Kemppi T2 User manual

T2, T4
1920640
1712
Robot Gun Mount
EN
OPERATING MANUAL

2Robot Gun Mount T2, T4© Kemppi Oy 2017 1712
OPERATING MANUAL
CONTENTS
1. Robot Gun Mounts T2 and T4........................................................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 – T2 ............................................................................7
6.1 Ambient conditions ..................................................................................7
6.2 Weight .......................................................................................................7
6.3 The microswitch ........................................................................................7
6.4 Triggering the emergency stop................................................................7
6.5 Maximum possible deection ..................................................................7
6.6 Triggering force.........................................................................................7
6.7 Triggering moment...................................................................................8
6.8 Product-specic gun data.........................................................................8
6.9 Abbreviations ............................................................................................8
6.10 The type plate............................................................................................9
7. Technical data – T4 ............................................................................9
8. Delivery scope....................................................................................10
9. Transport..............................................................................................10
10. Storage..................................................................................................10
11. Functional description....................................................................10
12. Robot Gun Mount T2 installation................................................11
12.1 Fastening robot mount T2 to the robot..................................................11
12.2 Adjusting the TCP....................................................................................12
12.3 Connecting the helix cable .....................................................................13
13. Operation.............................................................................................13
14. Unmounting.......................................................................................13
15. Maintenance and cleaning ...........................................................14
16. Troubleshooting................................................................................15
17. Removing the mount......................................................................16
17.1 Disposal ...................................................................................................16
17.2 Materials ..................................................................................................16
17.3 Consumables...........................................................................................16
17.4 Packaging ................................................................................................16
18. Codes for ordering ...........................................................................17

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OPERATING MANUAL
1. ROBOT GUN MOUNTS T2 AND T4
This document provides product information for the
Kemppi Robot Gun Mount units T2 and T4.
2. PREFACE
Congratulations on your purchase of this product. Used
correctly, Kemppi products can signicantly 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 specications 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 specications presented in this manual are subject to
change without prior notice.
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.

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OPERATING MANUAL
3. IDENTIFICATION
Kemppi Robot Gun Mount T2 is used in industry and the
trade for connecting the robot and the tool.This robot gun
mount is a three-dimensionally acting safety cutout that
is adaptable to all types of robots and handling machines
via a robot ange. These operating instructions describe
Kemppi Robot Gun Mount T2 only. Kemppi Robot Gun
Mount T2 must be operated only as supplied or equipped
with authentic Kemppi spare parts.
Figure 1: Kemppi Robot Gun Mount T2
4. CE MARKING
This device fulls 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 T2 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
modications 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 qualied personnel.
Qualied 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 notication and warning system. Read these
sections carefully, and follow the instructions.
Note: These items give the user a useful piece of
information.
Caution: A caution 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 reecting 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 sucient 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.
Damagedcablesmaycauseinjury 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 qualied personnel.
• The product has been developed and manufactured in accordance with state-of-
the-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 unmodied, technically perfect condition,
within the limits described in these instructions.
• Always observe the limit values specied 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 sucient 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 – T2
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 Weight
Model Weight
Robot Gun Mount T2 0.96 kg
6.3 The microswitch
Type of voltage DC
Voltage rating 24 V peak value
Load max. 100 mA
6.4 Triggering the emergency stop
The gure depicts triggering the emergency stop switch (1). With a distance of 400 mm,
it must move approx. 9–11 mm.
Figure 2: Triggering of the emergency stop
1
2
1. Triggering moment
2. Triggering force X, Y
Switching point Deection in X and Y direction Approx. 1.4–1.7°
Deection in Z direction Approx. 1.3–1.6 mm
6.5 Maximum possible deflection
In the direction … of the X axis and Y axis 7°
… of the Z axis Approx. 5 mm
6.6 Triggering force
Kemppi Robot Gun Mount T2 is equipped with an L type spring. Other spring types are
available on request.
The triggering force at 400 mm can be summarized thus.
With “L” spring 44 N
With “XL” spring 71 N

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OPERATING MANUAL
6.7 Triggering moment
With “L” spring 15 Nm
With “XL” spring 25 Nm
Figure 3: Triggering weight with a maximum robot acceleration of 5 m/s2
1
2
3
4
Type2 XL
Type2 3L
Type2 3M
Type2 3S
Triggering weight (kg)
5.00
0.00
100 200 300 400
Distance from the robot ange (mm)
6.8 Product-specific gun data
The following table applies to the entire Kemppi gun system, including gun neck,
gun mount and cable assembly. The table below presents product-specic gun data
in line with EN 60 974-7.
Type Type of cooling Load (A) ED (%) Wire Ø (mm) Gas ow (l/min)
CO₂ M21
500-g gas 340 320 100 0.8–1.6 10–30
500-w liquid 340 340 100 0.8–1.6 approx. 20
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
reected 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 the load 340 A at 100 % duty cycle require an engineered solution.
Contact Kemppi sales.
6.9 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

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OPERATING MANUAL
6.10 The type plate
Robot Gun Mount T2 is identied by a sticker or a Kemppi logo. When contacting the
service sta, please remember to check the production stamp near the Kemppi logo.
Figure 3: T2 type plate
23
1
1. Robot Gun Mount T2
2. The type plate
3. Robot mount serial number
7. TECHNICAL DATA – T4
Kemppi Robot Gun Mount T4 is a solid bracket without collision sensibility. It is
recommended that the robot itself is equipped with the collision sensing ability, when
Kemppi Robot Gun Mount T4 is used. Gun orientation can be adjusted in 30 degree
steps.

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OPERATING MANUAL
11. FUNCTIONAL DESCRIPTION
The holding force of the inserted springs is directly applied to the release ange
and xes the switching axis, which is positioned by three pins, in the zero position.
In the event of collision, the switching axis tips over, the release ange pushes the
spring plate toward the base of the housing, and the trigger is actuated by the
spring plate’s actuating mechanism. The applied switching voltage is interrupted.
Figure 5: Functional diagram
M8×1 M9×0.5
3
1
2
3 Signal1
2 24 V2
1 GND3
1. 3-pole ange plug
2. Microswitch triggered
3. Microswitch in resting position
8. DELIVERY SCOPE
The delivery for a gas-cooled gun includes the following components:
• Kemppi Robot Gun Mount T2 or T4
• Operating instructions
• Cylinder-head screws, M4×55 (6 pcs.)
• Certicate of conformity
• Connection cable
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.
9. 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.
10. STORAGE
The physical conditions for storage in a closed room are -10 °C to 55 °C.

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OPERATING MANUAL
12. ROBOT GUN MOUNT T2
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.
12.1 Fastening robot mount T2 to the robot
This section describes how to fasten robot mount T2 to the robot.
Before attaching Kemppi robot mount T2 (5), rst place the robot (7) in maintenance
position.
For fastening the gun (1) to the robot mount (5), a gun mount (2) is required.
The parts of the system are depicted in the gure below.
Figure 6: Fastening robot mount T2 to the robot
3
6
1
4
7
2
5
891011121314
1. Gun neck
2. Gun segment holder upper part
3. Dowel screw, 8 H7
4. Helix cable
5. Robot mount T2
6. Robot ange
7. Robot
8. Cylinder-head screw
9. Cylinder-head screws, M4×55 (6 pcs.)
10. Feather key
11. Gun segment holder lower part
12. Clamping ring
13. Cylinder head screw, M8
14. M8 nut with washer

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OPERATING MANUAL
For fastening robot mount T2 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. Use the cylinder-head screw (8) to attach the robot
ange (6) to the robot (7).
2. Use cylinder-head screws (9) to attach the robot
mount (5) to the robot ange (6)
3. Use the clamping ring (12) and cylinder-head screw
(13) to attach the bracket (11) to the robot mount
(5).
4. Use the dowel screw (3) and nut (14) to attach the
gun mount (2) to the bracket (11).
12.2 Adjusting the TCP
This section describes how to adjust the TCP.
The parts of the system are depicted in the gure below.
Figure 7: Adjusting the TCP
6
54321
1. M8 nut
2. Dowel screw, 6H7
3. Gun segment holder upper part
4. M6 nut
5. Dowel screw, 8H7
6. Gun segment holder lower part
Proceed as follows:
1. Loosen the nut (1), and adjust the gun mount (3)
to the desired TCP.
2. Tighten the nut (1).
3. To make the position chosen permanent,
proceed as follows:
a. Drill a Ø 5.8 mm bore hole into the bracket
(6), and use a reamer to ream the bore for
the dowel screw (2).
b. Use a dowel screw (2) and a nut (4) to secure
both brackets (6 and 3).

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OPERATING MANUAL
12.3 Connecting the helix cable
This section describes how to adjust the TCP.
The parts of the system are depicted in the gure below.
Figure 8: Connecting the helix cable
1
3
5
2
4
6
Proceed as follows:
1. Plug the helix cable (4) into the connector housing (6), using the angled male
connector (5).
2. Plug the ange plug (2) into the torch (3) and the cable assembly (1).
3. Lock both connectors to prevent their accidental disconnection.
4. For the switching function, see the functional diagram (10).
1. Cable assembly
2. Flange plug
3. Gun
4. Helix cable
5. Angled male connector
6. Robot Gun Mount T2
connector housing
13. OPERATION
The device may only be operated by qualied 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 applicable.
14. 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 A7 MIG Gun 500-g or the A7 MIG Gun 500-w welding guns,
as applicable.

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OPERATING MANUAL
15. MAINTENANCE AND CLEANING
Scheduled maintenance and cleaning are prerequisites for a long service life and
trouble-free 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 voltages can be produced because of defective cables.
• Check all live cables and connections for proper installation.
• Replace any parts that have suered 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 qualied 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 single-
shift operation.

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OPERATING MANUAL
16. 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
Robot gun mount cannot
be attached
Wrong gun mount used Use the correct gun mount
Robot Gun Mount T2 mounting ange is defective Send the robot mount for repair
Robot Gun Mount T2 does
not activate the stop signal
Cable not connected between the robot mount and the
cable assembly
Connect the cable
Cable defective Replace the cable
Robot gun mount switch defective Send the robot mount for repair
Robot Gun Mount T2
does not reset to the zero
position
Mounted load is too heavy Reduce the mounted load
Mechanical defect Observe the data provided by the manufacturer
Attachment parts (bracket etc.) not correctly connected Send the robot mount for repair
Check whether the attachment parts are properly connected
Robot Gun Mount T2
triggered when there is no
fault
Mounted load is too heavy
• Robot speed is too high
Adapt the load to the specications
See Chapter 6

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OPERATING MANUAL
17. REMOVING THE MOUNT
This section describes how to remove robot mount T2.
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. Remove the parts to be disconnected:
3
6
1
4
7
2
5
8910111213
14
17.1 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.
17.2 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 innitely
recyclable. The plastic materials used are marked in preparation for appropriate sorting
of the materials for later recycling.
17.3 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.
17.4 Packaging
The shipping packaging has been reduced to a minimum. Packaging materials are always
selected with attention to their possible recyclability.
1. Gun neck
2. Gun segment holder upper part
3. Dowel screw, 8 H7
4. Helix cable
5. Robot Gun Mount T2
6. Robot ange
7. Robot
8. Cylinder-head screw
9. Cylinder-head screws, M4×55
(6 pcs.)
10. Feather key
11. Gun segment holder lower part
12. Clamping ring
13. Cylinder-head screw, M8
14. M8 nut with washer

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OPERATING MANUAL
18. CODES FOR ORDERING
Robot gun mount Product code
Robot Gun Mount T2 L SP600605
Robot Gun Mount T2 XL SP600606
Robot Gun Mount T4 SP600604
Segment holder for Robot Gun Mount T2 SP600608
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 Gun Mount T2.
To get the correct type of the adapter ange for the
robot's 6th axis, please notify Kemppi about the robot
manufacturer and model.

And you know.