Kemppi A7 Cooler User manual

1920720
1636
A7 MIG WelderA7 Cooler
EN
OPERATING MANUAL

2
A7 Cooler© Kemppi Oy 2016 1636
OPERATING MANUAL
CONTENTS
1. Introduction..........................................................................................3
1.1 General ......................................................................................................3
1.2 Product introduction.................................................................................3
2. Installation .............................................................................................4
2.1 Removal from packaging..........................................................................4
2.2 Locating the machine ...............................................................................4
2.3 Serial number ............................................................................................4
2.4 Installation and main parts .......................................................................4
2.4.1 Assembling the equipment ......................................................................4
2.4.2 Main parts of cooling unit ........................................................................4
2.5 Preparing for operation.............................................................................5
3. Operation...............................................................................................8
3.1 Cooler operation .......................................................................................8
3.2 Overheat signal lamp................................................................................8
3.3 Storage ......................................................................................................8
4. Maintenance.........................................................................................9
4.1 Daily maintenance ....................................................................................9
4.2 Monthly maintenance...............................................................................9
4.3 Every sixth months....................................................................................9
4.4 Flow switch adjustment..........................................................................10
4.5 Trouble shooting.....................................................................................10
5. Disposal of the machine.................................................................11
6. Ordering codes..................................................................................11
7. Technical data....................................................................................11

3
A7 Cooler© Kemppi Oy 2016 1636
OPERATING MANUAL
1. INTRODUCTION
1.1 General
Congratulations on choosing the A7 Cooler cooling
unit. 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 manual 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 authorised 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 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.
1.2 Product introduction
A7 Cooler is used for liquid cooling of welding gun. It is
designed for Kemppi's robotic welding equipment A7
MIG Welder, but it can also be used in manual welding. It
is fully compatible with FastMig X product family.
The operation of A7 Cooler is controlled by a micro-
processor. To ensure critical cooling of the welding gun
in robotic applications, the unit has a ow switch in the
return line.

4
A7 Cooler© Kemppi Oy 2016 1636
OPERATING MANUAL
2. INSTALLATION
2.1 Removal from packaging
The equipment is packed in durable packages specially
designed for them. Check the equipment before taking
it into use, to make sure that the equipment or a part
of it have not got damaged during the transportation.
Also check that the delivery corresponds your order and
that you have received all the necessary instructions for
installing and operating the equipment. The packaging
material can be recycled.
2.2 Locating the machine
Place the machine on a horizontal, stable and clean
ground. Protect the machine from heavy rain and burning
sunshine. Check that there is enough space for cooling air
circulation in front of and behind the machine.
2.3 Serial number
The serial number of the machine is marked on the
machine CE-marking. Identicating the serial number is
the only proper means of maintaining and identifying
parts for a specic product. It is important to make
correct reference to the serial number of the product
when making repairs or ordering spare parts.
2.4 Installation and main parts
2.4.1 Assembling the equipment
The equipment is assembled in the following order:
1. A7 Cooler 6068220
2. Transport unit PM500 6185291
(If used with FastMig)
Assembly the transport unit according to the instructions
in the package. Fasten the cooling unit to the transport
unit by using the screws and bolts delivered with the
equipment.
2.4.2 Main parts of cooling unit
4
2
1
3
5
6
7
8
Front machine
1. Housing
2. Test switch
3. Overheat control lamp
4. Filling hole
Back side
5. Mains voltage connection cable
6. Control cable
7. Cooling water output hose
8. Cooling water input hose

5
A7 Cooler© Kemppi Oy 2016 1636
OPERATING MANUAL
2.5 Preparing for operation
Cooling liquid is harmful! Avoid also contact with skin
or eyes. In case of injury, seek for medical help.
See also 2.4.2. Main parts of cooling unit.
1. Fasten the lter unit's mounting plate to the
cooler's front panel. Then connect the lter unit
to the snap connector and fasten the unit to the
mounting plate. Inside the cooler there is a ow
switch, factory-adjusted to 1 litres per minute. To
change the ow rate, loosen the locking screws
of the black slide control and move it to show the
desired ow rate.
2. Connect the mains voltage and control connectors
of the cooler unit to the corresponding connectors
on the base of the power supply. The connection
can be established through the base of the power
supply when the devices are separated or through
the right side of the A7 Cooler unit by removing
the right side plate.
TEST
3. Attach the power supply on the cooler.
4. Connect the cooling water hoses with the wire
feed unit, follow colour markings.
5. Fill the reservoir with cooling liquid. It is preferred
to use Kemppi brand cooling liquid. Also water
can be used, if the temperature doesn't go below
0 degrees Celsius. The capacity of the reservoir is
3 litres.
6. Switch on the power supply.
7. Press and hold down the test switch until the
torch hoses are lled with liquid.
When A7 Cooler is connected to the power source
for the rst time, the cooler function is normally active. To
deselect the cooler function, follow the instructions below
depending on the power source type in use.

6
A7 Cooler© Kemppi Oy 2016 1636
OPERATING MANUAL
Filter unit and ow switch
Depending on the FastMig model in question and the control panel type tted, please
follow the graphical instruction below in order to deselect or select water-cooling
function. FastMig Pulse or FastMig X operation is set to 'AUTO', FastMig KM, KMS and M
equipment is set as water function ‘ON’from the factory.
If no cooler is tted, deselect the cooler function as instructed in the following. Welding
will be prevented if cooler function is enabled and no cooler is tted.
A7 MIG Welder, FastMig X and Pulse
The factory default setting for A7 MIG Welder, FastMig X and Pulse is AUTO. If a cooling
unit is not connected and the operator tries to establish air-cooled operation together
with an air-cooled gun, Err 27 is displayed. To establish air-cooled operation, select
cooler ‘OFF’. This is done in the ‘System Cong Menu’ as follows: Press the Menu button
on the X 37 power source panel. Move the menu display arrow (via panel's left-hand
up-down arrow keys) to select ‘System Cong Menu’ and then press the select button.
Choose‘Water Cooling:Auto’and change via control knob to setting‘Water Cooling:OFF’,
then press Back/Exit. Cooler will then be set to the ‘OFF’ state for air-cooled operation.
Reset power source via on/o switch and continue welding.
When selected, the operation of the cooling unit is automatic, starting when welding
commences. When welding stops the pump will continue operation for approx. 5 min,
so reducing the gun and the cooling liquid to ambient temperature.
FastMig M, KMS and KM
When leaving the factory, cooling unit status is set 'ON'. If no cooling unit is connected,
set the cooling unit status to 'OFF'. Depending on your panel type follow the instructions
described in the graphic below. Having selected the cooling state required, reset the
power source by switching o at the main on/o switch. Restart the power source and
weld.
MR 200/MR 300

7
A7 Cooler© Kemppi Oy 2016 1636
OPERATING MANUAL
SF 51/SF 54
WIRE INCH
weld
data
V
A
m/min
4T
SETUP
2T
U
MMA
MIG
MMA
PANEL
SF 51
W001318
DYNAMICS
ARC FORCE
GAS TEST
GAS TEST
ARC FORCE
DYNAMICS
GAS TEST
ARC FORCE
DYNAMICS
SF 52W/SF 53W and MS 200/MS 300
POWER
U
AV
m/min
mm
MINILOG
POWER
A
C
D
B
KM
GAS TEST
DYNAMICS
WIRE INCH
weld
data
V
A
m/min
4T
SETUP
2T
KM
W001319
LOCAL
REMOTE
A B
GAS TEST
DYNAMICS
WIRE INCH
weld
data
V
A
m/min
4T
SETUP
2T
KM
W001319
LOCAL
REMOTE
C
After completing the preparations explained above, the device is ready for welding.
Before welding, read the operating instructions.

8
A7 Cooler© Kemppi Oy 2016 1636
OPERATING MANUAL
3. OPERATION
3.1 Cooler operation
See also 2.4.2. Main parts of cooling unit
The A7 Cooler cooler operation is controlled by the
microprocessor of the power supply. The cooler pump
starts to operate when the welding begins. After the
welding has stopped, the pumpwill operate 1 to 5minutes
longer depending on the welding time. During this time
the liquid will cool down to the ambient temperature and
cools down the welding gun.
Check the tank liquid level regularly and add liquid, if
necessary.
If the tanks coolant liquid level runs low, welding is
stopped and an error code appears on the FastMig panel.
See trouble-shooting 4.5.
3.2 Overheat signal lamp
The overheat signal lamp is lighting when temperature
control of the machine has detected cooling water
overheat. The ventilator cools down the machine and
when the lamp goes out welding can be started again.
3.3 Storage
The machine must be stored in a clean and dry room.
Protect the machine from rain and keep it away from
direct sunshine in places where temperature exceeds
+25° C. Check that there is free space in front of and
behind the machine for air circulation.

9
A7 Cooler© Kemppi Oy 2016 1636
OPERATING MANUAL
4. MAINTENANCE
Watch out for mains voltage when handling electric
cables!
In planning product maintenance machine utilization
degree and circumstances should be considered.
Careful use and preventive maintenance help to avoid
unnecessary production disturbances and breaks.
4.1 Daily maintenance
The following maintenance opeations should be carried
out daily:
• Check water level and input ow, add liquid if
needed.
• Check cables and connections. Tighten, if
necessary and replace defect parts.
• Check that there are no leakages in the cooling
water hoses.
4.2 Monthly maintenance
Check and clean the lter unit on the front panel once a
month:
1. Unscrew the cup from the lter and remove the
lter from the pivot.
2. Clean the lter net using water and compressed
air.
3. Replace the lter net and the cup.
4.3 Every sixth months
The following maintenance opeations should be carried
out at least every sixth months:
• Clean o dust and dirt. Change the cooling
liquid and wash up the pipes and water reservoir
with pure water.
• Check seals, cables and connections. Tighten, if
necessary and replace defect parts.

10
A7 Cooler© Kemppi Oy 2016 1636
OPERATING MANUAL
4.4 Flow switch adjustment
The ow switch is located inside the cooler, on top of the water tank. If the cooler
is already connected to the power source, you must disconnect it (see chapter 2.5).
Loosen the locking screws of the black slide control and move it to show the desired
ow rate. Tighten the locking screws and reconnect the cooler to the power source.
3,0 2,0
2,5 1,6
1,0
3,0 2,0
2,5 1,6
1,0
3,0 2,0
2,5 1,6
1,0
4.5 Trouble shooting
See also 3.2. Overheat signal lamp.
Overheat signal lamp is lit.
The unit is overheated.
• Check water circulation.
• Check that there is enough free space in front of and behind the machine for
cooling air circulation.
Error code Err5 or Err 27 on the FastMig panel
• Check the liquid hoses for damages.
• Remove any hose blockages.
• Check water circulation, add liquid if needed.
For further information and assistance, contact your nearest Kemppi service workshop.