Kemppi A7 350 Integration Manual
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Kemppi A7 350 Integration Manual

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A7 MIG Welder
A7 MIG Welder
350, 450

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Summary of Contents for Kemppi A7 350

  • Page 1 A7 MIG Welder A7 MIG Welder 350, 450...

  • Page 2: Table Of Contents

    ............© Kemppi Oy 2020...
  • Page 3 WeldingMemoryChannel ..............© Kemppi Oy 2020...

  • Page 4: Introduction

    While every effort has been made to ensure that the information contained in this guide • Create memory channels. is accurate and complete, no liability can be accepted for any errors or omissions. Kemppi • Make a system backup. reserves the right to change the specification of the product described, at any time, without advance notice.

  • Page 5: Hardware Installation

    After installation, make sure all cables and hoses have enough space to move and are attached properly. Remember that the cable, plugs, and other electrical devices may be installed or replaced only by a person authorized to perform such operations. © Kemppi Oy 2020 A7 MIG Welder 2002...
  • Page 6 Fieldbus Fieldbus Figure 3.1: Connection diagram, gas-cooled system Figure 3.2: Connection diagram, water-cooled system © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 7: Power Source

    Connection and installation of the power cable and plug should be carried out only by a suitably qualified person. © Kemppi Oy 2020 A7 MIG Welder 2002...
  • Page 8 The touch sensor electrical characteristics are found in Motor (+) A7 MIG Welder Operating manual. Motor (–) Supply (+24 V) Wire inch input Collision sensor input Touch sensor output for gas nozzle (+50…+200 V) G. Tachometer (+5 V) © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 9: Welding Torch

    In order to operate properly, the push-pull torch must Figure 3.6, “Wire inch button connection”). be configured for use. The configuration is described in Subsection 5.1.4, “General robot settings”. Figure 3.6: Wire inch button connection © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 10: Touch-Sensing With The Gas Nozzle

    Figure 3.8: Opening-action (left) and closing-action (right) switches Connect the collision sensor to pins E and H of the peri- Figure 3.7: Touch sensor gas nozzle connection pheral connector (see Figure 3.9, “Collision sensor connection”). © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 11: Interconnection Cable Set

    This parameter is not available in the web user interface. Figure 3.11: Interconnection cable set (wire feeder end) Arc measurement cable Cooling hoses Shielding gas hose Welding cable Wire feeder control cable © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 12: Wire Feeder Control Cable

    At the wire feeder, make the connection to the control cable connector. At the power source, connect the cable to the control cable connector at the rear of the robot interface unit. © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 13: Fieldbus Communication

    Figure 3.13: Installing a fieldbus adapter The choices are enabled by interchangeable Anybus CompactCom M30 modules manufactured by HMS. See the Table 3.2: Kemppi Oy vendor IDs and device description files A7 MIG Welder Operating manual for the complete list of modules and their order codes.

  • Page 14: Ethernet (Web User Interface Server)

    (max. 110 V). After a gate door switch action, the system is recovered automatically. The emergency inputs are configured via software. The configuration is described in Subsection 5.1.7, “Emergency stop settings. ” © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 15: Touch Sensor Status Fast Output

    Connect the other end of the cable to the hardware input of the robot controller. Figure 3.16: Fast status output connector Supply in +24 V Status signal out Supply GND © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 16: Dual Wire Feeder Support

    The wire feeder configuration is described in Subsection 5.12, “Wire feed settings”. Figure 3.14 Connecting two wire feeders into A7 MIG Welder system © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 17: Installation

    Slide the top cover off by pulling from the handle in the front panel. 12. Unplug the primary wire feeder from the motherboard A101 and from the touch sensor card A102. A101 Remove the plug from the extension connector slot. A105 A102 © Kemppi Oy 2020 A7 MIG Welder 2002...
  • Page 18 15. Plug a touch sensor cable between the switching card A105 input and the touch 18. Plug the water valve control cables to the switching card A105. sensor card output A102. A101 A101 A105 A102 A105 A102 A102 © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 19: Connect The Second Wire Feeder

    The extension kit includes support for water valves. Should you want to use valves to control the circulation, please contact Kemppi service for instructions and guidance. Only one wire feeder can be used for arc voltage measurement at the time. Do not branch the arc measurement cables.

  • Page 20: Accessing The Web User Interface

    Go to the Main menu > Robot > Network settings, and address given by the DHCP server (DHCP enabled). configure the DHCP enabled, address, Subnet mask, Gateway parameters to match your networking environment. © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 21: Opening The Web User Interface

    (or, if login is required, to the login page). Figure 4.1: Enter the IP address in the network browser Figure 4.2: Welding display page The web user interface now ready for use. © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 22: System Configuration

    The initial Total welding cable length 22 m value is 3.5 A. The system issues a warning when the long- term average current exceeds the warning threshold. © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 23: Gas Sensor Settings

    Set the gas mixture according to the concentration of the shielding gas used in your configuration. This value must be changed every time the shielding gas is changed. The gas mixture affects the function of the gas flow sensor. © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 24: General Robot Settings

    SELECT AT ROBOT alternative. Not all interface modes support the touch tool’s selection by a robot. For more information, see Section 5.2, “The digital robot interface”. © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 25: Watchdog Settings

    This timeout value specifies how fast the welding system stops welding if the robot stops sending fieldbus data. The robot must perform continuous transitions on Watchdog signal of the digital robot interface within the timeout period. © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 26: Digital Robot Interface

    The fieldbus settings are stored in the fieldbus module. If you replace the module, the settings must be reconfigured. The fieldbus settings are not included in the system backup file. A factory reset does not affect the fieldbus settings. © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 27: Setting Up Scaling Values

    Gate door switch alternative To set up the scaling values, go to Welding settings > KEMPPI3 KempArc Pulse TAST support Welding system > General robot settings. KEMPPI4 A7 MIG Welder default table 16–99 (Reserved) © Kemppi Oy 2020 A7 MIG Welder 2002...
  • Page 28 Conclusion: The operator uses the control value 555 to achieve the welding voltage of 25 V. The actual welding voltage achieved by using this value is 24.9 V (the less significant digits are lost). © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 29: Users

    “Admin” in the system, with administrator privileges. The initial PIN code for all users, including the Admin user, is 0000 (four zeroes). Require users to change their PIN code at the first login. © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 30: Memory Channels

    Specify the location on your computer where you want to store the file. The backup file can be used to transfer the settings from one system to another. © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 31: I/O Tables

    TouchSensorOn CollisionDetected OnlineControl GasFlowOk OnlineControl GasFlowOk Watchdog Watchdog ErrorReset ErrorReset AirBlow AirBlow (Not in use) (Not in use) WeldingWireFeedSpeed WeldingWireFeedSpeed (Not in use) (Not in use) DigitalOutput1 DigitalOutput1 DigitalOutput2 DigitalOutput2 DigitalOutput3 DigitalOutput3 © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 32: Kemppi3: Kemparc Pulse Customized Table

    GateDoorOpen SimulationMode DigitalInput2 WireInch DigitalInput3 WireRetract DigitalInput4 GasBlow DigitalInput5 TouchSensorToolSel DigitalInput6 TouchSensorOn CollisionDetected OnlineControl GasFlowOk Watchdog ErrorReset AirBlow (Not in use) WeldingWireFeedSpeed (Not in use) DigitalOutput1 DigitalOutput2 DigitalOutput3 (Not in use) TAST © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 33: Kemppi4: A7 Mig Welder Default Table

    CraterFillOn (Not in use) (Not in use) (Not in use) (Not in use) (Not in use) DigitalOutput1 DigitalInput1 DigitalOutput2 DigitalInput2 DigitalOutput3 DigitalInput3 DigitalOutput4 DigitalInput4 DigitalOutput5 DigitalInput5 DigitalOutput6 DigitalInput6 DigitalOutput7 DigitalInput7 DigitalOutput8 DigitalInput8 © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 34: Kemppi5: A7 Mig Welder Table For Pulse Process Control

    CraterFillOn (Not in use) (Not in use) (Not in use) (Not in use) (Not in use) DigitalOutput1 DigitalInput1 DigitalOutput2 DigitalInput2 DigitalOutput3 DigitalInput3 DigitalOutput4 DigitalInput4 DigitalOutput5 DigitalInput5 DigitalOutput6 DigitalInput6 DigitalOutput7 DigitalInput7 DigitalOutput8 DigitalInput8 © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 35: Cust1: Customer-Specific Table

    (Not in use) (Not in use) (Not in use) (Not in use) (Not in use) WireFeedSpeed WeldingCurrent Voltage / FineTuning WeldingVoltage (Not in use) (Not in use) (Not in use) (Not in use) © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 36: Cust3: Customer-Specific Table

    (Not in use) (Not in use) (Not in use) (Not in use) OnlineControl (Not in use) (Not in use) (Not in use) MemoryChannel WeldingMemoryChannel WireFeedSpeed WeldingWireFeedSpeed Voltage / FineTuning WeldingVoltage (Not in use) WeldingCurrent © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 37: Cust5: Customer-Specific Table

    (Not in use) TouchSensed (Not in use) RobotHasControl (Not in use) DigitalInput2 (Wire OK) (Not in use) (Not in use) (Not in use) (Not in use) (Not in use) LocalRemote (Not in use) SimulationMode © Kemppi Oy 2020 A7 MIG Welder 2002...
  • Page 38 Table 6.1: Control functions in the A7 MIG Welder system Voltage 0.1 V FineTuning Dynamics MemoryChannel PulseCurrent PulseBaseCurrent PulseFrequency 5000 0.1 Hz PulseLength 10 us Control signals WeldingAllowed SimulationMode StartWelding WireInch WireRetract GasBlow AirBlow TouchSensorToolSel TouchSensorOn OnlineControl Watchdog ErrorReset HotStartOn CraterFillOn © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 39: Wirefeedspeed

    0.5 m/min. In scaled mode: • The minimum setup value is 0 (0.0 m/min). With this value, the welding system limits the minimum speed to 0.5 m/min. © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 40: Finetuning

    If the OnlineControl signal is cleared (0), the fine tuning from the active memory channel is used. above that are automatically interpreted as 199. • The minimum step is 1. © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 41: Pulsecurrent

    • The maximum setup value is 500 (500 A). • The maximum setup value is 500 (5000 µs). • The minimum step is 1 (1 A). • The minimum step is 1 (10 µs). © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 42: Startwelding

    5.0 m/min. dynamics. • 0 = Wire retract off • 1 = Wire retract on This signal has no effect during welding or simulated welding. © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 43: Watchdog

    • 0 = Hot start off • 1 = Hot start on © Kemppi Oy 2020 A7 MIG Welder 2002...
  • Page 44 Table 6.2: Status functions in the A7 MIG Welder system Value range I/O table Function Bits Status values WeldingCurrent 1024 WeldingVoltage 0.1 V WeldingWireFeedSpeed 8/16 0.1 m/min MotorCurrent 0.1 A GasFlowRate 0.1 l/min ErrorNumber WeldingMemoryChannel TAST 6500 WeldingProcess © Kemppi Oy 2020 A7 MIG Welder 2002...
  • Page 45 Value range I/O table Function Bits Status bits Ready PowerSourceReady CoolingUnitOk ProgramSaved RobotHasControl CycleOn ArcOn GasFlowOk MainCurrentOn CurrentOk MotorCurrentOk WFSpeedOk TouchSensed Error CollisionDetected ToleranceError WireStuck GateDoorOpen © Kemppi Oy 2020 A7 MIG Welder 2002...
  • Page 46 Value range I/O table Function Bits Status bits DigitalInput1 DigitalInput2 DigitalInput3 DigitalInput4 DigitalInput5 DigitalInput6 DigitalInput7 DigitalInput8 Deprecated status bits PanelLocked LocalRemote AutoManual © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 47: Weldingcurrent

    ErrorReset the value scaling formula. control signal or from a user interface. • The minimum value is 0 (no error). • The maximum value is 255. • The minimum step is 1. © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 48: Digital Robot Interface

    • 1 = Welding cycle in progress • 14 = WiseThin+ system. • 0 = Cooling unit error • 1 = Cooling unit OK © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 49: Arcon

    • 1 = Current within the limits • 0 = Collision detected • 1 = Collision not detected This function is not implemented in the A7 MIG Welder. The status is always OK (1). © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 50: Toleranceerror

    This signal function is deprecated. The status is always 1 (local). This function is not implemented in the A7 MIG Welder. The status is always OK (0). 6.2.30 AutoManual This signal function is deprecated. The status is always 0 (manual). © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 51: 43 6.3 Timing Diagrams

    CycleOn ArcOn ArcOn Symbol Description Typical Units Cycle-on time Arc establishment Pre-gas time + Pre-gas time + time open-air distance + 2050 The maximum time is limited by a wire feeding time-out. © Kemppi Oy 2020 A7 MIG Welder 2002...
  • Page 52 Wire touch response time PS.WireStuck E₂ Setup time (Welding phase going) PS.ArcEstablished Setup time (RI Cycle-on) Power source startup time Arc establishment response time H₁ Setup time (Arc established) H₂ Setup time (Arc on) © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 53: Welding Stop Timing

    Units Arc off time Cycle off time Post-gas time + Pre-gas time + The minimum cycle-off time is determined by power-source shutdown time, when the post-gas time is less than 300 ms. © Kemppi Oy 2020 A7 MIG Welder 2002...
  • Page 54 Setup time (Cycle off) ML.SetWireFeedOn Wire touch off time ML.SetPowerSourceOn Arc off response time ML.CreepStartGoing ML.WeldingPhaseGoing F₁ Setup time (Arc established) PS.InUse F₂ Setup time (Arc off ) PS.WireStuck Power source shutdown time PS.ArcEstablished © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 55: Memory Channel Change Timing

    Ready to weld Load memory channel data Load curve data Apply curve data Ready to weld Symbol Description Typical Units Total time Memory channel loading time Welding curve loading time Data setup time © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 56: Online Control Timing

    Load memory channel data Load curve data Apply ne w data Memory channel mode Symbol Description Typical Units Total time Setup file loading time Memory channel loading time Welding curve loading time Data setup time © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 57: Wire Inch And Retract Timing

    Wire fe eding on Stop De celeration Wire fe eding off Symbol Description Typical Units Stop response time Wire feeder motor deceleration time * The deceleration time depends on the wire feed speed before stop. © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 58: Touch Sensor Timing

    Ready Touch sensor Power on Voltage drop Power off Symbol Description Typical Units Symbol Description Typical Units Control response time Control response time Relay action time Power-off cycle time (voltage drop time) © Kemppi Oy 2020 A7 MIG Welder 2002...

  • Page 59: Emergency Stop Response Timing

    Hardware response time µs Error setup time Welding system stop time Power source off time (arc off time) Wire feed stop time Touch sensor off time ErrorNumber and Error signal setup time © Kemppi Oy 2020 A7 MIG Welder 2002...
  • Page 60 And you know.

This manual is also suitable for:

A7 450

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