Kemppi A5 MIG 1500 User manual

1500
1920360
R01
A5 MIG Orbital System
EN
OPERATING MANUAL

2A5 MIG Orbital System© Kemppi Oy 2021 R01
OPERATING MANUAL
CONTENTS
1. Introduction..........................................................................................3
1.1 General ......................................................................................................3
1.2 About the product ....................................................................................4
1.3 Compatibility.............................................................................................4
2. Installation .............................................................................................5
2.1 Connecting to a FastMig welding machine .............................................5
2.2 Connecting to a non-FastMig welding machine......................................5
2.3 Guide ring assembly .................................................................................6
2.4 Mounting the carriage on the guide ring.................................................6
2.5 Selecting a welding gun ...........................................................................7
2.6 Installing the welding gun........................................................................7
3. Operation...............................................................................................8
3.1 Carriage functions.....................................................................................8
3.2 Carriage control panel...............................................................................8
3.2.1 Start menu ............................................................................................8
3.2.2 Menu options ........................................................................................8
3.2.3 Setup menu A......................................................................................11
3.3 Remote control unit ................................................................................13
3.3.1 Basic functions.....................................................................................13
3.3.2 Alt functions........................................................................................13
3.4 Fine-adjustment of gun position............................................................14
3.5 Kemppi Wise application software .........................................................14
3.6 Ordering information..............................................................................15
3.7 Technical data..........................................................................................16
4. Troubleshooting................................................................................17
4.1 Operation problems................................................................................17
5. Maintenance.......................................................................................18
5.1 Daily maintenance ..................................................................................18
5.2 Periodic maintenance .............................................................................18
6. Disposal ................................................................................................18

3A5 MIG Orbital System© Kemppi Oy 2021 R01
OPERATING MANUAL
1. INTRODUCTION
1.1 General
Congratulations on choosing A5 MIG Orbital System 1500
welding equipment. 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 product.
The technical specications of the equipment can be
found at the end of the manual.
Please read the operating manual and the safety
instructions booklet carefully before using the equipment
for the rst time. For your own safety and that of your
working 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 website 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 particular attention in
order to minimise damage and harm are indicated with
below symbols. 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
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.

4A5 MIG Orbital System© Kemppi Oy 2021 R01
OPERATING MANUAL
1.2 About the product
A5 MIG Orbital System 1500 is a complete set of welding
mechanization equipment designed especially for orbital
applications.The mechanical design of this orbital carriage
is very exible, and it can be used for:
• horizontal joints
• vertical joints
• welding with or without weaving.
The carriage is divided into two drive units, each of which
can be independently adjusted for dierent guide ring
diameters. Each drive unit has its own motor of which one
pulls and the other pushes to ensure stable operation at
both raising and lowering movement.
The system includes two control panels; one on the
carriage front surface and the other on the remote control
unit. During welding, the system can be operated by using
the remote control unit that provides the operator with
the most used controls of the carriage. The weaving unit
is synchronized with the movement of the carriage for
various weaving patterns.
1.3 Compatibility
A5 MIG Orbital System 1500 is compatible with the
following welding equipment:
• FastMig M and FastMig X: all wire feeders and
control panels
• MXF 65 and MXF 67 wire feeders
• FastMig Pulse 350/450 power sources
• Control panel PF 65
• FastMig KMS 300/400/500 power sources
• Control panels SF 52W and SF 54
• SuperSnake mechanization models
• Other power source brands with limitations.
Some of the functions are available only if the wire
feeder has the right control panel. For example, changing
memory channels at the welding carriage is available only
if the wire feeder has a control panel with the channel
remote control feature.

5A5 MIG Orbital System© Kemppi Oy 2021 R01
OPERATING MANUAL
2. INSTALLATION
2.1 ConnectingtoaFastMigweldingmachine
To connect the carriage system to the FastMig welding
equipment:
1. Connect welding cable to welding gun connector.
2. Connectcontrolcable toremotecontrolconnectionat
the wire feeder.
3. Connect control cable to 7-pin connection at the
carriage unit.
4. Connectremotecontrolunitto7-pin connector onthe
carriage front panel.
With Kemppi mechanization welding gun, the control
cable is integrated into the gun cable. The trigger mode
must be set to 2T. With other welding guns, you need to
use a separate control cable. See the ordering codes at the
end of this document.
2.2 Connecting to a non-FastMig welding
machine
You need a transformer (1-phase, 230 VAC) to power the
carriage. In this setup, the start button and the adjustment
of welding voltage and wire feed speed are not accessible
through the remote control device.
Do the following to connect:
1. Connect welding gun to the wire feeder.
2. Attach welding gun to the carriage gun holder.
3. Connect transformer to the carriage.
4. Start welding by pressing the gun trigger.
When using a manual welding gun, start and stop
the arc with the gun trigger and start the carriage motion
with the remote control as usual. The trigger mode must
be set to 4T. See FastMig operation manual for further
instructions.
When using a Supersnake:
1. Use the mechanization model of Supersnake.
2. Connect as usual to the wire feeder, and connect the
carriage with the welding gun to the Supersnake.
This model includes a bus coupler with which to
connect.

6A5 MIG Orbital System© Kemppi Oy 2021 R01
OPERATING MANUAL
2.3 Guide ring assembly
Guide rings are available for all standard pipe sizes. Each
guide ring includes circa ±20 mm diameter adjustment
range. See ordering codes for each size at the end of this
guide.
2 – 4 mm Pipe O.D.
2
3
1
1. Adjust the support legs (1) so that the ring ts tightly
around the pipe. There are four support legs, two of
which are spring loaded to allow easy centering of
the guide ring.
It is important to position the guide ring in centered
position, as it reduces the need to adjust stick-out length
during welding.
2. Mount the guide ring around the pipe so that locking
lever (2) is on the opposite side of the joint.
Distance from joint center line should be about
230 mm.
3. Clampthe guide ring in position withthelocking lever.
2.4 Mountingthecarriageontheguidering
1. Turn the carriage locking lever (1) to release the front
support wheel (2).
2. Mount the carriage on the guide ring and adjust the
angle of the drive wheels (4) so that the vertical
support wheels (3) are in contact with the guide
ring.
3. Lock to position with the locking lever.
4. Run the carriage forward and backward and make
adjustments if necessary.
Adjust the front support wheel (2) so that the at
surface of the wheel meets the edge of the guide ring.

7A5 MIG Orbital System© Kemppi Oy 2021 R01
OPERATING MANUAL
2.6 Installing the welding gun
1. Fasten the gun holder on the weaving unit.
2. Fasten the gun on the holder.
3. Connect the control cable.
4. Ensure that the weaving unit is in center position.
5. Use adjustment screws and weaving displacement
adjustment to ne-adjust the position of the gun.
2.5 Selecting a welding gun
Kemppi mechanization guns offer various benefits
compared with manual welding guns. Carriage control and
powering signals are integrated in the gun cable, so there
is only one cable needed between the wire feeder and
the welding carriage. This also enables the adjustment of
carriage functions and welding parameters at the remote
control device.
Kemppi offers three welding gun models designed
especially for mechanized welding:
PMT MN32C (Multi Neck model)
Multiple neck designs. Slightly bent neck available for
mechanized welding. Extra-long gas nozzle and contact
tip are available, suitable especially for root welding in
narrow grooves.
MMT42C
Gas-cooled straight neck model
MMT42C
Water-cooled straight neck model for heavy applications
Please see the technical details of the welding guns in
their documentation.

8A5 MIG Orbital System© Kemppi Oy 2021 R01
OPERATING MANUAL
3. OPERATION
3.1 Carriage functions
1. STOP button on top of the carriage is the same as
in the remote control device
2. Display to show menu settings and their values
3. Menu button move from one menu to another
4. Scroll left/right buttons to change values of menu
settings
3.2 Carriage control panel
3.2.1 Start menu
P1 CH off
<8> 45 6mm
This is the initial view on the carriage display.
1. Program number (P1)
2. Remote memory channels on/o (CH O )
3. Carriage speed (8 cm/min)
4. Weaving speed (45 mm/s)
5. Weaving width (6 mm)
Press MENU to continue.
3.2.2 Menu options
Program selection
P1 CH on
<8> 45 6mm
The item to be adjusted (P1) is blinking in the display.
Select the program to store the settings:
1. Use + and – buttons to browse programs.
2. Select the program to use: P1…P5.
3. Press MENU to continue.

9A5 MIG Orbital System© Kemppi Oy 2021 R01
OPERATING MANUAL
Speed Car
P1 CH on
Speed Car 8cm/m
Set the carriage travel speed:
1. Use + and – buttons to change the speed.
2. Set the carriage speed within the range
5–150 cm/min.
3. Press MENU button to continue.
Speed
P1 CH on
Speed <-> 45mm/s
Set the weaving speed i.e. the speed at which the torch
moves from one side of the groove to the other during
the weaving motion:
1. Use + and – buttons to change the speed.
2. Set the weaving speed within the range
10–50 mm/s.
3. Press MENU to continue.
Width
P1 CH on
Width <-> 6mm
Set the width of the weaving motion:
1. Use + and – buttons to change the width from
center (1 mm = 0.5 mm on each side).
2. Set the weaving width within the range 0–30 mm
3. Press MENU to continue.

10 A5 MIG Orbital System© Kemppi Oy 2021 R01
OPERATING MANUAL
Pattern
P1 CH on
Pattern <-> 0
1 2
0
Determine the pattern used in weaving. Use + and –
buttons to select any of the three patterns:
0. Travels constantly while weaving (triangular).
1. Travels when weaving, stands during delay.
2. Travels during delay, stands when weaving
(square).
Press MENU to continue.
Hold out
P1 CH on
Hold out 0.1s
Set outer dwell time (the time that the torch holds at the
outer side of the weaving motion):
1. Use + and – buttons to change the time.
2. Press MENU to continue.
Hold in
P1 CH on
Hold in 0.1s
Set inner dwell time (the time that the torch holds at the
inner side of the weaving motion):
1. Use + and – buttons to change the time in
seconds.
2. Press MENU to continue.