Kemppi A3 MIG User manual

1920860
1826
A7 MIG WelderA3 MIG Welder
EN
OPERATING MANUAL

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A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
CONTENTS
1. Introduction..........................................................................................3
1.1 General ......................................................................................................3
2. Installation .............................................................................................4
3. System Overview ................................................................................5
3.1 Power Source.............................................................................................5
3.2 Control panel.............................................................................................6
3.3 DIP switches ..............................................................................................7
3.4 Wire feeder ................................................................................................8
4. Using the welder...............................................................................11
4.1 Basic controls...........................................................................................11
4.2 Control panel...........................................................................................11
4.3 Standard MIG features ............................................................................14
4.4 Optional MIG features.............................................................................15
4.5 Memory channels....................................................................................16
4.6 Synergic 1-MIG, WiseThin, and WiseRoot welding .................................17
4.7 Welding and system setup......................................................................20
4.8 Touch sensor (seam search)....................................................................23
4.9 Collision sensor .......................................................................................25
5. Troubleshooting................................................................................26
5.1 Typical problems .....................................................................................26
5.2 Error codes...............................................................................................27
6. Operation disturbances..................................................................28
7. Maintenance.......................................................................................29
7.1 Daily maintenance ..................................................................................29
7.2 Periodic maintenance .............................................................................29
7.3 Service Workshop maintenance .............................................................29
8. Disposal ................................................................................................30
9. Ordering numbers............................................................................30
10. Technical data....................................................................................31

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OPERATING MANUAL
1. INTRODUCTION
1.1 General
Congratulations on choosing the A3 MIG Welder system.
When used correctly, Kemppi products can signicantly
increase the productivity of your welding and provide
years of economical service.
This operating manual contains important information
on the use, maintenance and safety of your Kemppi prod-
uct. The technical specications of the equipment can be
found at the end of the manual.
Please read the manual carefully before using the equip-
ment for the rst time. For your own safety and that of
your working environment, pay 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 at www.kemppi.com.
The specications presented in this manual are subject to
change without prior notice.
Important notes
Items in the manual that require attention in order to
minimize damage and harm are indicated by the sym-
bols below. Read these sections carefully and follow their
instructions.
Note: Gives the user a useful piece of information.
Caution: Describes a situation that may result in
damage to the equipment or system.
Warning: Describes a potentially dangerous situation.
If not avoided, it will result in personal damage or fatal
injury.
Disclaimer
While every eort has been made to ensure that the infor-
mation 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
2. INSTALLATION
The product is packed in specially designed transport
cartons. However, always make sure the products have
not been damaged during transportation prior to this.
Product packaging material is recyclable.
When moving the welding machine, never pull it
from the welding gun or other cables. For lifting the power
source, use the handles on top of the power source.
Detailed installation instructions and the technical
information that is out of the scope of this manual are
found in the A3 MIG Welder Integration guide.
Operating environment
The machines included in the system are suitable for both
indoor and outdoor use. Always make sure that the air
ow to the machine is unrestricted. The recommended
operating temperature range is -20…+40°C.
Positioning the machines
Place the machine on a sturdy, level surface that is dry
and will not allow dust or other impurities to enter the
machine´s cooling air ow. Preferably, situate the ma-
chine in a suitable carriage unit so it is above oor level.
• The surface inclination may not exceed
15 degrees.
• Ensure the free circulation of the cooling air.
There must be at least 20 cm of free space in
front of and behind the machine for cooling-air
circulation.
• Protect the machine against heavy rain and
direct sunshine.
Do not operate the machine in the rain.
Never aim the spray of sparks from a grinding
machine toward the equipment.

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OPERATING MANUAL
3. SYSTEM OVERVIEW
A3 MIG Welder system
A3 MIG Welder is a welding system for welding automa-
tion that includes all welding devices needed in robot
welding.
2
3
4
A3 Power Source 400
1
Figure 3.1 A3 MIG Welder system
1. Power Source
2. Wire feeder
3. MIG torch
4. Interconnection cable set
3.1 Power Source
A3 MIG Power Source 400
1
12
10
11
9
2
7
6
5
8
3
4
Figure 3.2 Power source, front and rear
1. Control panel
2. Main switch
3. Main power indicator light (ON/OFF)
4. Overheating indicator
5. System conguration DIP switches
6. Control cable connection
7. Welding cable connection, negative pole ( – )
8. Welding cable connection, positive pole ( + ),
front and rear
9. DeviceNet and safety stop connection
10. Wire feeder connection
11. Fuse (6.3 A, delayed)
12. Mains power cable
The A3 Power Source 400 is designed for demanding professional use. The power
source is suitable for MIG/MAG, 1-MIG, WiseRoot and WiseThin processes. It sup-
ports also WiseFusion function. The Wise processes and functions are optional and
can be activated by licenses.

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A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
3.2 Control panel
The control panel is used for controlling and monitoring the operation of the
power source and the wire feeder. The buttons and knobs are used for adjusting
functions. The displays and indicators reect the operating modes of the machine.
1
765 8
4
39
2
Figure 3.4 Control panel layout
1. Miscellaneous functions
2. Displays
3. System and welding setup
4. Synergic program selection
5. Welding process selection
6. Welding program setup
7. Memory channel setup
8. Robot control indicator
9. Control knobs

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OPERATING MANUAL
3.3 DIP switches
The A3 Power Source comprises two DIP switch panels
on the right side of the power source. The switches can
be accessed through a hole in the cover plate. The hole is
covered by a rubber plug. The rst panel (P1) congures
DeviceNet baud rate and Mac ID. The second panel (P2)
congures the touch sensor, safety stop, collision sensor,
eldbus byte order, and watchdog.
By default, all DIP switches are OFF.
ON
12345678
P1
ON
12345678
P2
Figure 3.5 DIP switches in the power source
Panel P1 –DeviceNet conguration
1-2 Baud rate 125-500 kbps
3-8 Mac ID 0-63
Panel P2 –System conguration
1-2 Touch sensor voltage 50-200 V
3 Safety stop OFF/ON
4 Collision sensor OFF/ON
5 Collision sensor switch type OPENING/CLOSING
6 Byte order LITTLE-ENDIAN/BIG-ENDIAN
7 Watchdog OFF/ON
8 (Reserved) (Reserved)
Figure 3.6: Quick guide for DIP switch conguration
3 4 5 6 7 8 Mac ID
OFF OFF OFF OFF OFF OFF 0
OFF OFF OFF OFF OFF ON 1
OFF OFF OFF OFF ON OFF 2
OFF OFF OFF OFF ON ON 3
...
ON ON ON ON OFF OFF 60
ON ON ON ON OFF ON 61
ON ON ON ON ON OF 62
ON ON ON ON ON ON 63
1 2 Baud rate
OFF OFF 125 kbps
OFF OFF 250 kbps
ON OFF 500 kbps
ON ON (Reserved)
1 2 Voltage
OFF OFF 50 V
OFF ON 80 V
ON OFF 110 V
ON ON 200 V

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A3 MIG Welder© Kemppi Oy 2018 1826
OPERATING MANUAL
3.4 Wire feeder
A3 Wire Feeder 25, Euro connector
1 2
3
7
4
5 6
Figure 4.9 Wire feeder with Euro connector, front and rear
1. Peripheral connector
2. Wire inch button
3. Euro connector
4. Wire feeder control cable connector
5. Wire liner connector
6. Welding cable connector
7. Gas inlet
A3 Wire Feeder 25, Power connector
1 2
3
4
5
6
7
Figure 4.10 Wire feeder with PowerPin connector, front and rear
1. Peripheral connector
2. Wire inch button
3. Gas outlet
4. PowerPin connector with welding cable joint
5. Wire feeder control cable connector
6. Wire liner connector
7. Gas inlet

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OPERATING MANUAL
Threading the wire and adjusting tightness
When changing the welding wire, the pressure arms need to be released. Ensure that the
groove of the feed rolls matches the diameter of ller wire used. Release the wire end
and cut o any deformed section before pulling it out from the wire feeder. Straighten
about 20 cm of the new ller wire and ensure the tip has no sharp edges. File if necessary,
as a sharp wire edge may damage the wire gun liner – particularly softer plastic liners.
Present the ller wire tip to the back of the wire feed rolls and press the wire inch button
on the wire feed front panel. Feed the wire to the gun contact tip and prepare to weld.

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OPERATING MANUAL
Wire feed rolls, metal
ø mm lower upper
Fe, Ss,
(Al, Mc, Fc)
V-groove
0.8 – 0.9 W006074 W006075
1.0 W006076 W006077
1.2 W004754 W004753
1.4 W006078 W006079
Fc, Mc, (Fe)
V-groove, knurled
1.0 W006080 W006081
1.2 W006082 W006083
1.4 – 1.6 W006084 W006085
2.0 W006086 W006087
Al, (Fc, Mc, Ss, Fe)
U-groove
1.0 W006088 W006089
1.2 W006090 W006091
1.6 W006092 W006093
Mount the lower feed roll, ensuring that the pin on the shaft ts in the cut on the
feed roll.
DuraTorque™ 400, 4-wheel wire feed mechanism accessories
Wire guide tubes
ø mm outlet tube middle tube inlet tube
Ss, Al,
(Fe, Mc, Fc)
plastic
0.6 SP007437 SP007429 SP007293
0.8 –
0.9
SP007438 SP007430 SP007294
1.0 SP007439 SP007431 SP007295
1.2 SP007440 SP007432 SP007296
1.4 SP007441 SP007433 SP007297
1.6 SP007442 SP007434 SP007298
2.0 SP007443 SP007435 SP007299
2.4 SP007444 SP007436 SP007300
Fe, Mc, Fc
metal
0.8 –
0.9
SP007454 SP007465 SP007536
1.0 SP007455 SP007466 SP007537
1.2 SP007456 SP007467 SP007538
1.4 –
1.6
SP007458 SP007469 SP007539
2.0 SP007459 SP007470 SP007540
2.4 SP007460 SP007471 SP007541
24.8.2005 12:55