Switch o the power source. Check that the cut-o card connector is
correctly connected. Restart the power source. If the problem is not resolved, switch o the power source and contact maintenance.
12 WELDING CABLE ERROR
The welding circuit is short-circuited. Incorrect cabling, or a defective cable, or an in-line arc-fed MMA/TIG power source, whose (+) pole is connected to the weld piece, is connected to the MIG/MAG power source outputs at the same time as MIG/ MAG is used, or the arc-fed power source is defective.
Serious error Switch o the MIG/MAG power source. Check that the welding cables are
correctly connected. Disconnect the (+) cable of the arc-fed power source or the entire arc-fed power source from the welding piece. Restar t the MIG/MAG power source. Contact the maintenance service if the error is not resolved.
5.2.2 Cooling unit errors
Code Description Severity Measures
27 GENERAL WATER COOLER ERROR
The cooling unit does not function properly, or coolant circulation is prevented, or the cooling unit is not connected but has been congured ON in the system.
Serious error Switch the cooling unit OFF from the system setup when there is no cooling
unit in the system. Check coolant circulation. Switch o and restart the power source. Contact the maintenance service if the error is not resolved.
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5.2.3 Wire feeder errors
Code Description Severity Measures
42 WIRE FEED MOTOR OVERCURRENT WARNING
The wire feed motor current is close to the current limit when the motor is running. The wire feeder rolls are too tight, the wire spool brake is too tight, or the wire liner is dirty.
Warning Check and replace the consumables in the wire feed unit and the torch.
43 WIRE FEED MOTOR OVERCURRENT ALARM
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.
Error Check and replace the consumables in the wire feeder unit and the torch.
44 WIRE FEED MOTOR SPEED ALARM
Wire feed motor tachometer signal missing. The tachometer is damaged or the wiring is broken.
Critical error Contact the maintenance service.
50 LICENSE IS MISSING
An attempt was made to use an optional accessory, welding program, or a specic setting for welding that has not been activated using a license code.
Error Acquire a license for the optional function you want from the device provider.
51 THE REAR FEED ROLLS ARE SPINNING
The rear feed rolls are loose. The wire feed speed is slowed down or varies.
Warning Tighten the rear feed rolls.
52 THE FRONT FEED ROLLS ARE SPINNING
The front feed rolls are loose. The wire feed speed is slowed down or varies.
Warning Tighten the front feed rolls.
53 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.
Error Reverse the robot arm until the torch no longer touches the obstacle. Check
the torch in case of damages.
5.2.4 Welding curve errors
Code Description Severity Measures
81 WELDING CURVE MISSING
Internal program error. The selected synergic welding curve was not found in the memory. The system memory card is detached or defective.
Error Switch o and restart the power source. Contact the maintenance service if
the error is not resolved.
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5.2.5 Robot interface errors
Code Description Severity Measures
131 THE FIELDBUS CARD HAS NOT BEEN FORMATTED.
Failed to initialize the eldbus card during start-up. The eldbus module is missing, has been incorrectly connected, or is damaged.
Serious error Check that the Anybus CompactCom M30 eldbus module is correctly
connected. Replace if necessary. Contact the maintenance service if the error is not resolved.
132 THE ROBOT IS NOT RESPONDING
Communication to the robot has been lost during welding. The eldbus cable has been broken or detached, or there is a robot failure. Welding is interrupted when a lost connection is detected.
Error Check the eldbus cable.
133 EMERGENCY STOP
A user has pressed the emergency stop button. Welding is immediately interrupted.
Error Identify the reason for the emergency stop. Do not release the emergency
stop button before the cause has been identied and resolved.
134 DOOR SWITCH ACTIVATED
The door of the welding cell is open, or the light eld of the photo-electric device has been broken by passing through it. Welding is immediately interrupted.
Error Close the gate door of the welding cell and acknowledge the signal.
135 LOGBOOK MEMORY CHIP NOT FOUND
The system cannot nd the logbook memory card. The microSD memory card has not been installed in robot interface unit’s card slot, or the contact is defective. The system can be used normally, but log entries cannot be recorded.
Warning Check that the microSD memory chip is correctly connected.
136 THE LOGBOOK MEMORY CARD IS DAMAGED
Failed to write to the logbook microSD memory card. The memory card or the contact is defective. The system can be used normally, but log entries cannot be recorded.
Warning Check the microSD memory card connection and replace the card, if
necessary.
137 THE LOGBOOK MEMORY CARD HAS NOT BEEN FORMATTED
Failed to read from the microSD memory card. The memory card has not been formatted. The system can be used normally, but log entries cannot be recorded.
Warning Format the logbook memory card by using the web user interface. Go to the
Settings > Backup restore and reset and click on the Reset logbook button.
138 LICENSE IS MISSING
An attempt was made to use an optional accessory, welding program, or a specic setting for welding that has not been activated using a license code.
Error Acquire a license for the optional function you want from the device provider.
139 WIRE FEEDER IS MISSING
No contact with the wire feeder. The wire feeder has not been connected to the system, or the connection is defective.
Error Check the connection and condition of the wire feeder interconnection cable.
140 THE LOGBOOK MEMORY CARD IS INVALID
The microSD memory card is the wrong type. The system can be used normally, but log entries cannot be recorded.
Warning Replace the microSD memory card with the right type of card. Kingston®
microSDHC Class-10 10MB/s, min. 4 GB is recommended.
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5.2.6 I/O device errors
Code Description Severity Measures
201 INPUT 1 ERROR
Input 1 reported an error.
Error In addition to an ordinary input signal function, each input of
the I/O device can be congured to report an error or a warning when the input status changes. The warning is just a notication from an event - it does not prevent the operation of the welding system. After clearing its cause, the warning state can be cleared. The error stops welding and prevents operation of the welding system until the situation is cleared and the error state is reset. Both warnings and errors are recorded into the logbook. See the A7 MIG Welder Integration guide for more information on the input conguration.
202 INPUT 2 ERROR
Input 2 reported an error.
Error
203 INPUT 3 ERROR
Input 3 reported an error.
Error
204 INPUT 4 ERROR
Input 4 reported an error.
Error
205 INPUT 5 ERROR
Input 5 reported an error.
Error
206 INPUT 6 ERROR
Input 6 reported an error.
Error
207 INPUT 7 ERROR
Input 7 reported an error.
Error
208 INPUT 8 ERROR
Input 8 reported an error.
Error
209 INPUT 1 WARNING
Input 1 reported a warning.
Warning
210 INPUT 2 WARNING
Input 2 reported a warning.
Warning
211 INPUT 3 WARNING
Input 3 reported a warning.
Warning
212 INPUT 4 WARNING
Input 4 reported a warning.
Warning
213 INPUT 5 WARNING
Input 5 reported a warning.
Warning
214 INPUT 6 WARNING
Input 6 reported a warning.
Warning
215 INPUT 7 WARNING
Input 7 reported a warning.
Warning
216 INPUT 8 WARNING
Input 8 reported a warning.
Warning
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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 overvoltages 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.
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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 qualied 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 proles.
Do not use pressure washing devices.
Only an authorized trained electrician should carry out
repairs to Kemppi machines.
7.3 Service shop 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.
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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
Code Product
6203500 A7 MIG WIRE FEEDER 25-LH-EUR Wire feeder, left handed, euro -connector
6203501 A7 MIG WIRE FEEDER 25-LH-PP Wire feeder, left handed, power pin -connector
6203502 A7 MIG WIRE FEEDER 25-RH-EUR Wire feeder, right handed, euro -connector
6203503 A7 MIG WIRE FEEDER 25-RH-PP Wire feeder, right handed, power pin -connector
6201450 A7 MIG POWER SOURCE 450 Welding power source, 450 A
6201350 A7 MIG POWER SOURCE 350 Welding power source, 350 A
6260458 ROBOT 70-5-GH CABLE SHOE Interconnection cable set, 5 meters, air cooled
6260459 ROBOT 70-5-WH CABLE SHOE Interconnection cable set, 5 meters, water cooled
6260449 ROBOT 70-10-GH CABLE SHOE Interconnection cable set, 10 meters, air cooled
6260460 ROBOT 70-10-WH CABLE SHOE Interconnection cable set, 10 meters, water cooled
6260480 ROBOT 70-20-GH CABLE SHOE Interconnection cable set, 20 meters, air cooled
6260481 ROBOT 70-20-WH CABLE SHOE Interconnection cable set, 20 meters, water cooled
6203520 A7 I/O DEVICE I/O device, 4 inputs, 4 outputs
SP800873 A7 I/O DEVICE EXTENSION CARD Extension card for I/O Device, +4 inputs, +4 outputs
6185485 A7 CONTROL CABLE 5 M Control cable, 5 meters
61854851 A7 CONTROL CABLE 10 M Control cable, 10 meters
61854852 A7 CONTROL CABLE 15 M Control cable, 15 meters
61854853 A7 CONTROL CABLE 20 M Control cable, 20 meters
6185486 A7 CONTROL CABLE EXTENSION 5 M Control cable extension, 5 m
61854861 A7 CONTROL CABLE EXTENSION 10 M Control cable extension, 10 m
9774121DEV ANYBUS-CC M30 DEVICENET DeviceNet eldbus adapter
9774121DEV12 ANYBUS-CC M30 DEVICENET M12 DeviceNet eldbus adapter, M12 connectors
9774121ETH ANYBUS-CC M30 ETHERNET/IP EtherNet/IP eldbus adapter, 1-port version
9774121ETH2 ANYBUS-CC M30 ETHERNET/IP 2-PORT EtherNet/IP eldbus adapter, 2-port version
9774121ETC ANYBUS-CC M30 ETHERCAT EtherCAT eldbus adapter
9774121PRF ANYBUS-CC M30 PROFIBUS PROFIBUS eldbus adapter
9774121PRN ANYBUS-CC M30 PROFINET IO PROFINET IO eldbus adapter, 1-port version
9774121PRN2 ANYBUS-CC M30 PROFINE T IO 2-PORT PROFINE T IO eldbus adapter, 2-port version
9774121MBR ANYBUS-CC M30 MODBUS-RTU Modbus-RTU eldbus adapter
9774121MBT ANYBUS-CC M30 MODBUS-TCP Modbus-TCP eldbus adapter, 1-port version
9774121MBT2 ANYBUS-CC M30 MODBUS-TCP 2-PORT Modbus-TCP eldbus adapter, 2-port version
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10. TECHNICAL DATA
A7 MIG Power Source 350, 450
A7 MIG Power source 350 450
Supply voltage 3~ 50/60 Hz 400 V, -15 % … +20 % 400 V, -15 % … +20 %
Mains connection cable H07RN-F 4G6 (5 m) H07RN-F 4G6 (5 m)
Maximum supply current 23 A 32 A
Eective supply current 21 A 25 A
Fuse 25 A delayed 35 A delayed
No-load voltage (peak) U0 = 85 V – 95 V U0 = 85 V – 95 V
Open circuit voltage (average) 85 V – 103 V 85 V – 103 V
Operating temperature range -20 °C … +40 °C -20 °C … +40 °C
Minimum generator power 35 kVA 35 kVA
External dimensions LxWxH 610 x 240 x 520 mm 610 x 240 x 520 mm
Weight (no mains connection cable) 40.2 kg 40.2 kg
Weight (with mains connection cable) 42.6 kg 42.6 kg
Degree of protection IP23S IP23S
Eciency (100 % duty cycle) 87 % 87 %
Power factor (at max. current) 0.85 0.88
Storage temperature range -40 °C … +60 °C -40 °C … +60 °C
Temperature class (main transformer) 155 (F) 155 (F)
EMC class A A
Minimum short circuit power Ssc of supply network 5.5 MVA 5.5 MVA
Welding range 20 A / 12 V - 350 A / 46 V 20 A / 12 V - 450 A / 46 V
Output (at 60 % duty cycle) 350 A 450 A
Output (at 100 % duty cycle) 330 A 350 A
Power supply for auxiliary devices 50 V DC / 100 W 50 V DC / 100 W
Max. apparent power 22 kVA 22 kVA
Idle power 25 W 25 W
Power supply for cooling unit 24 V DC / 50 VA 24 V DC / 50 VA
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OPERATING MANUAL
A7 Cooler
A7 Cooler
Operating temperature range -20 °C … +40 °C
External dimensions LxWxH 570 x 230 x 280 mm
Weight (no accessories) 11 kg
Degree of protection IP23S
Storage temperature range -40 °C … +60 °C
EMC class A
Operating voltage (safety voltage) 400 V -15 % … +20 %
Cooling power 1 kW
Maximum pressure 0.4 MPa
Tank volume Approx. 3 l
A7 I/O Device
A7 I/O Device 4/4
Operating temperature range -20 °C ... +40 °C
External dimensions LxWxH 262 x 162 x 91 mm
Weight (no accessories) 2.3 kg
Weight (extension card installed) 2.5 kg
Degree of protection IP44
Storage temperature range -40 °C ... +60 °C
EMC class A
Input voltage rating +24 V DC
Input current rating 100 mA
Output voltage rating +24 V DC
Output current rating 100 mA
Operating voltage (safety voltage) 50 V DC
A7 MIG Wire Feeder 25
A7 MIG Wire Feeder 25
Operating temperature range -20 °C ... +40 °C
External dimensions LxWxH 380 x 250 x 170 mm
Weight (no accessories) 7.8 kg
Degree of protection IP21S
Storage temperature range -40 °C ... +60 °C
EMC class A
Gun connection Euro
Wire feed mechanism 4-roll, two motors
Filler wire sizes (Fe solid) 0.8 mm - 1.6 mm
Filler wire sizes (Fe cored) 1.0 mm - 1.6 mm
Filler wire sizes (Ss) 0.8 mm - 1.6 mm
Filler wire sizes (Al) 1.0 mm - 2.4 mm
Filler wire sizes (CuSi) 0.8 mm - 1.2 mm
Wire feed speed adjustment 0.5 m/min - 25 m/min
Operating voltage (safety voltage) 50 V DC
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And you know.
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