T1
1920630
1616
Robot Gun Mount
EN
OPERATING MANUAL
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Robot Gun Mount T1© Kemppi Oy 2016 1616
OPERATING MANUAL
CONTENTS
1. Robot Gun Mount T1 .........................................................................3
2. Preface ....................................................................................................3
3. Identification .........................................................................................4
4. CE marking ............................................................................................4
5. Safety .......................................................................................................4
5.1 Designated use ..........................................................................................4
5.2 Responsibilities of the user .......................................................................4
5.3 Personal protective equipment ................................................................4
5.4 Signs used in the documentation .............................................................5
5.5 Warning and notice signs .........................................................................5
5.6 Emergency instructions ............................................................................5
5.7 Operation safety ........................................................................................5
5.8 Product safety............................................................................................6
6. Technical data ......................................................................................7
6.1 Ambient conditions ..................................................................................7
6.2 General data ..............................................................................................7
6.3 Weight .......................................................................................................7
6.4 The microswitch ........................................................................................7
6.5 The spring ..................................................................................................7
6.6 General data ..............................................................................................7
6.7 Product-specic gun data .........................................................................8
6.8 Abbreviations ............................................................................................8
6.9 The type plate ............................................................................................8
7. Delivery scope ......................................................................................9
8. Transport ................................................................................................9
9. Storage ....................................................................................................9
10. Functional description ....................................................................10
11. Robot Gun Mount T1 installation .............................................10
11.1 The maintenance position of the robot .................................................10
11.2 Fastening robot mount T1 to the robot ..................................................11
11.3 Mounting the corrugated hose clamp ...................................................12
11.3.1 Motoman® models ................................................................................12
11.3.2 ABB®, Reis®, and OTC® models .................................................................12
11.4 Mounting the hose assembly on the robot ............................................13
11.5 Mounting the liner ..................................................................................15
11.6 Attaching the A7 MIG G gun neck ..........................................................15
11.7 Attaching the A7 MIG W gun neck .........................................................15
12. Operation .............................................................................................16
13. Unmounting .......................................................................................16
14. Maintenance and cleaning ...........................................................16
14.1 Cleaning robot mount T1 with A7 MIG Gun 500-g ................................17
14.2 Cleaning robot mount T1 with A7 MIG Gun 500-w ................................18
15. Troubleshooting ................................................................................19
16. Removing the mount ......................................................................20
16.1 Disposal ...................................................................................................20
16.2 Materials ..................................................................................................20
16.3 Consumables ...........................................................................................20
16.4 Packaging ................................................................................................20
17. Codes for ordering ...........................................................................21
18. Contact tip Life + ..............................................................................22
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OPERATING MANUAL
1. ROBOT GUN MOUNT T1
This document provides product information for the
Kemppi Robot Gun Mount T1 unit.
2. PREFACE
Congratulations on your purchase of this product. Used
correctly, Kemppi products can signicantly increase the
productivity of your welding and provide many years of
economical service.
This operation manual contains important information on
the use, maintenance, and safety of your Kemppi product.
The technical specications of the equipment can be
found in the chapter “Technical data” and at the end of
this manual.
Please read the manual carefully before using the
equipment for the rst time. For your own safety and that
of your work 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: www.kemppi.com.
The specications presented in this manual are subject to
change without prior notice.
Disclaimer
While every eort has been made to ensure that the
information contained in this guide is accurate and
complete, no liability can be accepted for any errors
or omissions. Kemppi reserves the right to change the
specication of the product described, at any time, without
prior notice. Do not copy, record, reproduce, or transmit
the contents of this guide without prior permission from
Kemppi.
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OPERATING MANUAL
3. IDENTIFICATION
Kemppi Robot Gun Mount T1 is used in industry and in the
trade for connecting the gun neck to a robot equipped
with central media guidance. It is available for gas-cooled
guns (A7 MIG Gun 500-g) and liquid-cooled guns (A7
MIG Gun 500-w) by means of dierent adapter anges.
These instructions describe Kemppi Robot Gun Mount T1
only. The Kemppi robot mount must only be operated as
supplied or equipped with authentic Kemppi spare parts.
Figure 1: Kemppi Robot Gun Mount T1
1
4 53 6
2
4. CE MARKING
This device fulls the requirements of the following EU
directives:
• The Machinery Directive, 2006/42/EC
• The EMC Directive, 2004/108/EC
• The RoHS Directive, 2011/65/EU
5. SAFETY
Read and follow the additional safety instructions
enclosed.
5.1 Designated use
Robot Gun Mount T1 may be used only for the purpose
described in these instructions, in the manner described.
Follow the operation, maintenance, and servicing
conditions whenever using the device.
Any other use is considered contrary to the intended use.
Unauthorized conversions or power-increasing
modications are not allowed.
The warranty does not cover wear parts and damage due
to overloading or improper use.
5.2 Responsibilities of the user
• Keep the operating instructions within easy reach
in the location of the device for reference, and
include the operating instructions when handing
over the product.
• Installation, operation, and maintenance work
may only be carried out by qualied personnel.
Qualied personnel are persons who, on account
of their special training, knowledge, experience,
and familiarity with the relevant standards, are
able to assess the tasks assigned to them and
identify possible dangers.
• Keep all other people out of the work area.
• Follow the accident prevention regulations of the
relevant country.
• Ensure good lighting of the work area, and keep
it clean.
• Observe the following standards and guidelines
in particular:
• 89/391/EEC: Directive on the introduction
of measures to encourage improvements in
the safety and health of workers at work
• 2009/104/EC: Directive concerning the
minimum safety and health requirements
for the use of work equipment by workers
at work
• 2004/108/EC: Directive on the
harmonization of the laws of the Member
States relating to electromagnetic
compatibility The occupational health and
safety regulations of the country in question
• Regulations on occupational safety and
accident prevention
5.3 Personal protective equipment
To avoid danger to the user, using personal protective
equipment (PPE) is recommended in these instructions.
PPE consists of the following:
• Protective clothing
• Safety goggles
• A class-P3 respiratory mask
• Gloves
• Safety shoes
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OPERATING MANUAL
5.4 Signs used in the documentation
Items in the manual that require particular attention, to
minimize damage and personal injury, are indicated with
a three-level notication and warning system. Read these
sections carefully, and follow the instructions.
Note: These items give the user a useful piece of
information.
Caution: A cautionary item describes a situation that
may result in damage to the equipment or system.
Warning: Warnings describe a potentially dangerous
situation. If not avoided, it will result in personal harm or
fatal injury.
5.5 Warning and notice signs
The following warning and notice signs can be found on
the product:
Read and observe the operating instructions!
These markings must always be legible. They must not be
covered, obscured, painted over, or removed.
5.6 Emergency instructions
In the event of an emergency, immediately interrupt the
following:
• The power supply
• The ow of compressed air
Further measures are described in the operating
instructions or in the documentation of other peripheral
devices.
5.7 Operation safety
Please study these operation safety instructions and
respect them when installing, operating, and servicing
the machine.
The welding arc and spatter
The welding arc harms unprotected eyes. Also be careful
with reecting ashes from the arc. The welding arc and
spatter burn unprotected skin. Wear safety gloves and
protective clothing.
Danger of re or explosion
Pay attention to re safety regulations. Remove ammable
or explosive materials from the welding location. Always
reserve sucient re-ghting equipment at the welding
location. Be prepared for hazards in special welding jobs –
for example, the danger of re or explosion in welding of
container-type work pieces.
Fire can break out from sparks even several hours after
the welding is done!
Cables
Always check the cables before operating the equipment.
Replace damaged cables without delay.
Damaged cables may cause injury or start a re. Connection
cables must not be compressed or come in contact with
sharp edges or hot work pieces.
The welding power circuit
Isolate yourself by using proper protective clothing, and
do not wear wet clothing. Never work on a wet surface or
use damaged cables. Do not place the MIG gun or welding
cables on the welding machine or on other electric
equipment. Do not press the MIG gun’s switch if the gun is
not directed towards a work piece.
Welding fumes
Make sure that there is sufficient ventilation during
welding. Take special safety precautions when welding
metals that contain lead, cadmium, zinc, mercury, or
beryllium.
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OPERATING MANUAL
5.8 Product safety
Hazards caused by improper use
If improperly used, the device can present risks to people and physical property.
• Use the device in line with its designated use only.
• Do not convert or modify the device to enhance its performance without
appropriate authorization.
The device may only be used by qualied personnel.
• The product has been developed and manufactured in accordance with state-ofthe-art technology and the recognized safety standards and regulations. These
operating instructions warn you against unavoidable residual risks to users, third
parties, devices, and other physical property.
Disregarding these warnings may result in risks to human life and health, harm to
the environment, or other physical damage.
• The product may only be operated in unmodied, technically perfect condition,
within the limits described in these instructions.
• Always observe the limit values specied in the technical data. Overloads lead to
destruction.
• Safety features of the device must never be disassembled, bridged, or otherwise
bypassed.
• During welding work outdoors, use suitable protection against the weather
conditions.
• Check the electrical device for any damage and for proper functioning in
accordance with its designated use.
• Never expose the electrical device to rain, and avoid damp or wet environments.
• Protect yourself from electrical accidents by using insulating mats and wearing
dry clothing.
• Never use the electrical device in areas subject to a risk of re or explosion.
• Arc welding may cause damage to the eyes, skin, and hearing. When working
with the device, always use the prescribed protective equipment.
• Metal vapors, especially from lead, cadmium, copper, and beryllium, are all
hazardous to the health! Ensure the use of sucient ventilation or extraction
systems. Always ensure compliance with the legal limit values.
• Using clean water, rinse work pieces that have been degreased with chlorinated
solvents, to prevent the risk of phosgene gas forming. Do not place degreasing
baths containing chlorine in the vicinity of the welding area.
• Adhere to the general re protection regulations, and remove ammable
materials from the vicinity of the welding work area before starting work.
• Keep suitable re-extinguishing equipment in the work area, ready for use.
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OPERATING MANUAL
6. TECHNICAL DATA
This chapter contains the technical data for the gun mount.
6.1 Ambient conditions
Table 1: Ambient conditions
Ambient temperature
25 °C to 55 °C
Transport and storage
-10 °C to 55 °C
Relative humidity
up to 70% at 20 °C
6.2 General data
Dimensions
Ø = 90 mm L = 162 mm
Weight of the T1 robot mount (excluding gun)
1.6 kg
Max. deection, X, Y axis
10°
Max. deection, Z axis
4–8 mm
Reset precision
± 0.1 mm
6.3 Weight
Model Weight
A7 Robot Gun 500-g 2.2kg
A7 Robot Gun 500-w 2.55 kg
6.4 The microswitch
Type of voltage
DC
Voltage rating
24 V peak value
Load
max. 100 mA
6.5 The spring
Triggering moment
9.6 Nm
Triggering force (at 400 mm distance)
24 N ± 2 N
Deection travel
5.3 mm ± 1 mm
Figure 2: The spring
1 32
• A4 = torsion max. ± 155°
• A5 = torsion max. +90° / -165°
• A6 = torsion max. ± 200°
Torsion A4 plus A6 is max. ± 355°.
6.6 General data
The table below presents the general torch data in line with EN 60 974-7.
A7 MIG Gun 500-g/500-w
Type of voltage DC
Polarity of the electrodes Usually positive
Wire types Commercially available round welding wires
Type of use Automatic
Voltage rating Peak value of 141 V
Protection type of the machineside connections
IP3X (EN 60 529)
Shielding gas (DIN EN439) CO₂ or M21
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OPERATING MANUAL
6.7 Product-specific gun data
The table below presents product-specic gun data in line with EN 60 974-7.
Type Type of
cooling
Load
(A)
ED
(%)
Wire Ø
(mm)
Gas ow
(l/min)
Weight
(g)
CO₂ M21
500-g gas 350 320 100 0.8–1.6 10–30 900
500-w liquid 450 400 100 0.8–1.6 approx. 20750
The cable assembly length is determined on the basis of the robot brand and model.
The load data have been determined under standard conditions, at low to medium
reected heat, with free air circulation and an ambient temperature of about 28 °C.
In use under more rigorous conditions, the load values must be reduced by 10–20%.
Applications with above 360 A are possible in connection with the use of liquid-cooled
Kemppi robot welding guns.
6.8 Abbreviations
DC
Direct current
ED
Duty cycle
MIG
Metal inert gas
MAG
Metal active gas
MAC value
Maximum allowable concentration of harmful substances in the
workplace
Voltage rating
Insulation resistance, electric strength, and protection class
TCP
Tool center point
6.9 The type plate
Robot Gun Mount T1 is identied by a sticker or a Kemppi logo. When contacting the
service sta, please remember to check the production stamp near the Kemppi logo.
For pulse-arc use, the load values are reduced by up to 35%.
Figure 3: T1 type plate
1
4
3
2
1. Type of device
2. Flange serial number
3. Consecutive number
4. Production date
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7. DELIVERY SCOPE
The delivery for a gas-cooled gun includes the following components:
• Kemppi Robot Gun Mount T1
• Operating instructions
• Screwdriver for hexagon-head screws, wrench size 2.5
• Sealing grease, silicone-free, 10 g can
• Certicate of conformity
• Cylinder-head screws, M4×10 (6 pcs.)
The delivery for a water-cooled gun includes the following components:
• Kemppi Robot Gun Mount T1
• Operating instructions
• Certicate of conformity
• Cylinder-head screws, M4×10 (6 pcs.)
For installation of the cable assembly for Robot Gun Mount T1, we recommend a pullin tool. It is not included in the scope of delivery and must be ordered separately as an
accessory.
The equipment parts and wear parts are ordered separately.
Order data and ID codes for the equipment parts and wear parts can be found in the
current catalogue. Contact details for advice and for placing orders can be found online at
www.kemppi.com.
8. TRANSPORT
The components are carefully checked and packed; however, damage may still occur
during shipping.
Checking procedure on
receipt of goods
Check that the shipment is correct by referring to the
shipping note.
In case of damage
Check the package and components for damage (perform
a visual inspection).
In the event of problems
If the goods have been damaged during transport, contact
the last carrier immediately. Keep the packaging (for
possible checks by the carrier).
Packaging for return of
the goods
Use the original packaging and the original packaging
material. If you have questions about the packaging and
safety during shipment, please consult your supplier.
9. STORAGE
The physical conditions for storage in a closed room are -10 °C to 55 °C.
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10. FUNCTIONAL DESCRIPTION
The Kemppi Robot Gun Mount T1 unit is used for accommodating the welding guns in
the exact position needed. The mount is fastened to the robot with cylinder-head screws
and a robot ange.
In order to cover the required performance ranges, there are two distinct mount versions
available, the gas-cooled A7 MIG Gun 500-g and the water-cooled A7 MIG Gun 500-w.
The inserted spring acts with its holding force directly upon the triggering ange and xes
the switching axis, which is positioned by three pins, in zero position.
In the event of a collision, Kemppi Robot Gun Mount T1 can be deected by 10° in X/Y
direction and thereby, as a buer, prevent damage to the gun, peripheral equipment, and
robot.
The integrated microswitches represent an additional component in the subordinate
safety circuit. In the event of a collision, the microswitches interrupt a circuit, which can,
for example, shut down the drive units of the robot.
The signal ow for this operation is carried out through the control cable in the cable
assembly.
11. ROBOT GUN MOUNT T1 INSTALLATION
Risk of injury due to unexpected start-up
For the entire duration of maintenance, servicing, unmounting, and repair work, the
following instructions must be adhered to:
• Switch o the power supply.
• Cut o the compressed air supply.
• Pull the power plug.
Read the safety instructions in this manual and the separate safety instructions.
The system may only be installed by authorized personnel.
11.1 The maintenance position of the robot
Before Robot Gun Mount T1 and the cable assembly can be mounted, the robot must be
placed in the maintenance position.
For the correct attachment of the robot mount and the cable assembly, set the 4th, 5th,
and 6th axes of the robot thus:
• 4th axis = neutral position
• 5th axis = neutral position
• 6th axis = neutral position
Figure 4: The maintenance position of the robot
A4
A5 A6
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OPERATING MANUAL
11.2 Fastening robot mount T1 to the
robot
This section describes how to fasten robot mount T1 to
the robot.
The parts of the system are depicted in the gure below.
Figure 5: Fastening robot mount T1 to the robot
1
4
5
3672
1. Kemppi robot mount T1
2. Robot ange
3. Cylindrical pins, M6×10 (4 pcs.)
4. 6 cylinder screws, M4×14
5. Robot
6. Cylindrical pins, M6×12 (4 pcs.)
7. Cylinder screws, M4×10
For fastening robot mount T1 to the robot, a robot
ange (2) is required. It must correspond to the hole pattern
of the robot mount (1) and of the robot.
Proceed as follows:
1. Mount robot ange (2) on the robot (5), using six
cylinder screws (4), with max. tightening torque
M = 3.5 Nm.
Ensure correct positioning of the cylindrical pin (6). It
species the reference position, relative to the robot.
2. Mount the robot mount (1) on the robot ange (2),
using six cylinder screws (7), with max. tightening
torque M = 3.5 Nm.
Ensure correct positioning of the cylindrical pin (3). It
species the reference position, relative to the robot.
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11.3 Mounting the corrugated hose
clamp
The corrugated hose clamp is mounted only with
Motoman®, ABB®, Reis®, and OTC® robots.
11.3.1 Motoman® models
This section describes how to mount the corrugated hose
clamp on Motoman® robots.
The parts of the system are depicted in the gure below.
Figure 6: Mounting the Motoman® corrugated hose clamp
1
4
3
2
5 mm
1. Robot
2. Cylinder screw, M6
3. Corrugated hose clamp
4. 2 cylinder screws, M4
Proceed as follows:
1. Fasten the corrugated hose clamp (3) to the robot
(1) with a cylinder screw (2).
2. Unscrew the cylinder screws marked “4” such that a
gap of approx. 5 mm is formed between the clamp
halves.
11.3.2 ABB®, Reis®, and OTC® models
This section describes how to mount the corrugated hose
clamp on ABB®, Reis®, and OTC® models.
The gure below refers to ABB® models.
Figure 7: Mounting the ABB®, Reis®, and OTC® corrugated
hose clamp
1. Robot
2. Cylinder screws, M6×25
3. Corrugated hose clamp
4. 2 cylinder screws, M4
Proceed as follows:
1. Fasten the corrugated hose clamp (2) loosely to the
robot (1) with cylinder screws (2) in such a way that
a gap of approx. 5 mm between the clamp halves
is formed.
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11.4 Mounting the hose assembly on the
robot
This section describes how to mount the hose assembly
on the robot.
When mounting liquid-cooled A7 MIG Gun 500-w and
cable assemblies, make sure that the mounting bores for the
water nipples and the O-rings are lubricated.
• When mounting liquid-cooled A7 MIG Gun 500-w
and cable assemblies, make sure that the water
nipples in the welding gun coupling for the A7
MIG Gun 500-w and cable assembly are inserted
correctly into the cable assembly adapter.
Observe the forced positioning.
• After mounting is complete, check for any leaks.
• When mounting liquid- and air-cooled cable
assemblies, make sure that all lines (the control
cable, water hoses, and gas / compressed air
lines) are installed without torsion and with
sucient clearance.
• When mounting liquid-cooled A7 MIG Gun
500-w and cable assemblies, make sure that the
mounting bores for the water nipples and the
O-rings are lubricated.
Figure 8: Mounting the A7 MIG gun cable assembly
1. Pull-in tool
2. Threaded sleeve
3. Bellows
4. Cable assembly connection
5. Cable assembly guide
6. 2 cylinder screws, M4
7. Mounting direction of the cable
assembly
8. Robot
9. Corrugated hose clamp
10. Robot mount T1
11. Welding gun coupling
12. Retaining screw
13. Washer
14. Fastening screw
Steps 1 to 10 refer to the specic versions of Kemppi’s T1 robot mount, with robot axes A4, A5, and A6.
Proceed as follows:
1. Unscrew the threaded sleeve (2) and bellows (3).
2. Unscrew the fastening screw (14) from the welding gun coupling (11) until the screw head and washer (13) make contact.
3. Introduce the cable assembly (6) from behind, through the 4th axis of the robot (8).
For mounting the pull-in tool, please observe the information in the appendix on page 22.
4. Insert the pull-in tool (1) through the robot mount (10) and the 5th axis of the robot (8).
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OPERATING MANUAL
5. Screw the pull-in tool (1) into the cable assembly connection (4) as far as it will go.
6. Pull the cable assembly through the 5th and 6th axes of the robot into the robot
mount as far as it will go, using the pull-in tool.
Position the cable assembly connection (4) by means of the positioning pin and the
groove of the welding torch coupling (11).
7. Secure the fastening screw (14), with max. tightening torque M = 7.5 Nm. Observe
the forced positioning.
Only if the cable assembly connection (4) has been correctly inserted can it be
attached with the fastening screw (14).
8. Unscrew the pull-in tool (1).
9. Slide the corrugated hose at the cable assembly (6) into the corrugated hose clamp
(9) as far as it will go, and clamp with cylinder screws.
Press the corrugated hose into the corrugated hose clamp, and rotate it until it is
rotating in the corrugated hose clamp.
10. Screw in the threaded sleeve (2) as far as it will go, and allow the bellows (3) to lock
into place in the groove.
11. The position numbers in the directions below refer to the following gure, showing
axis positions.
12. Attach the wire feeder (1) to the wire feeder mount (3).
13. Fasten the cable assembly (2) to the wire feeder (1) by using the connection
provided for connection to the machine.
14. Mount the control line of the robot mount for the EMERGENCY STOP switch at the
wire feed unit.
15. Unscrew the fastening screws at the wire feeder (1).
We recommend the following procedure for determining the optimal position of the
wire feeder at extreme welding positions:
Figure 9: Axis positions
A CB
A. Wire feeder
B. Cable assembly
C. Wire feeder mount
See also Section 11.1.
Please observe the operation instructions for the relevant wire feeder.
• The wire feeder can be adjusted horizontally by means of long holes; do not
tighten them during the installation of the cable assembly. Swivel the robot
on the J5 axis by +/- 90°. After that, carry out a torsional movement on the J6
axis by +/- 240°. This will precisely position the wire feeder.
16. Tighten fastening screws at the wire feeder (1).
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11.5 Mounting the liner
New liners have to be shortened to the actual length of the cable assembly.
• For handling the liners, please observe the enclosed wire guide liner mounting
instructions.
• Strip 350 mm of the insulation sheathing of the liner from the front end after
determining the correct length.
11.6 Attaching the A7 MIG G gun neck
This section describes how to attach the A7 MIG G gun neck.
Figure 10: Attaching the A7 MIG G gun neck
1. A7 MIG G gun neck
2. Hexagon wrench
3. Gun mount T1 G
4. Set screws (2 pcs.)
Proceed as follows:
1. Equip the A7 MIG G gun neck (1) with a tip adapter, contact tip, and gas nozzle.
2. Insert the A7 MIG G gun neck (1), via the guide grooves, into the robot mount (3) as
far as it will go.
3. Tighten the set screws (4) with a hexagon wrench (2). Tightening torque
M = 2.5 Nm.
11.7 Attaching the A7 MIG W gun neck
This section describes how to attach the A7 MIG W gun neck.
Figure 11: Attaching the A7 MIG W gun neck
1. A7 MIG W gun neck
2. Positioning pin
3. R obot mount T1
4. Retaining nut
Proceed as follows:
1. Equip the A7 MIG W gun neck (1) with a tip adapter, contact tip, and gas nozzle.
2. Introduce the positioning pin (2) into the marked bore. The A7 MIG W gun neck (1)
can only be fastened in this position.
3. Screw down the A7 MIG W gun neck (1) with the retaining nut (4) on the robot
mount (3).
After the gun has been used for several days, it may no longer be possible to
disconnect it by hand. To disconnect the gun, use a suitable wrench. Do not use pliers to
disconnect the gun.
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OPERATING MANUAL
12. OPERATION
The device may only be operated by qualied personnel.
Because the robot mount is integrated into the gun’s welding process, the operation
steps are performed after the relevant gun has been installed.
Please observe the operating instructions for the A7 MIG Gun 500-g or the A7 MIG Gun
500-w welding guns, as appropriate.
13. UNMOUNTING
Unmounting may only be carried out by specialist personnel. Please make sure that
the shutdown procedures for all components mounted in the welding system are strictly
observed before removal from operation begins.
Risk of injury due to unexpected start-up
For the entire duration of maintenance, servicing, unmounting, and repair work, the
following instructions must be adhered to:
• Switch o the power supply.
• Cut o the compressed air supply.
• Pull the power plug.
Removal from operation depends on the type of welding gun. Please observe the
operating instructions for the 7 MIG Gun 500-g or the A7 MIG Gun 500-w welding
guns, as appropriate.
14. MAINTENANCE AND CLEANING
Scheduled maintenance and cleaning are prerequisites for a long service life and troublefree operation.
Once a month, thoroughly clean the robot mount to remove all dirt and welding spatter.
Risk of injury due to unexpected start-up
For the entire duration of maintenance, servicing, unmounting, and repair work, the
following instructions must be adhered to:
• Switch o the power supply.
• Cut o the compressed air supply.
• Pull the power plug.
Electric shock
Dangerous voltage can be produced because of defective cables.
• Check all live cables and connections for proper installation.
• Replace any parts that have suered damage, deformation, or wear.
The maintenance intervals listed are recommended values and assume single-shift
operation.
• Maintenance and cleaning work may only be carried out by qualied and
trained specialists.
• Always wear your personal protective clothing when performing maintenance
and cleaning work.
• When replacing the liquid-cooled A7 MIG Gun 500-w hose assemblies, make
sure that any coolant residues are removed from the robot mount.
• The maintenance intervals listed are recommended values and assume singleshift operation.
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OPERATING MANUAL
14.1 Cleaning robot mount T1 with A7
MIG Gun 500-g
This section describes how to clean robot mount T1 with
A7 MIG Gun 500-g.
Figure 12: Cleaning robot mount T1 with A7 MIG Gun 500-g
1. Bellows
2. Cover ring
3. O -ring, 28×1.5
4. 2 set screws
5. R obot mount T1
6. Screw
7. Washer
8. Fastening screw
9. Threaded sleeve
Risk of injury
Serious injuries can be caused by parts articulating rapidly.
When cleaning with compressed air, wear suitable
protective clothing – in particular, safety goggles.
Proceed as follows:
1. Clean (5) with compressed air.
2. Unscrew the threaded sleeve (9), and pull it o,
together with the bellows (1).
3. Turn the cover ring (2) to the right as far as it will
go, and remove it.
4. Check the O -ring (3) for wear, and replace it if
necessary.
5. Clean the bores of the set screws (4) with
compressed air.
6. Check the set screws (4) for wear, and replace them
if necessary.
7. Grease the O-ring (3) with sealing grease (included
in the delivery).
8. Remove the screw (6), washer (7), and fastening
screw (8), and clean them, as a single assembly,
with compressed air.
9. Blow compressed air through the bores.
10. Attach the fastening screw (8) and washer (7), and
then remove the screw labeled “6” again.
11. Mount the set screws (4), O-ring (3), cover ring (2),
and threaded sleeves (9, then 1).
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Robot Gun Mount T1© Kemppi Oy 2016 1616
OPERATING MANUAL
14.2 Cleaning robot mount T1 with A7
MIG Gun 500-w
This section describes how to clean robot mount T1 with
A7 MIG Gun 500-w.
Figure 13: Cleaning robot mount T1 with A7 MIG Gun 500-w
1. O -ring, 36×2
2. Gas duct
3. Set screw
4. R obot mount T1
5. 4 O -rings, 3×1.5
6. 2 O -rings, 7×1.5
7. 2 compression sleeves
8. 2 compression springs
9. 2 balls
10. Screw
11. Washer
12. Fastening screw
13. Retaining ring
14. Bellows
Risk of injury
Serious injuries can be caused by parts articulating rapidly.
When cleaning with compressed air, wear suitable
protective clothing – in particular, safety goggles.
Proceed as follows:
1. Pull o the retaining ring (13), together with the bellows (14).
2. Check the O -ring (1) for wear, and replace it if necessary. Before replacing, grease
the O-rings (1) with sealing grease (included in the delivery).
3. Remove the screw (10), washer (11), and fastening screw (12), and clean them, as a
single assembly, with compressed air.
4. Blow compressed air through the bores.
5. Remove the balls (9), compression springs (8), and compression sleeves (7); check
them for damage; and replace them if necessary.
6. Clean robot mount T1 (4) with compressed air.
7. Grease the O-rings (6 and 5) with sealing grease (included in the delivery).
8. Mount the O-rings (6 and 5) on the compression sleeves (7).
9. Mount the balls (9), compression springs (8), and compression sleeves (7).
10. Detach the set screw (3) and gas duct (2), and check them. If necessary, replace
them.
11. Reinstall the fastening screw (12), washer (11), and screw (10).
12. Attach the bellows (14) and retaining ring (13).
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OPERATING MANUAL
15. TROUBLESHOOTING
Risk of injury due to unexpected start-up
For the entire duration of maintenance, servicing, unmounting, and repair work, the
following instructions must be adhered to:
• Switch o the power supply.
• Cut o the compressed air supply.
• Pull the power plug.
In the event of any doubts or problems, please contact your retailer or the
manufacturer.
Please also consult the operating instructions for the other welding components,
such as the power supply and air pressure line.
Problem Cause Solution
Emergency stop signal Cable assembly connected incorrectly See Section 11.4
• Change the feeding system positioning, if possible
• Have it checked and replaced by qualied personnel
Too little play of the cable assembly between feeder and
robot mount
Unscrew cable assembly from feeder and reconnect it, free of torsion
Control line, cable assembly, or board defective
Cable assembly cannot
be introduced into robot
mount T1
No grease on the O-rings of the adapter Lubricate the O-rings with grease
No grease in the mounting bores of the liquid-cooled cable
assembly adapter
Grease the bores
The hose assembly adapter is not inserted correctly into the
module (ensure correct alignment)
• Use the pull-in tool
• Align guide groove
Hose assembly creates
ripples in the robot axis
Cable assembly too long Change the feeding system positioning, if possible
Inaccurate torch reset Dirt deposits in the housing Remove dirt deposits; clean the housing
Robot mount damaged Verication by qualied personnel
Gas loss Liner diameter too large Use a smaller liner
Liner insuciently stripped on the torch side Strip liner 350 mm on the torch side
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Robot Gun Mount T1© Kemppi Oy 2016 1616
OPERATING MANUAL
16. REMOVING THE MOUNT
This section describes how to remove robot mount T1.
Unmounting may only be carried out by specialist personnel. Please make sure that
the shutdown procedures are strictly observed before the unmounting work begins.
Ensure this also for the components integrated into the welding system.
Risk of injury due to unexpected start-up
For the entire duration of maintenance, servicing, unmounting, and repair work, the
following instructions must be adhered to:
• Switch o the power supply.
• Cut o the compressed air supply.
• Pull the power plug.
See also Chapter 13.
Proceed as follows:
1. Disconnect the cable assembly (2) from the wire feeder (1). See Figure 9, in
Section 11.4.
2. Unscrew the threaded sleeve (2) and bellows (3), and remove the fastening screw
(14). See Figure 12, in Section 14.1.
3. Disconnect the gun neck, and remove it. See
• Section 14.1
• Section 14.2
16.1 Disposal
For disposal, the locally applicable regulations, laws, provisions, standards, and guidelines
must be observed. For the welding torch system to be properly disposed of, it must be
unmounted rst.
16.2 Materials
This product consists for the most part of plastics, steel, and non-ferrous metals. Steel and
non-ferrous metals can be melted down, so iron materials are almost innitely recyclable.
The plastic materials used are marked in preparation for appropriate sorting of the materials
for later recycling.
16.3 Consumables
Oils, greases, and cleaning agents must not contaminate the ground or enter the sewer
system. These materials must be stored, transported, and disposed of in suitable containers.
Please observe the relevant local regulations and the disposal instructions on the safety
data sheets supplied by the manufacturer of the consumables. Also, contaminated cleaning
tools (brushes, rags, etc.) must be disposed of in accordance with the information provided
by the manufacturer of the consumables.
16.4 Packaging
The shipping packaging has been reduced to a minimum. Packaging materials are always
selected with attention to their recyclability.
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OPERATING MANUAL
17. CODES FOR ORDERING
Robot gun Item code
A7 MIG gun 500-g SP600575
A7 MIG gun 500-w SP600574
Robot gun mount Item code
Gun mount T3 W SP600574
Gun mount T3 G SP600575
Gun mount T1 W SP600588
Gun mount T1 G SP600589
Gun mount T2 L SP600605
Gun mount T2 XL SP600606
Segment holder for T2 gun mount SP600608
Gun neck Item code
Gun neck A7 MIG 500-w 0˚ SP600550
Gun neck A7 MIG 500-w 22˚ SP600551
Gun neck A7 MIG 500-w 35˚ SP600552
Gun neck A7 MIG 500-w 45˚ SP600553
Consumable parts for A7 MIG guns
Item Type Order code
Contact tip
holder
M8 For liquid-cooled neck SP600629
M8 For gas-cooled neck SP600560
Contact tip Life + Wire Ø Hole Ø
0.8 0.9 W007919
0.9 1.05 W007920
1.0 1.15 W006826
1.2 1.4 W006518
1.6 1.8 W007921
Gas nozzle Bottle form, NW 16/+3 Liquid-cooled SP600554
Bottle form, NW 16/0 Liquid-cooled SP600555
Bottle form, NW 16/-2 Liquid- cooled SP600556
Conical, NW 16/+3 Liquid-cooled SP600557
Conical, NW 16/0 Liquid-cooled SP600558
Conical, NW 16/-2 Liquid-cooled SP600559
Bottle form, NW 16/+3 Gas-cooled SP600626
Conical, NW 16/0 Gas-cooled SP600627
Bottle form, NW 16/0 Gas-cooled SP600643
Bottle form, NW 16/-2 Gas-cooled SP600644
Conical, NW 16/+3 Gas-cooled SP600645
Conical, NW 16/-2 Gas-cooled SP600646
Gas diuser SP600563
Nozzle insulator Insulator SP600561
Insulator, high-temp. SP600562
Neck liner (For wire brake module)
Neck liner, W500, steel 1.0-1.2 SP600564
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OPERATING MANUAL
Liner Liner chili 2.0/4.7, 2.5 m, ROBOT PP SP600667
Liner chili HP 2.0/4.7, 2.5 m, ROBOT EU SP600666
Liner chili HP 2.0/4.7, 2.5 m, ROBOT PP SP600668
Liner chili 2.0/4.7, 2.5 m, ROBOT EU SP600665
PP = Power pin
HP = Heat protection
EU = Euro connection
18. CONTACT TIP LIFE +
The pull-in tool accessory serves for the correct mounting of cable assemblies. The
O-rings at the rod of the pull-in tool indicate the mounting positions of cable assembly
versions A7 MIG Gun 500-g and A7 MIG Gun 500-w. The pull-in tool must only be used
for robot mount T1.
And you know.
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