Kemppi A7 350 Quick setup guide

350, 450
1920310
2002
A7 MIG WelderA7 MIG Welder
EN
INTEGRATION GUIDE

2A7 MIG Welder© Kemppi Oy 2020 2002
INTEGRATION GUIDE
CONTENTS
1. Introduction..........................................................................................4
2. Integration step by step...................................................................4
3. Hardware installation ........................................................................5
3.1 Procedures before use ..............................................................................5
3.2 System overview .......................................................................................5
3.3 Power source .............................................................................................7
3.4 Cooling unit...............................................................................................7
3.5 Wire feeder ................................................................................................7
3.6 Welding torch............................................................................................9
3.6.1 Mounting............................................................................................9
3.6.2 Push-pull torches .................................................................................9
3.6.3 Wire inch button ..................................................................................9
3.6.4 Torch-cleaning with compressed air.........................................................9
3.6.5 Touch-sensing with the gas nozzle.........................................................10
3.7 Collision sensor .......................................................................................10
3.8 Interconnection cable set .......................................................................11
3.8.1 The arc measurement cable..................................................................11
3.8.2 Wire feeder control cable .....................................................................12
3.8.3 Welding cable....................................................................................12
3.8.4 Shielding gas hose..............................................................................12
3.8.5 Cooling hoses ....................................................................................12
3.9 Fieldbus communication ........................................................................13
3.10 Ethernet (web user interface server) ......................................................14
3.11 Emergency input functions ....................................................................14
3.12 Touch sensor status fast output..............................................................15
3.13 Dual wire feeder support ........................................................................16
3.13.1 Installation ........................................................................................17
3.13.2 Connect the second wire feeder............................................................19
3.14 Powering up ............................................................................................19
4. Accessing the Web user interface ..............................................20
4.1 Conguring the network settings ..........................................................20
4.2 Opening the web user interface ............................................................21
5. System configuration ......................................................................22
5.1 Welding system, sensors and devices ....................................................22
5.1.1 General settings .................................................................................22
5.1.2 Wire feed settings...............................................................................22
5.1.3 Gas sensor settings .............................................................................23
5.1.4 General robot settings.........................................................................24
5.1.5 Touch sensor settings..........................................................................24
5.1.6 Collision sensor settings ......................................................................24
5.1.7 Emergency stop settings......................................................................24
5.1.8 Watchdog settings..............................................................................25
5.1.9 Welding system time...........................................................................25
5.2 Digital robot interface.............................................................................26
5.2.1 Fieldbus settings ................................................................................26
5.2.2 Selecting the proper I/O table...............................................................26
5.2.3 Setting up scaling values .....................................................................27
5.3 Users ........................................................................................................29
5.4 Memory channels....................................................................................30
5.5 System backup ........................................................................................30
5.6 I/O tables .................................................................................................31
5.6.1 KEMPPI1: KempArc Pulse default table....................................................31
5.6.2 KEMPPI2: KempArc Pulse customized table .............................................31
5.6.3 KEMPPI3: KempArc Pulse customized table .............................................32
5.6.4 KEMPPI4: A7 MIG Welder default table....................................................33
5.6.5 KEMPPI5: A7 MIG Welder table for pulse process control ............................34
5.6.6 CUST1: Customer-specic table.............................................................35
5.6.7 CUST2: Customer-specic table.............................................................35
5.6.8 CUST3: Customer-specic table.............................................................36
5.6.9 CUST4: Customer-specic table.............................................................36
5.6.10 CUST5: Customer-specic table.............................................................37

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6. Digital robot interface.....................................................................38
6.1 Control functions ....................................................................................38
6.1.1 WireFeedSpeed..................................................................................39
6.1.2 Voltage.............................................................................................39
6.1.3 FineTuning ........................................................................................40
6.1.4 Dynamics..........................................................................................40
6.1.5 MemoryChannel ................................................................................40
6.1.6 PulseCurrent......................................................................................41
6.1.7 PulseBaseCurrent ...............................................................................41
6.1.8 PulseFrequency..................................................................................41
6.1.9 PulseLength ......................................................................................41
6.1.10 WeldingAllowed.................................................................................41
6.1.11 SimulationMode ................................................................................41
6.1.12 StartWelding .....................................................................................42
6.1.13 WireInch ...........................................................................................42
6.1.14 WireRetract .......................................................................................42
6.1.15 GasBlow ...........................................................................................42
6.1.16 AirBlow.............................................................................................42
6.1.17 TouchSensorToolSel............................................................................42
6.1.18 TouchSensorOn..................................................................................42
6.1.19 OnlineControl....................................................................................42
6.1.20 Watchdog .........................................................................................43
6.1.21 ErrorReset .........................................................................................43
6.1.22 HotStartOn........................................................................................43
6.1.23 CraterFillOn .......................................................................................43
6.1.24 WireFeederSelect ...............................................................................43
6.2 Status functions.......................................................................................44
6.2.1 WeldingCurrent .................................................................................47
6.2.2 WeldingVoltage .................................................................................47
6.2.3 WeldingWireFeedSpeed ......................................................................47
6.2.4 MotorCurrent ....................................................................................47
6.2.5 GasFlowRate......................................................................................47
6.2.6 ErrorNumber .....................................................................................47
6.2.7 WeldingMemoryChannel .....................................................................48
6.2.8 TAST ................................................................................................48
6.2.9 WeldingProcess..................................................................................48
6.2.10 Ready...............................................................................................48
6.2.11 PowerSourceReady.............................................................................48
6.2.12 CoolingUnitOk...................................................................................48
6.2.13 ProgramSaved ...................................................................................48
6.2.14 RobotHasControl................................................................................48
6.2.15 CycleOn............................................................................................48
6.2.16 ArcOn ..............................................................................................49
6.2.17 GasFlowOk........................................................................................49
6.2.18 MainCurrentOn ..................................................................................49
6.2.19 CurrentOk .........................................................................................49
6.2.20 MotorCurrentOk.................................................................................49
6.2.21 WFSpeedOk ......................................................................................49
6.2.22 TouchSensed .....................................................................................49
6.2.23 Error ................................................................................................49
6.2.24 CollisionDetected...............................................................................49
6.2.25 ToleranceError ...................................................................................50
6.2.26 WireStuck .........................................................................................50
6.2.27 GateDoorOpen ..................................................................................50
6.2.28 PanelLocked......................................................................................50
6.2.29 LocalRemote .....................................................................................50
6.2.30 AutoManual ......................................................................................50
6.3 Timing diagrams .....................................................................................51
6.3.1 Welding startup timing........................................................................51
6.3.2 Welding stop timing ...........................................................................53
6.3.3 Memory channel change timing............................................................55
6.3.4 Online control timing..........................................................................56
6.3.5 Wire inch and retract timing .................................................................57
6.3.6 Touch sensor timing............................................................................58
6.3.7 Emergency stop response timing ..........................................................59

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INTEGRATION GUIDE
1. INTRODUCTION
The A7 MIG Welder is a complete welding system for automated welding applications.
This guide, together with the A7 MIG Welder operating manual, instructs you on how to
set up the system and perform the necessary cable connections and setup conguration
to get the system running.
Important notes
Items in the manual that require particular attention for minimizing damage and harm
are indicated with the symbols below. Read these sections carefully, and follow their
instructions.
Note: A note item gives the user a useful piece of information.
Caution: Caution items describe 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.
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 advance notice. Do not copy, record, reproduce, or transmit the contents of this
guide without prior permission from Kemppi.
The web user interface server, part of the robot interface unit, is meant to be used only
in point-to-point connection with one authorized personal computer. For the sake
of condentiality, it is not recommended to connect the A7 MIG Welder system to any
public or internal network. Kemppi is not liable for errors or damage resulting from non-
compliance with this recommendation.
2. INTEGRATION STEP BY STEP
To ensure safe and ecient integration of the welding system, follow these simple
steps:
1. INSTALL THE HARDWARE
• Make sure that all the components are OK.
• Mount the cooling unit, if any, on the power source.
• Attach all required equipment to the robot and to the
welding cell.
• Make all required cable connections.
• Power up the system.
2. ACCESS THE WEB USER INTERFACE
• Congure the network connection by means of the
setup panel.
• Open the web user interface using a web browser.
3. CONFIGURE THE SYSTEM
• Congure the welding system, sensors, and devices.
• Congure the digital robot interface.
• Congure system users.
• Create memory channels.
• Make a system backup.
After completion of these steps, the system is ready for welding.
For detailed instructions on each step, consult the corresponding section of this
document.

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3. HARDWARE INSTALLATION
3.1 Procedures before use
The product is packed in specially designed transport
cartons. Unpack the products from the cartons, and check
that they have not been damaged during transportation.
Check that the contents are complete and nothing is
missing.
The product’s packaging material is recyclable.
When moving the welding machine, never pull it by the
welding-gun or other cables. For lifting the power source
and the robot interface unit, use the recesses at both ends of
the robot interface unit.
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.
3.2 System overview
The welder system supports both gas- and water-cooled
torches. An interconnection cable set without cooling
hoses is available for gas-cooled torches (see Figure 3.1,
“Connection diagram, gas cooled system”). Water-cooled
torches require a cooling unit and an interconnection
cable set with cooling hoses, both sold separately (see
Figure 3.2, “Connection diagram, water-cooled system”).

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Fieldbus
Figure 3.1: Connection diagram, gas-cooled system
Fieldbus
Figure 3.2: Connection diagram, water-cooled system

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3.3 Power source
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 machine
in a suitable carriage unit so that it is above oor level.
• The surface inclination may not exceed 15
degrees.
• Ensure the free circulation of 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.
The power plug
The power source comes without a plug for connection
to the electrical grid. Attach a plug suitable for your
power-supply standard to the power cable. Check the
connections, attach the plug to a socket, and switch the
electrical power on from the welding power source to
verify that the machine works properly.
Switch the machine o, and unplug it from the power
socket before continuing to further steps in the hardware
installation.
If local or national regulations specify that an
alternative power cable is required, the cable must be
replaced in conformity with the regulations. Connection
and installation of the power cable and plug should be
carried out only by a suitably qualied person.
Remove the machine’s left-hand cover plate to enable
attachment of an electrical cable. The power source unit
can be connected to a 400 V, 3~ power supply.
If changing the power cable, take the following facts
into consideration:
• The cable enters the machine through the inlet
ring on the rear panel and is fastened in place
with a cable clamp (05).
• The phase conductors of the cable are coupled to
connectors L1, L2, and L3.
• The protective ground line, colored green and
yellow, is coupled to the marked connector.
• If you are using ve-lead cable, do not connect
the neutral conductor.
05
*
L3
L2
L1
*In S-type cables there is a protective grounding conductor,
green-and-yellow striped.
3.4 Cooling unit
If you use a water-cooled welding torch, you need a
cooling unit installed as part of the welder system. Attach
the cooling unit to the power source. See the detailed
installation instructions in the operating manual delivered
with the cooling unit package.
The cooling hose connections are described in Subsection
3.8.5, “Cooling hoses.”
The wire feeder has no connectors for cooling hoses.
Use a special adapter to connect the cooling hoses to the
welding torch cooling connectors.
3.5 Wire feeder
Use a two-part mounting bracket to mount the wire
feeder securely on the robot arm. Fasten the upper part of
the bracket to the bottom of the wire feeder and the lower
part to the robot arm. Finish the installation by putting the
bracket parts together and xing them in place with bolts.
See the illustrated instructions included in the product
delivery package.
Mounting brackets are available for the most commonly
used welding robots. See the complete list at
www.kemppi.com.
The wire feeder connections are described in Section 3.8,
“Interconnection cable set.”

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Filler wire
Connect the wire liner to the ller wire inlet
connector on the rear of the wire feeder. Connect
the other end of the wire liner to the wire drum or
spool, and run the wire up to the wire feeder either
manually or by using wire inch functionality at the
wire drum.
Peripheral connector
For a push-pull welding torch, a collision sensor, and other
peripheral devices, the wire feeder has a common 10-pin
peripheral connector at the front of the wire feeder. The
connections of the push-pull torch and the peripherals are
described later in this document.
Figure 3.3: Peripheral connector pinout
A. Motor (+)
B. Motor (–)
C. Supply (+24 V)
D. Wire inch input
E. Collision sensor input
F. Touch sensor output for gas nozzle (+50…+200 V)
G. Tachometer (+5 V)
H. Supply GND
I. Tachometer GND
J. Tachometer input
Table 3.1: Electrical characteristics for the peripheral supplies
Value Min. Typical Max. Unit
Motor supply voltage (RMS) 24 48 V
Motor supply voltage (peak) 75 V
Motor supply current 0 5 A
Supply voltage 23.0 24.0 24.5 V
Supply current 0 150 780*mA
Tachometer supply voltage 4.9 5 5.1 V
Tachometer supply current 120 125 130*mA
Touch sensor output voltage** 50 200 V
Touch sensor output current** 10 mA
*This is the short-circuit current.
** The touch sensor electrical characteristics are found in
the A7 MIG Welder Operating manual.

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3.6 Welding torch
3.6.1 Mounting
Fasten the welding torch securely to the robot arm, using
a robot mount (T1, T2, or T3). See the detailed mounting
instructions in the delivery packages for the welding torch
and robot mount.
For the welding torch, the wire feeder is equipped with a
Euro MIG torch connector. Push the torch connector into
the Euro connector on the wire feeder, and tighten the
collar.
If you are using a water-cooled torch, connect the red-
and-blue marked cooling hoses to the corresponding
hoses coming from the cooling unit in the interconnection
cable set. For details, see Subsection 3.8.5,“Cooling hoses”.
3.6.2 Push-pull torches
If using a push-pull torch, you need to connect the torch
motor and any tachometer to the 10-pin peripheral
connector. For the connector pinout see Section 3.5,
“Wire feeder”. The motor is connected to pins A and B (see
Figure 3.4,“Push-pull motor connection”). The tachometer
is connected to pins G, I, and J (see Figure 3.5, “Push-pull
motor with tachometer”).
In order to operate properly, the push-pull torch must
be congured for use. The conguration is described in
Subsection 5.1.4, “General robot settings”.
M
A
B
Figure 3.4: Push-pull motor connection
S
M
A
B
G
J
I
Figure 3.5: Push-pull motor with tachometer
3.6.3 Wire inch button
If the welding torch is equipped with a wire inch button,
connect it to pins D and H of the peripheral connector (see
Figure 3.6, “Wire inch button connection”).
D
H
Figure 3.6: Wire inch button connection
3.6.4 Torch-cleaning with compressed air
The wire feeder is equipped with a compressed-air valve
for torch-cleaning. The wire feeder has appropriate fast
connectors for 6 mm nylon hose at the rear (inlet) and
front (outlet).
If you are using a torch with air-cleaning capability,
connect the compressed-air hose of the torch to the front
connector, and connect a hose from an air compressor to
the rear connector.
Do not modify the wire feeder. Use adapters if needed.
In automated operation, the torch-cleaning function is
controlled by a robot by using the digital robot interface.
To test the function manually:
• Press the air blow button on the wire feeder, or
• Use the air blow test function in either the setup
panel or the web user interface, or
• Control the air blow by means of the robot teach
pendant

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3.6.5 Touch-sensing with the gas nozzle
The default way to use the touch sensor of the welder
system is to use the welding wire as the touch tool.
Alternatively, you can use the gas nozzle of the welding
torch.
If the gas nozzle is used for touch-sensing, connect pin F of
the peripheral connector to the gas nozzle, using an extra
wire (see Figure 3.7,“Touch sensor gas nozzle connection”).
For instructions on how to congure the touch sensor, see
the A7 MIG Welder Operating manual.
F
Figure 3.7: Touch sensor gas nozzle connection
3.7 Collision sensor
The collision sensor is an external device that protects
the torch neck from bending and being damaged. It is
integrated into the mount between the robot arm and the
welding torch. The sensor sends a signal to the robot to
stop welding when a collision is detected at the welding
head.
Not all robot mounts feature a collision sensor. See the
manual of the robot mount for more information.
The welder system supports two types of collision
sensors, an opening-action switch sensor and a closing-
action switch sensor. The opening-action switch keeps
the relevant electrical circuit normally closed and opens
it on a collision, while the closing-action switch keeps
the electrical circuit normally open and closes it upon a
collision (see Figure 3.8, “Opening-action and closing-
action switches”).
The switch type is congured via software. The collision
sensor conguration is described in Subsection 5.1.6,
“Collision sensor settings.”
Figure 3.8: Opening-action (left) and closing-action (right)
switches
Connect the collision sensor to pins E and H of the peri-
pheral connector (see Figure 3.9, “Collision sensor
connection”).
E
H
Figure 3.9: Collision sensor connection
Some collision sensors have LED status indicators coupled
with the switch and therefore require supply voltage.
Connect pin C of the peripheral connector to supply
power to the indicators (see Figure 3.10, “Collision sensor
with LED indicators”).
C
E
H
Figure 3.10: Collision sensor with LED indicators

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3.8 Interconnection cable set
The interconnection cable set contains several cables and
hoses wrapped in a strong fabric sleeve equipped with
a zipper. The cable set is used for delivering the welding
power, shielding gas, cooling liquid, and control signals
from the welding power source to the wire feeder.
The interconnection cable set is available with and without
cooling hoses.
A
D
E
C
B
Figure 3.11: Interconnection cable set (wire feeder end)
A. Arc measurement cable
B. Cooling hoses
C. Shielding gas hose
D. Welding cable
E. Wire feeder control cable
3.8.1 The arc measurement cable
The arc measurement cable is a part of the arc voltage
measurement function, which is used to calibrate the
actual arc voltage and power regardless of the welding
cable diameter or length.
Connect the cable to the arc measurement input
connector at the rear of the power source.
Connect the cable to the arc measurement
output connector at the wire feeder.
For using the arc voltage calibration, connect a
separate earth cable (included in the package)
from the wire feeder to the work piece, near the
weld joint.
Check the route of the earth cable. Incorrect routing
can cause damage to the cable or the robot when the
robot is moving.
When the system is ready to run, calibrate the power
source by welding with 1-MIG, MIG or with Pulse MIG for
at least 5 seconds, with the arc measurement cable and
the earth cable connected. After calibration the earth
cable can be detached, although it is recommended to
use it always. The cable is required when monitoring arc
voltage.
Using the arc measurement cables aects the
functionality of the touch sensor. See the A7 MIG Welder
Operating manual for details.
If you are using a sub-feeder, enter the length of
the sub-feeder to the SubFeederLength parameter in the
setup panel. This parameter is not available in the web
user interface.

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3.8.2 Wire feeder control cable
The wire feeder control cable provides power to the wire
feeder and transmits the control data between the wire
feeder and the robot interface unit. It also contains the
touch sensor voltage line from the robot interface unit to
the wire feeder.
Figure 3.12: Wire feeder control cable connector pinout
A. Power supply GND
B. Data in/out
C. Power supply +50 V
D. (not connected)
E. Touch sensor voltage (+50…+200 V)
F. (not connected)
G. (not connected)
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.
At the power source, the connector must be connected
to the back of the robot interface unit. Do not use any other
control cable connectors.
3.8.3 Welding cable
The welding cable delivers welding power from the power
source to the welding head.
At the wire feeder, connect the cable to the screw
terminal on the front of the unit.
At the power source, connect the cable to the (+)
connector on the back of the power source unit.
3.8.4 Shielding gas hose
The shielding gas hose delivers the shielding gas to the
welding torch.
At the wire feeder, connect the hose to the shielding
gas snap connector.
Connect the other end of the hose to the shielding
gas supply.
3.8.5 Cooling hoses
Cooling hoses deliver the cooling liquid from the cooling
unit to the welding head.
• At the wire feeder, connect the cooling hoses
directly to the hoses coming from the welding
torch.
• At the power source, connect the cooling hoses
to the cooling unit located under the power
source.
The wire feeder does not have connectors for cooling
hoses. Use special adapters if required.

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3.9 Fieldbus communication
This welding system supports the following eldbus
choices for communication between the welding
equipment and the welding robot.
Ethernet:
EtherNet/IP
EtherCAT
PROFINET
Modbus TCP
Others:
DeviceNet
PROFIBUS DP-V1
Modbus RTU
The choices are enabled by interchangeable Anybus
CompactCom M30 modules manufactured by HMS. See the
A7 MIG Welder Operating manual for the complete list of
modules and their order codes.
Do not remove or attach the eldbus module when the
power is switched on. Doing so could damage the module.
There is a connection slot for the module on the back of
the robot interface unit. Place the appropriate type of
Anybus module in the slot (see Figure 3.13, “Installing a
eldbus adapter”). Ensure that it sits properly in its place.
Tighten the two screws on the module after you have
placed it into the slot. Connect a suitable eldbus cable to
the connector of the Anybus module and the other end of
the cable to the robot controller.
Figure 3.13: Installing a eldbus adapter
Table 3.2: Kemppi Oy vendor IDs and device description les
Fieldbus Vendor ID Device description le
EtherNet/IP 1-port and 2-port 1403 (integer) EDS (Electronic Data Sheet)
EtherCAT 00FE0001h (hexadecimal) ESI (EtherCAT Slave Information)
PROFINET 1-port and 2-port 0368h (hexadecimal) GSD (General Station Description)
Modbus TCP 1-port and 2-port ”Kemppi” (text) The Modbus standard does not feature a device
description le.
DeviceNet 1403 (integer) EDS (Electronic Data Sheet)
PROFIBUS DP-V1 0368h (hexadecimal) GSD (General Station Description XML)
Modbus RTU ”Kemppi” (text) The Modbus standard does not feature a device
description le.

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3.10 Ethernet (web user interface server)
The welder system is equipped with a web user interface.
The server for the web user interface is in the robot
interface unit, and the connector for the server is at the
rear of the unit.
Connect the web user interface server to a laptop
computer, to another PC, or to a local area network by
using a CAT-5 or CAT-6 shielded Ethernet RJ-45 cable.
The communication speed of the network is 100 Mbps
(100Base-TX) and the maximum length of the cable is 90
m. Both crossover and direct cables are suitable.
The network conguration is described in Chapter 4,
“Accessing the web user interface”.
3.11 Emergency input functions
There are two emergency input functions in the system,
for the emergency stop and gate door switch.
• The emergency stop function halts the system
when the operator presses an emergency stop
button. After an emergency stop, the system
must be recovered manually.
• The gate door switch halts the system when a
protective gate door is opened. Shielding gas
testing, the torch clean-up function (compressed-
air valve), wire inch, wire retraction, and the touch
sensor can be used in this situation. The touch
sensor voltage is automatically lowered to a
safety level (max. 110 V). After a gate door switch
action, the system is recovered automatically.
Both inputs have a separate three-pin connector at the
rear of the robot interface unit. The connectors have
identical pinout (see Figure 3.14, “Emergency input
connector pinout”). The inputs are galvanically isolated
from each other and from the other hardware I/O of the
robot interface unit. The inputs have individual short-
circuit-protected +24 V DC power supplies, each providing
up to 100 mA of continuous current.
Figure 3.14: Emergency input connector pinout
A
B C
A. Supply out +24 V, 100 mA
B. Emergency input signal
C. Supply GND
There are four alternative ways of connecting the
emergency stop and gate door switches (see Figure 3.15,
“Connecting the emergency stop switches”). Select one of
these ways on the basis of your emergency stop circuitry
and the switch types used. Connect the emergency stop
circuitry to the emergency input connector by using
custom cables.
The emergency inputs are congured via software. The
conguration is described in Subsection 5.1.7,“Emergency
stop settings.”
Opening-action switch on 0
V line (default) A
B
C
Opening-action switch on
+24 V line A
B
C
Closing-action switch on 0
V line A
B
C
Closing-action switch on
+24 V line A
B
C
Figure 3.15: Connecting the emergency stop switches

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3.12 Touch sensor status fast output
This welding system is equipped with an instantly
responding touch-sensing feature for locating the work-
piece in teaching of the welding robot.
In normal operation, the status of the touch sensor is
passed to the robot via a eldbus connection. However,
eldbus bus latency aects the eciency of operation. To
avoid delays, the hardware-based fast output can be used
for better response. For connection of fast status output,
the robot must have at least one hardware input available.
Connect the fast output to the touch sensor fast status
output connector on the rear of the robot interface unit by
using a custom cable. Connect the other end of the cable
to the hardware input of the robot controller.
A
B C
Figure 3.16: Fast status output connector
A. Supply in +24 V
B. Status signal out
C. Supply GND
The fast output requires an external 18–36 V power
supply.
The output is galvanically isolated from other
hardware and is short-circuit-protected. The maximum
continuous switching current is 100 mA @ +24 V.

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3.13 Dual wire feeder support
Dual wire feeder support in the A7 MIG Welder system
Fieldbus
1
2
3
4
5
6
Figure 3.14 Connecting two wire feeders into A7 MIG Welder system
1. Dual wire feeder extension kit
2. Extra control cable
3. Extra welding cable
4. Second wire feeder
5. Web user interface
6. Fieldbus
The A7 MIG Welder supports two wire
feeders, one operational at the time.
This feature is enabled by an optional
extension kit. The extension kit is
installed inside the robot interface unit.
The kit includes a wire feeder switching
card, a at band cable, and a harness
with connectors for the wire feeder
and for the mother board of the robot
interface unit. The operational wire
feeder can be selected from the setup
panel or web user interface, or let to be
selected from the robot pendant. The
wire feeder conguration is described in
the Subsection 5.12, “Wire feed settings”.

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3.13.1 Installation
Switch the power source o and install the extension kit into the robot interface unit.
Ensure that all the cables are installed properly. Test the system by switching the power
source on and selecting the wire feeder between the WF1 and WF2 from the setup panel
or between the Wire feeder 1 and Wire feeder 2 from the web user interface. The extension
card should indicate the selection by amber LED lights. After successful installation, switch
the power source o and close the robot interface unit.
Follow these steps to install the extension kit:
7. Unscrew four screws, two from the front panel and two from the back panel.
8. Slide the top cover o by pulling from the handle in the front panel.
9. Remove the plug from the extension connector slot.
10. Mount the switching card side by side with the touch sensor card.
11. Fix the secondary wire feeder control connector to the extension connector slot
by using four screws.
12. Unplug the primary wire feeder from the motherboard A101 and from the touch
sensor card A102.
A101
X2
X2
X3 X3
A105 A102

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13. Plug the primary wire feeder to the switching card A105 primary outputs (harness X3
to A105 X6 and harness X2 to A105 X3).
A101
X2
X2
X3 X3
A105 A102
14. Plug the secondary wire feeder to the switching card A105 secondary outputs.
A101
X7
X4
X4
X7
A105 A102
15. Plug a touch sensor cable between the switching card A105 input and the touch
sensor card output A102.
X2
X5
A102
A101
X2X5
A105 A102
16. Plug a bus cable between the switching card A105 input and the mother board A101
output.
X2
X2
A101
X2X2
A105 A102
17. Plug a at band cable between the switching card A105 and the mother board A101.
A101
X1
X10
X1X10
A105 A102
18. Plug the water valve control cables to the switching card A105.
A101
X9X8
X8
X9
A105 A102

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3.13.2 Connect the second wire feeder
Connect the interconnection cable of the second wire feeder to the weld+ connector in
the front panel of the power source. Connect the control cable of the second wire feeder
to the extension connector in the back panel of the robot interface unit. Switch the power
source on and test the wire feeders by performing a wire feed test for both wire feeders.
Selecting the wire feeders from the setup panel or web user interface for the test.
In water-cooled systems with two water-cooled torches the cooling water circulation
must be equally distributed into both torches. It is recommended to connect the torches in
serial. In parallel the water ow can dier between the torches and may cause damage to the
torch. 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.
3.14 Powering up
Before powering up the welding system, check all cable connections.
Attach the power plug to an electrical socket, and switch the machine on. Check that
the machine starts up properly. The setup panel boots up within 10 seconds. The Web
UI is usually accessible in 30 seconds.
The Web UI access time depends greatly on the network conguration in use. The
fastest conguration is a direct connection with xed IP addresses. With a local area
network and DHCP, the access time can be signicantly longer.

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4. ACCESSING THE WEB USER
INTERFACE
4.1 Configuring the network settings
The web user interface starts up automatically on power-
up. However, before one can access the Web UI from the
computer connected to the web user interface server, the
network settings must be properly congured from the
setup panel.
Go to the Main menu > Robot > Network settings, and
congure the DHCP enabled, IP address, Subnet mask,
and Gateway parameters to match your networking
environment.
DHCP
If you have a DHCP server in your network and you want to
enable a DHCP client function in the Web UI, change the
DHCP enabled parameter’s value to ON. The IP address,
subnet mask, and gateway information will come from
the DHCP server, and you don’t need to congure these
parameters. Switching this parameter’s value to OFF lets
you specify the IP settings manually.
When the DHCP client is switched on, it takes some
time for the client to establish a connection to the DHCP
server and retrieve the address information. Usually the
retrieval time is no longer than 60 seconds. During that
time, the old values are displayed for the IP address, subnet
mask, and gateway.
IP address
Specify an IP address for the web user interface server
(DHCP disabled) – for example, 10.0.0.20 – or display the
address given by the DHCP server (DHCP enabled).
Subnet mask
Specify a subnet mask for the web user interface server
(DHCP disabled) – for example, 255.255.255.0 – or display
the mask given by the DHCP server (DHCP enabled).
Gateway
The web user interface does not use a gateway address.
You can leave this parameter as it is (DHCP disabled) or
display the address supplied by the DHCP server (DHCP
enabled).
Congure your computer’s network settings accordingly.
Ensure that your computer has an IP address dierent
from that of the web user interface – for example,
10.0.0.21. Other settings must match each other.