Kemppi A7 TIG Orbital System 150 Operating Instructions Manual
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Kemppi A7 TIG Orbital System 150 Operating Instructions Manual

Kemppi A7 TIG Orbital System 150 Operating Instructions Manual

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A7 TIG Orbital System
150

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Summary of Contents for Kemppi A7 TIG Orbital System 150

  • Page 1 A7 TIG Orbital System...

  • Page 2: Table Of Contents

    ............... .. © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...
  • Page 3 ....................© Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 4: Introduction

    INTRODUCTION 1.1 General Important notes Congratulations on choosing A7 TIG Orbital System 150 welding equipment. Used correctly, Kemppi products can Items in the manual that require particular attention in significantly increase the productivity of your welding and order to minimise damage and harm are indicated with provide years of economical service.

  • Page 5: About The Product

    1.2 About the product A7 TIG Orbital System 150 is used for TIG orbital welding. It The system offers a wide operating range and good is a semi-automatic welding method where the arc moves reach and is suitable for automatically and without interruption 360° around tubes •...

  • Page 6: Weld Head

    7.5-metre hose (longer cables are available). The weld head is clamped on tubes by changeable collets. It includes a chamber for shielding gas. Spesific collets are recommended for each tube outer diameter (OD). © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 7: Collets

    (1 set = two pairs). Collets are specified by: • Weld head model • Outer diameter (OD) of the tube or pipe. Two types of collets are available: flush and extended. © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 8: Flush Collets

    Therefore, flush collets have minimal width alignment of tube ends. © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 9: Controller Unit

    Water flow A7 TIG Orbital System 150 features a clear color display, a control knob, and press buttons. Its intuitive graphical user The water flow sensor has a factory preset trip point that interface offers easy-to-use menus and auto programming is not adjustable.

  • Page 10: Installation

    Connect the weld head’s power cable to the Gas In (from cylinder) negative terminal ( – ). Welding power connector ( – ) G. Earth return connector ( + ) © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 11: Suitable Collets To The Collet Frame

    Over-tightening can result in damage to the collet frame or Look through the hole on top of the weld head to tubing. ensure that the alignment is right. Close the hole cover. © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 12: Operation

    150 series controller Tungsten Length Calculator. If the controller is not available, calculate cut-length by using the formula below or a calculator on the Kemppi website. Length calculation formula: Length = rotor gear radius – tube radius – arc gap ©...

  • Page 13: Holder

    The tungsten electrode angles (included angle) between 15° to 30° enable the most automated welding. position) e.g. in case of stripped threads in the rotor. Kemppi recommends 20° for autogenous welding in the general current range used with the 150 series weld heads.

  • Page 14: Electrode Sharpeners

    Desktop model (recommended) allows more precise lengths. It recycles dust into liquid instead of air. You can Fill the water tank with 3.5 liters of Kemppi torch also use a hand-held model. Only sharpening is possible coolant fluid or equivalent (Monopropylenglycol).

  • Page 15: Preparing For Welding

    If the tube wall thickness variation exceeds 10%, conductivity is poor due to oxidation or contaminated from use chamfer cut of 5° on the inside of the tube machining operations, primarily lubricants. ends. © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 16: Shielding And Backing Gas

    When using backing gas, also use dual flow- chemistry, which can affect weld mechanical and corrosion meter regulator that allows having two independently resistance properties adversely. regulated (shielding and backing gas) circuits from one gas bottle. © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 17: Weld Head Control Panel

    Rotation forward or reverse: with these buttons you can move the rotor gear to either direction when welding arc is not on. This is useful when mounting or replacing the electrode or checking its condition. © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 18: Start-Up

    To run a weld in Library Move cursor to (highlighted in red). Press Select. Move cursor to desired program and press Select. Also use cursor and Select to Review Parameters, Review Notes, and Edit Weld. © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...
  • Page 19 • To move to the next screen, press the Next soft key. • Certain items are selected using Enter: for example, the digit to be changed (00.00) or the text labeling subroutine. © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 20: Using Auto Program

    If Password Protection has been applied, you will Press Next when finished. be asked for your password to continue. Select Weld Number using the control knob. Press Next when finished. Back to move to previous screen. © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 21: Override Limit Function

    Run a different weld program. Press Next when finished. Completion of programming Press Main to exit to Main Menu. Press to immediately weld with the new program. © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...
  • Page 22 Use cursor to select item. Modify with the control knob. Certain items may not be modified. The cursor will bypass these items. Choose Next to move through levels and edit as you go. © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 23: Alphanumeric Labeling

    To end text entry and move to the next line on the screen, press Up or Down. Select Weld Number with control knob. Press Next. © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 24: Pulsing Levels

    Move the cursor to the desired line and use the control knob or Enter and control knob for OD and Wall Thickness. You can turn on Auto tack program if necessary using the control knob. Press Next. © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 25: Pre-Purge - Upslope Screen

    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 150 1615...
  • Page 26 Pass 1, Level 2 Move the cursor and enter values with the control knob and press Next, or if no change is necessary, just press Next. © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 27: Other Screens

    Yes on the display), it will cause the weld head to automatically rewind at completion of a weld and come to a halt at the starting rotational position. Post‐purge will also occur simultaneously with auto rewind. © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 28: Maintenance Menu

    You can set/reset the weld counter at any specific number using the control knob. Copy Welds (power source internal memory) © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...
  • Page 29 The gas solenoid is pulled in during Use the control knob to scroll through the alternatives. pre‐purge, welding, and post‐purge. Setting the units of measure The control knob lets you scroll between Standard and Metric. © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 30: Copying/Transferring Files To Memory Stick

    (or presently stored) on the Until the stick has finished initializing, a message will stick. appear on the display “Data Key Not Ready”. If no stick is installed, ERROR message will also display. © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 31: Printing Welds

    The stick will require approximately 1 minute to initialize, at which time the LCD on the side of the key will slowly pulse. When the stick is ready, the LCD blinks rapidly 5 times. © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 32: Tungsten Electrode Length Calculator

    70% of the tube wall. If the intention is to make the weld to immediately follow tacking, set the welding program as the “Next Weld to Run” and the program is loaded automatically. © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 33: Additional Details

    15020 Extended cables Weight 32 kg weld head model 15030 Degree of protection IP 23 weld head model 15040 Operating temperature -20…+40 °C weld head model 15060 © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...
  • Page 34 17.0 16.4 15.9 Purge plug kit 10−100 mm 6206009 0.906 16.5 15.9 15.4 Oxygen content meter 10−1000 ppm 6206008 14.2 25.4 1.000 15.3 14.7 Printer paper roll 58 mm SP800692 © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...
  • Page 35 25.4 1.000 28.6 28.0 27.5 26.9 1.059 27.8 27.3 26.8 28.0 1.102 27.3 26.7 26.2 29.0 1.142 26.8 26.2 25.7 30.0 1.181 26.3 25.7 25.2 33.7 1.327 24.4 23.9 23.4 © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...
  • Page 36 54.0 2.126 26.9 26.3 25.8 60.3 2.374 23.7 23.2 22.7 63.5 2.500 22.1 21.6 21.1 70.0 2.756 18.9 18.3 17.8 76.1 2.996 15.8 15.3 14.8 76.2 3.000 15.8 15.2 14.7 © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...
  • Page 37 35.0 1.378 48.6 48.0 47.5 38.1 1.500 47.0 46.5 46.0 40.0 1.575 46.1 45.5 45.0 41.0 1.614 45.6 45.0 44.5 42.4 1.669 44.9 44.3 43.8 44.5 1.752 43.8 43.3 42.8 © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 38: Collets

    108.0 4.252 45.8 45.3 44.8 114.3 4.500 42.7 42.1 41.6 127.0 5.000 36.3 35.8 35.3 129.0 5.079 35.3 34.8 34.3 139.7 5.500 30.0 29.4 28.9 152.4 6.000 23.6 23.1 22.6 © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...
  • Page 39 1.902 1001238-1.902 1001240-1.902 26.9 1001242-26.9 1001244-26.9 2.000 1001238-2.00 1001240-2.00 28.0 1001242-28 1001244-28 29.0 1001242-29 1001244-29 30.0 1001242-30 1001244-30 35.0 1001242-35 1001244-35 40.0 1001242-40 1001244-40 41.0 1001242-41 1001244-41 44.5 1001242-44.5 1001244-44.5 © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...
  • Page 40 53.0 1001250-53 1001252-53 54.0 1001258-54 1001260-54 54.0 1001250-54 1001252-54 60.3 1001258-60.3 1001260-60.3 60.3 1001250-60.3 1001252-60.3 70.0 1001258-70 1001260-70 70.0 1001250-70 1001252-70 76.1 1001258-76.1 1001260-76.1 76.1 1001250-76.1 1001252-76.1 85.0 1001258-85 1001260-85 © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 41: Tungsten Electrode Material

    5.1.2 Tungsten electrode material Collet product codes for 15060 weld head Tube OD Collet, Collet, Flush Tube OD Collet, Collet, Flush Kemppi uses ceriated tungsten to increase electrode life, (inch) Extended (mm) Extended arc starting, and stability, and recommends this material 2.000 1001262-2.000 1001264-2.000...

  • Page 42: Troubleshooting

    .1mm, which will result in an inconsistent penetration and some standard and typical situations that may present during normal environmental use weld bead width. when using the A7 TIG Orbital System 150. • Collets should be specified to ± .5mm when ordered. Problem: Check the following: The "wheel base"...
  • Page 43 • Oil, dirt or other contaminant on tube ID/OD. Hole in gas line aspirating air. • Pre-purge/postpurge time too short • Poor welding tube alloy • Gas flow rate ID or OD too low © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 44: Maintenance

    Only an authorized trained electrician should carry out Press and measure the actual amount traveled Kemppi recommends that the travel speed are checked or actual run time (or the length of wire). repairs to Kemppi machines. once daily to ensure accuracy.

  • Page 45: Cleaning The Weld Head

    • Clean with alcohol or other suitable solvent and a lint free cloth before reassembling. © Kemppi Oy 2016 A7 TIG Orbital System 150 1615...

  • Page 46: Printer Operation And Maintenance

    This software printouts remain stable for five (5) years, and they can be can be downloaded from the Kemppi datastore as an email archived if suitably stored. This printer uses Thermal Paper attachment. Please contact Kemppi’s service department P/N SP800692.

  • Page 47: 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 48 And you know.

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