Kemppi A7 TIG Orbital System 300 Operating Manual
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Kemppi A7 TIG Orbital System 300 Operating Manual

Kemppi A7 TIG Orbital System 300 Operating Manual

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A7 TIG Orbital System
300

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Summary of Contents for Kemppi A7 TIG Orbital System 300

  • Page 1 A7 TIG Orbital System...

  • Page 2: Table Of Contents

    3.1.7 Shield gas effects ................. . © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...
  • Page 3 ....................© Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 4: Introduction

    INTRODUCTION 1.1 General Congratulations on choosing A7 TIG Orbital System 300 Important notes welding equipment. Used correctly, Kemppi products can significantly increase the productivity of your welding and Items in the manual that require particular attention in provide years of economical service.

  • Page 5: About The Product

    The unit is operated by a remote pendant that or an angled AGC kit. contains all controls. The weld heads allow use in a fabrication facility or in field construction/maintenance applications. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 6: Weld Head

    Oscillation stroke is adjustable from 0 to 16 mm at torch speeds up to 1520 mm per minute. The A7 TIG Orbital System 300 includes an open-type weld Arc gap control head to be fastened on the tube with a guide ring. Insertion kits can be used in guide rings to adapt them to smaller Arc gap control stroke measures 13 mm.

  • Page 7: Controller Unit

    When using Autorewind, the weld head rotates in All the functions of A7 TIG Orbital System 300 are reverse until it finds home location. accessible via one handheld device. The remote control...

  • Page 8: Compatibility

    Oscillation Speed: decrease/increase welding oscillation speed in both programming and welding modes. The A7 TIG Orbital System 300 controller is compatible Oscillation Amplitude: decrease/increase oscillation with A7 TIG Orbital System150 weld heads using an amplitude (torch weave width) during both adapter cable.

  • Page 9: Installation

    Welding power connector ( – ) Earth return connector ( + ) Resettable fuses TRVL = travel motor, WIRE = Wire feed motor, OSC = oscillation (weave), AGC = Automatic gap control © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 10: Water Cooler

    You can fill the water tanks with normal tap water. When employing TIG system at temperatures below +8 °C, add an anti-freeze medium. Fill the water tank with 3.5 liters of Kemppi torch coolant fluid or equivalent (Monopropylenglycol). Use max. 40 % of coolant fluid added to water. This will provide freezing protection to ‐25 °C.

  • Page 11: Weld Head Set-Up

    • A voltage sensing lead is directly attached to feedback for both oscillation and cross seam adjustment. the torch and provides the arc voltage signal used for arc gap control (AGC) operation. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...
  • Page 12 A longer setscrew may be required depending on the piece units that are bolted together by two recessed length of the insert. This is provided if required as part of captive socket-head screws. the insert kit. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 13: Installing Guide Ring On Tube

    Make the end of the fixture square and hold the guide ring tightly against it. Tighten the guide ring against the pipe. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 14: Mounting The Weld Head

    Adjust tensioner length as required and tighten side. with moderate finger force only. Rock the machine lightly to ensure that drive sprocket is properly meshed with the chain. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 15: Wire Spool

    Using an adjustable wrench or pliers, gently rotate the tensioning arm to increase the spring force on the drive roller. Tighten both screws. This adjustment should not be made with wire in the mechanism © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 16: Electrode

    38 mm torque). Use the adjustment screws to set the correct torch angle and position. For most applications, the torch centreline should pass through the centre line of the pipe. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 17: Torch Centering

    Press the Home button to rotate weld head to the next home position. Lower the electrode to position about 1.5 mm above the work (if not using Touch Start mode). © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 18: Operation

    76 to 190 cm/min. For 360° orbital welding, the higher the frequency of 1 Hz is typical for tungsten electrode speeds wire speed, the you need to use pulsillation to control the of 63 to 90 mm/min. weld puddle size. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 19: Root-Pass Procedure

    Observe the chill marks on the weld bead surface. If the chill marks are closer than 0.8 * root land thickness, increase travel speed by 3 mm/min until you have reached the needed reinforcement. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 20: Fill Passes, Oscillation (Weave), And Stringer Bead Techniques

    • If the weld bead is convex, the AGC will have to reinforcement in the horizontal pipes (5G position). constantly correct arc length and the wire entry becomes critical (entry angle should be 15 to 30°). © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 21: Shield Gas Effects

    Radius: 2.4 mm ±0.4 mm Root face: 1.5 mm +0.26 mm – - 0.13 mm Bevel angle: 20° ±0.5° If using counterbore, a 2 mm root face thickness is al- lowed. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 22: Other Preparations

    Use an abrasive cloth to remove any surface oxides or contaminants. Clean the tube end back to approximately 12 mm. Ensure that the tube ID is similarly cleaned © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 23: Controller Unit Menus

    • Screen allows purging of backing gas and coolant. Press Start Weld to initiate weld or press Purge purge gas lines when first connecting a weld head to power source. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...
  • Page 24 Weld in Progress 3.3.1.2 Help The A7 TIG Orbital System 300 contains a context-sensitive help that shows information and instructions about the Pre-Purge screen and line currently selected. This view provides explanation or assistance on an item highlighted by the cursor.

  • Page 25: Maintenance Menu

    In the Main Menu screen, press Menu. This will open the Maintenance Menu screen. Most functions are password- Weld numbers 1–99 are files stored in the internal memory protected if this option is selected. of the power source. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...
  • Page 26 If no stick is installed or it has not yet finished initializing, an error message displays. Press Dnload to download all stored print files to the stick. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 27: Options Menu

    Use the control knob to scroll through the alternatives. feeder, the filler wire feed motor is disabled during the test mode. Setting the units of measure The control knob lets you scroll between Standard and Metric. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 28: Compatible Weld Head Models

    (or the length of wire). Enter the measured value and press Save. Repeat this process until you have achieved desired accuracy, then press Back to return to the Maintenance menu. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 29: 300-Head Guide Ring Speed Factors

    Pipe 14.000” (355.6 mm) 46.5 *This value is the radial height of the guide ring. See calculation of guide ring factor. To determine actual tungsten electrode speed from carriage speed: © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 30: Advanced Help

    If the intention is to make the weld to immediately follow competent electric repair technician. tacking, set the welding program as the “Next Weld to Run” and the program is loaded automatically. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 31: Autoprogram

    OD, wall thickness, material, bevel type, number of passes, program mode, and guide ring factor. You can chain several programs, or if you use the same welds repeatedly, return automatically to the beginning of the program. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...
  • Page 32 Enter all parameters manually. Autoprogram is designed only for predefined J grooves. Use cursor to select line, control knob to modify. To complete programming, press Main to exit to Main Menu. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 33: Alphanumeric Labelling

    Move the cursor to the desired line and use the control knob or Enter plus control knob for OD and Wall Thickness. Turn on auto program if required using the control knob. Press Next. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...
  • Page 34 • LP Wire: percentage of high pulse travel speed to be used during low pulse current Period (O = Off ). © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...
  • Page 35 Time Remaining: automatically calculated once Level Time is entered. • Total Time: total time for weld in seconds. Enter values and press Next soft key to go to Level 2. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...
  • Page 36 • Pulsing Downslope: choice of pulse current or steady-state current during downslope period (Yes or No) • Final Amps: weld current level just prior to arc termination • Post‐purge: period gas flows after arc termination (seconds) © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 37: Prepurge - Upslope

    Home positions, welding always starts at one of them. b) Press the AGC Inhibit key a second time to turn off After a full 360° revolution, downslope will occur at 360° the oscillator and re-center the torch. Home. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 38: Editing A Weld Program

    Use Next to move through levels, editing them as you go. Use Enter to copy one level parameters to the next, but remember that you will override the original parameters. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 39: Completing The Programming

    Updating can be done via USB media. Consult Kemppi workshop service for detailed instructions when Start welding by pressing the Arc On button. updating. © Kemppi Oy 2016...

  • Page 40: Shielding Gas

    (sugar), incomplete fusion, porosity and changes in weld chemistry, which can affect weld mechanical and corrosion resistance properties adversely. Purging is recommended when welding stainless steel, nickel alloys, and most nonferrous base metals. Argon is commonly used. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 41: Purging The Pipe Id With Inert Gas

    If the weld joints are pre-tacked in larger Kemppi offers a purge plug kit that includes a selection of assemblies, tape each unwelded joint to prevent plugs ranging from 10 to 100 mm ID as well as an oxygen excessive loss of purge gas.

  • Page 42: Additional Details

    Axial clearance Torch C/L to rear extremity: 220 mm Torch C/L to front extremity: 10 mm Radial clearance 64 mm (2.5”) with standard spool 51 mm (2.0”) with low profile spool © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 43: Ordering Information

    4.3 Ordering information Kemppi uses ceriated tungsten which increases electrode life, arc starting, and stability. We recommend this for orbital use. 2% ceriated involves no radiation risk. These tungsten electrodes are commonly marked in grey color. Ordering codes of standard length (175 mm) tungsten electrodes and electrode...
  • Page 44 GUIDE RING KIT, 300 (219.1 MM) 10.750” 103853-10750 GUIDE RING KIT, 300 (273.1 MM) 12.750” 103853-12750 GUIDE RING KIT, 300 (323.9 MM) 14.000” 103853-14000 GUIDE RING KIT, 300 (355.6 MM) © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...
  • Page 45 GUIDE RING INSERTION KIT (19.05 MM) 102222-337 GUIDE RING INSERTION KIT (8.56 MM) 102222-750-L GUIDE RING INSERTION KIT (19.05 MM) 102222-342 GUIDE RING INSERTION KIT (8.69 MM) 102222-751 GUIDE RING INSERTION KIT (19.08 MM) © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 46: Troubleshooting

    Should you experience a malfunction from your machine, please consult the trouble- shooting sections below first, and complete some basic checks. If the machine malfunction cannot be corrected with these measures, contact your Kemppi maintenance service workshop. The problems listed and the possible causes are not definitive but serve to suggest some standard and typical situations that may present during normal environmental use when using the A7 TIG Orbital System 300.

  • Page 47: Root-Pass Refinement For Horizontal Pipe (5G Position)

    • Change tungsten electrode geometry: Use a greater included angle tip geometry. ID bead concave 360º • Decrease current. around pipe • Increase wire speed. • Increase travel speed. • Change prep geometry. • Change tungsten geometry. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 48: Common Weld Defects: Identification And Prevention

    • Tubes not tightly butted together • Gas flow rate ID or OD too low • Tubes ends not square • ID purge gas pressure too high; create larger gas exit hole © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 49: Warnings/Error Messages

    8. Master Slave Comm Error Check master slave board 9. Slave Reset Error Check slave board Communication Error between Pendant and Controller Communications failure Press Main to try again or call Kemppi for help © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...
  • Page 50 OSC Speed must be less than xxx IPS (### mm/m). Comment: XXX is the maximum speed allowed for the selected weld head. 17. New Weld Creation Wire Spd must be less than xxx IPM( ### mm/m). © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...
  • Page 51 37. Weld Number xxx Pass You cannot add and delete at the same time. Maintenance Error Comment: weld password protection mode 31. Data Save Failure Calibration save fails; go back to save again (ECA01). © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...
  • Page 52 Comment: when loading next weld program if the next weld program is set wrong. 44. Load Failure File format error Comment: code could be EPC03. 50. Pendant Configuration Done Remote control configuration has changed; reboot the machine. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 53: Checking Machine Setup During Booting

    The default weld head was reset to D Head; press Next to continue. 15. Data Load Failure Machine SN was reset to default; contact Kemppi for support. 16. Data Load Failure Machine Data is reset to default; contact Kemppi for support.

  • Page 54: Machine System Messages

    • Insufficient water flow • Insufficient gas flow • Arc voltage too high • Arc voltage too low • Contact of tungsten electrode with work piece • Any arc outage © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 55: Maintenance

    Do not use compressed air for cleaning as there is a risk that the dirt will compact even more tightly into gaps of cooling profiles. Do not use pressure washing devices. Only an authorized trained electrician should carry out repairs to Kemppi machines. Calibration Calibrate the system every twelve (12) months. Contact Kemppi service for detailed instructions.

  • Page 56: Weld Head Maintenance

    Contact Kemppi to provide rapid the coating can flake off under the pressure of the wire Also remove the small PVC retaining clamp from turn-around service for all equipment.

  • Page 57: Water Cooler Maintenance/Flushing Procedure For The Torch Cable

    If this is the case, you can purchase collet replacement of the hoses. • The gas-lens-type collet bodies give better bodies with wrenching flats from Kemppi. gas coverage of the weld, especially in drafty situations as compared to the spud type.

  • Page 58: Cleaning The Weld Head

    • Remove the rotor gear and polish if necessary with a fine wire brush to remove any traces of arcing. • Clean with alcohol or other suitable solvent and a lint free cloth before reassembling. © Kemppi Oy 2016 A7 TIG Orbital System 300 1615...

  • Page 59: Printer Operation And Maintenance

    Software loading detergent. • Do not clean using any solvents. Kemppi Service Workshops can also test and load firmware • Never wet the inside of the printer. and welding software. © Kemppi Oy 2016...

  • Page 60: Disposal

    The owner of the equipment is obliged to deliver a decommissioned unit to a regional collection centre, as per the instructions of local authorities or a Kemppi representative. By applying this European Directive you will improve the environment and human health.
  • Page 61 And you know.

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