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

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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3.2.3 Setup menu A
P1 CH off
<8> 45 6mm
Long press of the MENU button activates Setup menu A,
which contains 3 options:
• CH remote
• WF+V fac
• Delay car
Brief press of the MENU button toggles the menu items.
No buttons pressed in 3 seconds or a new long press on
MENU button exits the Setup Menu A.
CH remote
A CH off
CH remote: 0
Use + and – buttons to set the remote memory channels
function on or o:
• If CH setting is OFF, the selected P setting only
enables the corresponding carriage program
(P1, P2 etc.).
• If CH setting is ON, the selected P setting also
activates the corresponding memory channel at
the wire feeder (CH1, CH2 etc.).
To use the wire feeder’s memory channels, the CH
REMOTE setting must be ON at the wire feeder. In this
case, the ne tuning is disabled at the carriage remote
control unit.
WF+V fac
A CH off
WF 0 V 0
Set the factor that is used for determining the roughness
of ne tuning and aects the adjustment of WFS and arc
voltage:
1. Use + button to select value 0, 1, 2, 3 or 4
(default = 2).
• Higher setting = wider steps
• Lower setting = narrower steps
2. Press MENU to continue.
The wire feeder scale varies according to the min/
max limits set in the power source. If the power source
holds narrow limits, the carriage may require a rough
scale. If limits have not been set in the power source, the
carriage requires a ner scale. Dierent applications may
benet from dierent scaling.

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Delay Car
A CH off
Delay Car: 600 ms
Set the start delay (the time that the carriage stands still
after welding has started):
1. Use + and – buttons to change the time.
2. Range: 100–3000 milliseconds
3. Press MENU to continue
Value CH2-CH5
A CH on
Value CH2: 4
Fine adjust the signal level of the memory channels at
the welding carriage for channels 2 to 5.
• Use + and – buttons to change the value.
You need to change these settings only if there is a
conict between the memory channels set by the wire
feeder and the welding carriage.
Adj0 WF
A CH on
Adj. 0 WF: 5
With this parameter you can ne-tune the signal zero
level for setting the wire feed speed value.
• Use + and – buttons to change the value.
In normal use, you never need to change the value
of this parameter.
Adj0 V
With this parameter you can ne-tune the signal zero
level for setting the voltage value.
• Use + and – buttons to change the value.
In normal use, you never need to change the value
of this parameter.

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3.3 Remote control unit
3.3.1 Basic functions
1. Press Stop to extinguish the arc and stop the
carriage.
2. Hold down ALT to activate the orange marked
secondary functions of the buttons.
3. CH rst press: Start test run (arc o) with
programmed speed and weaving.
4. CH second press during welding/running: Carriage
speed increases (up), or decreases (down).
5. CH long press: High-speed transportation (arc o).
Moves the centerline of weaving or welding to the
button's direction
The direction is determined when facing the carriage
control panel. If you are standing on the other side of the
carriage, the directions are reversed
Increases or decreases the weaving width by 1 mm per
press of button (0.5 mm on both sides).
3.3.2 Alt functions
Starts welding to the button’s direction. If on test run, the
arc ignites.
Activate the next (up) or previous (down) program,
including memory channel, if CH REMOTE is ON at the
wire feeder.
Increase (+) or decrease (-) the arc voltage
Increase (+) or decrease (-) the wire feed speed
Fine-adjustment of voltage and wire feed only works
when CH REMOTE is OFF at the wire feeder.
Stop terminates the operation of the carriage and stops
welding.

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3.4 Fine-adjustment of gun position
When the welding gun is xed in position and connected,
adjust its position vertically by turning the wheel on the
vertical slide clockwise (up) or counterclockwise (down).
3.5 Kemppi Wise application software
When using Kemppi FastMig welding equipment, you
can further optimize the quality and productivity of your
mechanized welding by using Wise application software.
There are several Wise processes and functions available
for dierent welding applications. For more information
about Wise, please refer to FastMig documentation or
Kemppi website at www.kemppi.com.

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3.6 Ordering information
Product name Product code
A5 MIG ORBITAL CARRIAGE 1500 6190715
A5 WEAVING TILT BRACKET 6190708
A5 WEAVING TURN BRACKET 6190709
A5 TORCH FLOATING HEAD 6190711
A5 MIG CARRIAGE TRANSFORMER 6190714
A5 MIG CARRIAGE CONTROL CABLE 6190716
PMT MN 32C welding gun (gas-cooled, multi-neck, 5 m, 320 A) 6250405
Neck 30°, 198 mm, RP (slightly bent neck for mechanized welding) W010975
MMT 42C welding gun (gas-cooled, 4.5 m) 6254207
MT51MWC welding gun (water-cooled, 4.5 m) 6255162
Root contact tip W008123
Root gas nozzle W008124
SUPERSNAKE GT 02SWC 15M 61541501
SUPERSNAKE GT 02SWC 25M 61542501C1
SUPERSNAKE GT 02SWC-70 20M 61542001
SUPERSNAKE GT 02SC 15 M 61531501
GUIDE RING FOR 6” PIPE 6190806
GUIDE RING FOR 8” PIPE 6190808
GUIDE RING FOR 10” PIPE 6190810
GUIDE RING FOR 12” PIPE 6190812
GUIDE RING FOR 14” PIPE 6190814
GUIDE RING FOR 16” PIPE 6190816
GUIDE RING FOR 18” PIPE 6190818
GUIDE RING FOR 20” PIPE 6190820
GUIDE RING FOR 22” PIPE 6190822
GUIDE RING FOR 28” PIPE 6190828
GUIDE RING FOR 36” PIPE 6190836
GUIDE RING FOR 48” PIPE 6190848
KEMPPI GUIDE RINGS
Pipe outer diameter (O.D.) Suitable guide ring
[Inch] [mm] Ordering
code
Guide ring
min max min max
5 7 127.0 177.8 6190806 RING FOR 6”PIPE DIAMETER
7 9 177.8 228.6 6190808 RING FOR 8”PIPE DIAMETER
9 11 228.6 279.4 6190810 RING FOR 10”PIPE DIAMETER
11 13 279.4 330.2 6190812 RING FOR 12”PIPE DIAMETER
13 15 330.2 381.0 6190814 RING FOR 14”PIPE DIAMETER
15 17 381.0 431.8 6190816 RING FOR 16”PIPE DIAMETER
17 19 431.8 482.6 6190818 RING FOR 18”PIPE DIAMETER
19 21 482.6 533.4 6190820 RING FOR 20”PIPE DIAMETER
21 23 533.4 584.2 6190822 RING FOR 22”PIPE DIAMETER
27 29 685.8 736.6 6190828 RING FOR 28”PIPE DIAMETER
35 37 889.0 939.8 6190836 RING FOR 36”PIPE DIAMETER
39 41 990.6 1041.4 6190840 RING FOR 40” PIPE DIAMETER
47 49 1193.8 1244.6 6190848 RING FOR 48” PIPE DIAMETER
49 51 1244.6 1295.4 6190850 RING FOR 50” PIPE DIAMETER
51 53 1295.4 1346.2 6190852 RING FOR 52” PIPE DIAMETER
53 55 1346.2 1397.0 6190854 RING FOR 54” PIPE DIAMETER
55 57 1397.0 1447.8 6190856 RING FOR 56” PIPE DIAMETER
57 59 1447.8 1498.6 6190858 RING FOR 58”PIPE DIAMETER
59 61 1498.6 1549.4 6190860 RING FOR 60” PIPE DIAMETER
61 63 1549.4 1600.2 6190862 RING FOR 62” PIPE DIAMETER
63 65 1600.2 1651.0 6190864 RING FOR 64” PIPE DIAMETER
65 67 1651.0 1701.8 6190866 RING FOR 66”PIPE DIAMETER
67 69 1701.8 1752.6 6190868 RING FOR 68” PIPE DIAMETER
69 71 1752.6 1803.4 6190870 RING FOR 70” PIPE DIAMETER

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3.7 Technical data
Input Power 30 – 55 V DC or 24 – 50 V AC
Carriage Speed 5 – 150 cm/min
Transport Speed 200 cm/min
Weaving speed 10 – 50 mm/s
Weaving width 0 – 30 mm
Weaving displacement ± 40 mm
Dwell time
(Adjustable on both sides separately)
0 – 2.0 s
Weaving patterns 3
Torch horizontal adjustment (manual) ± 40 mm
External dimensions (LxWxH)* 365 x 385 x 300 mm
Weight 9.0 kg
*) Height measured from pipe surface

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4. TROUBLESHOOTING
4.1 Operation problems
Should you experience a malfunction from your machine,
please consult the troubleshooting sections below rst,
and complete some basic checks.
If the machine malfunction cannot be corrected with
these measures, contact your Kemppi maintenance
service workshop.
The problems listed and the possible causes are not
denitive but serve to suggest some standard and typical
situations that may present during normal environmental
use when using the A5 MIG Orbital System 1500.
Below instructions only apply to possible problems with
the carriage. Always ensure that the related welding
system is functional and ready for welding.
Problem: Check the following:
Carriage won’t work • Check that power reaches carriage (display is ON).
• Check that the welding power source is switched ON.
• Check the gun control connection and possible
Supersnake and separate control cable connections
• Check that control panels are switched on.
Dirty, poor quality weld • Check shielding gas supply.
• Check and set gas ow rate.
• Check gas type for application.
• Check that correct welding program is selected.
• Check correct selection on the control panel.
• Check power supply – phase down?
Arc is not ignited or welding
starts or stops strangely
Check that remote control buttons have been pressed
correctly:
• Stop+Up/Down ignites the arc and starts the carriage.
• If carriage is moving fast but arc is o, you may have
pressed Start button for too long.
Carriage moves unevenly • Carriage is not correctly mounted on the guide ring.
Check carriage position.
• Wheels are not in line with the guide ring. Check the
angle and adjust if necessary.
Torch height varies along the
pipe
• Pipe is not precisely round shaped. Adjust height if
necessary.

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5. MAINTENANCE
When considering and planning routine maintenance, please consider the frequency of
machine use and the working environment.
Correct operation of the machine and regular maintenance will help you avoid
unnecessary downtime and equipment failure.
Make sure that the carriage does not start accidentally when your ngers are in the
wheel area.
5.1 Daily maintenance
• Check that all cables and plugs are intact.
• Keep the carriage and the torch holder clean.
• Check that all parts slide smoothly. Add grease or clean spatters if necessary.
• Check the gun’s condition.
5.2 Periodic maintenance
Periodic maintenance should only be carried out by a suitably qualied person.
Check at least every half year:
• Electric connectors of the machine – clean any oxidized parts and tighten loose
connections.
• Condition of the drive and support wheels. If worn, change.
Do not use compressed air for cleaning as there is a risk that the dirt will compact
even more tightly into gaps of cooling proles.
Do not use pressure washing devices.
Only an authorized trained electrician should carry out repairs to Kemppi machines.
6. DISPOSAL
Do not dispose of electrical equipment with normal waste!
In observance of European Directive 2002/96/EC on waste electrical and electronic
equipment, and its implementation in accordance with national law, electrical
equipment that has reached the end of its life must be collected separately and taken
to an appropriate environmentally responsible recycling facility.
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.