Kemppi A7 TIG Orbital System 300 User manual

150
1920380
1615
A7 TIG Orbital System
EN
OPERATING MANUAL

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A7 TIG Orbital System 150© Kemppi Oy 2016 1615
OPERATING MANUAL
CONTENTS
1. Introduction..........................................................................................4
1.1 General ......................................................................................................4
1.2 About the product ....................................................................................5
1.3 Weld head..................................................................................................6
1.3.1 Tube diameters and weld head outline dimensions.......................................6
1.3.2 Collets..................................................................................................7
1.3.3 Collet frame and collets ...........................................................................7
1.3.4 Flush collets ..........................................................................................8
1.3.5 Extended collets / combination.................................................................8
1.4 Controller unit ...........................................................................................9
1.4.1 Front panel............................................................................................9
1.4.2 Gas ow................................................................................................9
1.4.3 Water cooler .........................................................................................9
1.5 Compatibility.............................................................................................9
2. Installation ...........................................................................................10
2.1 Controller unit connectors......................................................................10
2.2 Connecting the weld head .....................................................................10
2.3 Suitable collets to the collet frame.........................................................11
2.4 Mounting the weld head ........................................................................11
3. Operation.............................................................................................12
3.1 Rotor gear................................................................................................12
3.2 Tungsten electrode .................................................................................12
3.2.1 Diameter and length .............................................................................12
3.2.2 Holder................................................................................................13
3.2.3 Geometry guidelines.............................................................................13
3.3 Electrode sharpeners ..............................................................................14
3.4 Filling water cooler with coolant ...........................................................14
3.5 Preparing for welding .............................................................................15
3.5.1 Preparing the workpiece........................................................................15
3.5.2 Shielding and backing gas .....................................................................16
3.6 Instructions for welding .........................................................................16
3.7 Weld head control panel.........................................................................17
3.8 Controller unit control panel .................................................................17
3.8.1 Start-up ..............................................................................................18
3.8.2 Main screen/Menu................................................................................18
3.8.3 Using Auto program..............................................................................20
3.8.4 Override Limit function .........................................................................21
3.8.5 Program information.............................................................................21
3.8.6 Alphanumeric labeling ..........................................................................23
3.8.7 Manual programming ...........................................................................23
3.8.8 Pulsing levels.......................................................................................24
3.8.9 RPM Step ............................................................................................24
3.8.10Pre-purge – Upslope Screen ...................................................................25
3.8.11Pass level screens .................................................................................25
3.8.12Other screens ......................................................................................27
3.8.13Override Limit function .........................................................................27
3.8.14Maintenance Menu...............................................................................28
3.8.15Options Menu......................................................................................28
3.8.16Copying/transferring les to memory stick ................................................30
3.8.17Deleting welds.....................................................................................30
3.8.18Printing welds......................................................................................31
3.8.19Tungsten electrode length calculator .......................................................32
3.8.20Advanced Help ....................................................................................32
3.8.21Autotack.............................................................................................32
4. Additional details..............................................................................33
4.1 Technical data..........................................................................................33
5. Ordering information ......................................................................33
5.1.1 Collets................................................................................................38
5.1.2 Tungsten electrode material...................................................................41

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OPERATING MANUAL
6. Troubleshooting................................................................................42
6.1 Operation problems................................................................................42
6.2 Tungsten electrode rotation not concentric to tube O.D.......................42
7. Maintenance.......................................................................................44
7.1 Periodic maintenance .............................................................................44
7.1.1 Factory and eld calibration ...................................................................44
7.2 Weld head maintenance .........................................................................44
7.2.1 Calibrating the weld head ......................................................................44
7.2.2 Cleaning the weld head .........................................................................45
7.2.3 Internal arcing .....................................................................................45
7.3 Printer operation and maintenance .......................................................46
7.3.1 Installing paper in the printer..................................................................46
7.3.2 Cleaning the printer ..............................................................................46
7.4 Updating software ..................................................................................46
7.5 Service Workshop maintenance ............................................................46
8. Disposal ................................................................................................47

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A7 TIG Orbital System 150© Kemppi Oy 2016 1615
OPERATING MANUAL
1. INTRODUCTION
1.1 General
Congratulations on choosing A7 TIG Orbital System 150
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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OPERATING MANUAL
1.2 About the product
A7 TIG Orbital System 150 is used forTIG orbital welding. It
is a semi-automatic welding method where the arc moves
automatically and without interruption 360° around tubes
or tting components.
The system consists of a weld head and a controller unit.
The controller unit includes an integrated TIG power
source and a cooling unit.
You can create and save up to 100 welding programs and
select the most suitable for each welding object by using
the unit’s graphic interface.
The system has been designed to weld tubes made of
various materials, including stainless steel, Duplex and
Titanium, up to wall thickness of 3 mm.
Weld heads of various (5) sizes enable welding pipes with
diameters from 3 to 150 mm.
The system oers a wide operating range and good
reach and is suitable for
• tube-to-tube
• tube-angle
• tube-to-tting welding.

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OPERATING MANUAL
1.3 Weld head
W009315
The weld head contains a U-shaped rotor gear that moves
the tungsten electrode orbiting the non-moving tube.The
head totally encloses the weld joint and allows the interior
of the head to be ooded with shielding gas. The system
includes water cooling for heavy duty cycles.
Control panel is in the handle, and assembly to the
controller is provided by a 7.5-metre hose (longer cables
are available).
The weld head is clamped on tubes by changeable collets.
It includes a chamber for shielding gas. Spesic collets are
recommended for each tube outer diameter (OD).
1.3.1 Tube diameters and weld head outline dimensions
A B
C D
15010 15020 15030 15040 15060
Weight (kg) 3.2 5.0 6.4 8.2 10.0
Tube Diameter (mm) 3–25 6–51 9–76 12–102 50–152.4
A (mm) 124 175 202 231 297
B (mm) 62 83 96 110 144
C (mm) 43 43 43 43 43
D (mm) 19 19 19 19 19

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1.3.2 Collets
Collets are used for clamping the weld head on the tube
or tting to be welded. Collets always come in pairs, and
they are mounted on the hinged collet frame with screws.
Collets are specied by:
• Weld head model
• Outer diameter (OD) of the tube or pipe.
Two types of collets are available: ush and extended.
1.3.3 Collet frame and collets
The collets mount in the weld head and are used to clamp
the head on to the tube or ttings to be welded.
• The collet frame swings open on a hinge and is
held closed using two latches on either side of
the head.
• Both sides of the collet frame open and close
independently.
• This allows one tube (or tting) to be clamped
in place and the second tube (or tting) to be
butted tightly to the rst clamped tube before it
is clamped.
Above function is solely to keep the head from moving
during welding, and it should not be used as a substitute for
external alignment xtures, clamps, or tack welding to hold
the workpieces aligned.
Each collet pair consists of two half-circle pieces that are
mounted on both sides of the hinged collet frame using
screws (see images below).
The collet frame and collets are connected to the work (+)
lead of the torch cable, and a separate return lead is not
needed.
Collet sets must be ordered separately. One weld head
requires two pairs of collets (1 set = two pairs).

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1.3.5 Extended collets / combination
Figure: A pair of extended collets
Extended collet is thicker than ush collet, and it extends
wider from the collet frame.Wider or thicker collets can be
used where the parts to be welded have enough straight
length to be clamped. The amount of extension is 18 mm
on each side of the weld head where extended collets are
used.
Advantages:
• More stable and more capability for holding both
welded pieces aligned with each other.
• Greater alignment capability due to longer
length.
Disadvantages:
• Takes more space, and may not allow welding in
tight places for example in certain tting-to-tube
welds, depending upon tting type.
• Requires a certain straight length of tube on
which to clamp.
1.3.4 Flush collets
Figure: A pair of ush collets
The outer surface of the collet pair is ush with the outer
face of the collet frame. Flush collets are used for joints
where there is very little straight length between the joint
and an obstruction.
Advantages:
• Enables welding in tight places where there is
not much room for clamping, for example when
welding ttings on a tube or pipe.
• Allows the minimum distance between the
tungsten electrode and an obstruction. For
example, if a tting must be welded there is
frequently only a minimal straight length on the
tting available for clamping.
Disadvantages:
• Less stable and less capability for holding both
welded pieces aligned with each other.
• The thicker or wider the collet, the greater
alignment capability it has to hold the tube
or tting so that both ends of the tubes to be
welded are squarely aligned. Therefore, ush
collets have minimal width alignment of tube
ends.
Figure: A combination of collets
Combination:
• Combination of extended and ush collet pair
can be used for tube-to-tting welding, for
example.
• If your application consists of tube-to-tting
welding but you need greater alignment
capability when mounting on the tube side, use
an extended collet pair on one side of the head
and a ush collet pair on the other

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OPERATING MANUAL
1.4 Controller unit
A7 TIG Orbital System 150 power source and cooling unit
are integrated inside the controller unit. This unit also
involves a printer to print welding parameters on paper.
The parameters can be saved on a memory stick through
the USB port. Programs can be stored in internal memory
(100) and saved on a memory stick.
1.4.1 Front panel
A7 TIG Orbital System 150 features a clear color display, a
control knob, and press buttons. Its intuitive graphical user
interface oers easy-to-use menus and auto programming
forautomatic calculation of weldingparameters,including:
• Electrode length calculator
• Creation of custom programs
• Instructions and information for the operator.
The power source front panel provides the controls to
develop, save, and call up welding programs.
1.4.2 Gas flow
The power source is equipped with a gas ow sensor that
is factory preset. Shielding gas must be owing to the
weld head to initiate a welding arc.
• If gas ow is insucient, pressing the Start Weld
button will not initiate a welding arc.
• If the gas ow is interrupted during welding, the
sensor will immediately extinguish the arc. A
warning message is displayed.
1.4.3 Water cooler
The controller unit contains an integrated water cooler
that monitors water circulation, and any failure or block
causes an alarm.
The water ow function is factory calibrated. Interruption
or insucient water ow (less than 0.5 LPM) results in
termination of welding and a warning message on the
display.
Water ow
The water ow sensor has a factory preset trip point that
is not adjustable.
• If water ow is insucient to actuate the
sensor, a welding arc cannot be initiated.
• Pressing Start Weld causes pre‐purge. When the
arc should be initiated, the starting sequence is
interrupted and a warning is displayed.
1.5 Compatibility
A7 TIG Orbital System 150 controller is compatible with
the 150 series of weld heads.

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OPERATING MANUAL
2. INSTALLATION
2.1 Controller unit connectors
A
E
B
F
C
G
D
All connections are located on the rear of the controller
unit:
A. Power ON/OFF
B. Resettable fuses
TRVL = Travel motor, (WIRE = Wire feed motor, not
available)
C. Weld head control cable
D. Gas Out (to weld head)
E. Gas In (from cylinder)
F. Welding power connector ( – )
G. Earth return connector ( + )
2.2 Connecting the weld head
A
B
C
D
All connections are located on the rear of the controller
unit. Do the following:
A. Connect the weld head’s control cable to the
connector marked with the weld head symbol.
B. Connect the weld head’s gas hose to the Gas Out
connector.
C. Connect the hose from gas cylinder to the Gas In
connector.
D. Connect the weld head’s power cable to the
negative terminal ( – ).
E
F
E. Connect the coolant hoses to two couplings. They
are dierent by their design to avoid incorrect
installation.
F. Connect the weld head’s power return cable to the
positive (+) terminal of the controller unit.

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OPERATING MANUAL
2.3 Suitable collets to the collet frame
The collets are designed to clamp rmly on the outside
diameter (OD) of the tube or ttings to be welded. The
interior diameter (ID) of standard collets is oversize relative
to the tube to be welded by .075 mm to allow for standard
dimensional tolerances. The collet halves that make a pair
are identical. They are engraved to show the tube OD or
tube tting OD and type.
1. Install the two (2) pairs of appropriate collets on
either side of the weld head collet frame using
button head screws. The collet inserts are not
threaded to eliminate stripped threads in the collet
frame, which is more expensive to repair or replace.
2. Accomplish rm clamping by slight over-closure
of the collet frame. Compliance and preload are
provided by the collet frame adjustable latch
mechanism.
The latch lever provides very high clamping loads
with minimal eort. After adjusting the thumbscrew on
the latch mechanism, the toggle action of the lever should
require no more than light pressure of one nger to close.
Over-tightening can result in damage to the collet frame or
tubing.
2.4 Mounting the weld head
Do the following:
1. Install suitable collets on the weld head.
2. Install suitable electrode in the holder.
3. Mount the weld head on the tube and align the
tungsten electrode with the welding joint.
4. Close one side of the weld head and lock it
against the tube with the latch.
5. Place the other tube very tightly against the rst
tube already clamped.
6. Close the other side of the weld head and lock
with the latch.
7. Look through the hole on top of the weld head to
ensure that the alignment is right.
8. Close the hole cover.

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OPERATING MANUAL
3. OPERATION
3.1 Rotor gear
Weld head contains a rotor gear that drives the electrode
around the tube. Rotor gear is U-shaped to allow
easy placement of the weld head on and o the tube.
Electrode is fastened on the rotor gear with an easily
replaceable electrode holder. The holder prevents the
rotor gear from damage.
Electrodes and holders are available in the following
diameters:
• 1 mm (.040”)
• 1.6 mm (.062”)
• 2.4 mm (.094”)
3.2 Tungsten electrode
ø 1.0 /1.6 / 2.4 mm
20 – 30°
14 – 75 mm
0.25 – 1.0 mm
Electrode diameter, tip geometry, and arc gap are
important factors in repetitive precision welding. The
electrode must be exactly the correct length with a
maximum tolerance of 0.1 mm.
Inserted into the holder and carefully bottomed, the
electrode forms exactly the correct arc gap. Pre-grinded
and cut-to-length electrodes are available.
3.2.1 Diameter and length
You can use multiple tungsten electrode sizes in each
weld head by changing the tungsten electrode holder.
Order the tungsten electrodes or cut them to a precise
length by yourself. When the tungsten is inserted into
the holder and bottomed, it will create the desired tip-to-
work distance without the need for adjustment.
Weld head Rotor gear
radius
15010 28.7 mm
15020 42.0 mm
15030 54.6 mm
15040 66.8 mm
15060 100.6 mm
The electrode must be precisely the correct length with
a maximum tolerance of 0.1 mm. Its correct length
depends on the weld head size, electrode diameter and
tube diameter.
To determine correct electrode length, use the
150 series controller Tungsten Length Calculator. If the
controller is not available, calculate cut-length by using the
formula below or a calculator on the Kemppi website.
Length calculation formula:
Length = rotor gear radius – tube radius – arc gap

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OPERATING MANUAL
3.2.2 Holder
To install the tungsten electrode and holder, do the
following:
1. Turn the controller power switch ON.
2. Using the +/- Rotation Jog on the weld head
handle, rotate the rotor until you can see the
electrode holder's postiion at the open throat
area of the weld head.
3. Using 3 mm x 6 mm cap screws, install the block
and tungsten electrode into desired position. The
tungsten electrode mount block is a split block.
a. Leave screws loose and push up against the
tungsten intu the holder.
b. Tighten screws, solid side rst, then split side.
The standard position of the tungsten electrode
as viewed from the side along the tube centerline is a 5°
down from 3 o’clock. This is to avoid breaking of tungsten
when installing the weld head on pre-tacked tube. You
can use alternative tapped holes in rotor (8 or 6 o’clock
position) e.g. in case of stripped threads in the rotor.
3.2.3 Geometry guidelines
Diameter
Use the smallest diameter tungsten electrode suitable
for the weld current range for positive arc ignition and
a stable arc. Thicker diameters handle high currents and
have a greater life at the expense of arc starting.
Electrode diameter Tube wall thickness
Up to 1.0 mm 1.0 mm
1.0–2.4 mm 1.6 mm (.062")
2.4–4.0 mm 2.4 mm (0.094”)
Arc gap
The tungsten electrode tip-to-work distance, the arc length
is kept to a minimum and produces a more stable arc and
deeper penetration. For general tube welding, the arc gap
should be adjusted between 0.75 mm (.03") and 1.8 mm
(.07").
Tube wall thickness Recommended arc length
0.5–1.0 mm 0.75 mm
1.0–2.0 mm 1.3 mm
2.0–4.0 mm 1.8 mm
Tip angle and at diameter
The tungsten electrode angles (included angle) between 15° to 30° enable the most automated welding.
Kemppi recommends 20° for autogenous welding in the general current range used with the 150 series
weld heads.
Tungsten electrode tip angle and at diameter
Electrode
Diameter mm
Flat diameter
mm
Included
Angle (deg)
Constant current
Range (amp)
Pulsed current
Range (amp)
1.0 mm 0.25 mm 20° 1
1.6 mm 0.5 mm 20° 8–50 8–100
1.6 mm 0.75 mm 20° 10–70 10–140
2.4 mm 0.75 mm 30° 12–90 12–180
2.4 mm 1.0 mm 30° 15–150 15–250
3.2 mm 1.0 mm 30° 20–200 20–300

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OPERATING MANUAL
3.3 Electrode sharpeners
Ultima – TIG – cut NEUTRIX
Use sharpener to sharpen the electrodes, to cut them to
correct length, and to help gather and recycle welding
dust.
Desktop model (recommended) allows more precise
lengths. It recycles dust into liquid instead of air. You can
also use a hand-held model. Only sharpening is possible
with the hand-held model, not accurately cutting to
length.
You can obtain a faster and more uniform grinding result
compared to manual grinding with an optional auto-grind
device.
Tungsten is the most suitable material for welding
electrodes but it is hazardous as waste and when breathed.
3.4 Filling water cooler with coolant
You can ll the water tanks with normal tap water. However,
the degree of water purity as well as the temperature of
the environment determine if you need to apply additives
and/or otherwise take care of the water supply.
When employing TIG system at temperatures below
+8 °C, add an anti-freeze medium.
1. Fill the water tank with 3.5 liters of Kemppi torch
coolant uid or equivalent (Monopropylenglycol).
2. Use max. 40 % of coolant uid added to water. This
will provide freezing protection to ‐25 °C.
Do not use distilled or demineralized water. Zinc
deciency causes corrosion and a risk of leakage.
Even if the temperature stays above +8 °C, use a
small quantity (ca. 10 %) of anti-freeze additive. It prevents
adverse algal growth in warm water.
The amount of cooling uid required depends on the cable
length of the weld head. Normally, 3.5 litres is sucient.
Check the level of coolant after several minutes of rst
turning on power to top o the coolant level as required.

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OPERATING MANUAL
3.5 Preparing for welding
1. Turn the power supply ON.
2. Clamp the weld head on the workpiece.
3. Purge the gas hose and chamber of the weld head
using the purge button on the power supply. Purge
the weld head and gas line for approximately ten
(10) minutes prior to the start of welding each shift.
4. Purge the tube ID in preparation for welding with
backing gas.
5. Load the appropriate weld program number as
described in the power supply manual. The red LED
on the handle next to the Home position ignites.
If this does not occur, press the Home button. The
rotor rotates until Start position is reached, and LED
ignites. Press the Start Weld button.
Do not start the head if it is out of its Home position
because it is then exposed to the walls of the chamber and
collets that are at work return potential. While welding, the
arc voltages are so low as to have no consequences, but
during the start sequence having the gear partially exposed
may cause misre. In rare cases this can create an arch-over,
allowing the follow on welding current to establish between
the rotating gear and the housing. This will only happen
if at the same time the tungsten-to-workpiece-to-collet
conductivity is poor due to oxidation or contaminated from
machining operations, primarily lubricants.
6. At the completion of the weld the auto rewind
function rotates the rotor into "open throat"
position to allow the weld head to be removed.
If you do not use this function, press the Home
button once again. The rotor rotates into correct
position to allow the weld head to be removed
from the workpiece.
7. Open both sides of the hinged collet frame and
remove the weld head from the workpiece.
3.5.1 Preparing the workpiece
For successful fusion welding, do the following:
1. Ensure that the tube ends (or ttings) are machined
square relative to their axis.
2. Place the two ends butt-tight together.
3. Leave no gap between the tube ends resulting
from lack of squareness or burrs left from the
machining process.
4. Once the tube end is faced o, check for burrs. Any
burrs must be carefully removed with a hand-held
deburring tool.
5. If the tube wall thickness variation exceeds 10%,
use chamfer cut of 5° on the inside of the tube
ends.
After the tube has been machined, it must be properly
cleaned using the following procedure:
1. Wipe the tube end with a lint-free towel dipped in a
solvent, such as acetone or denatured alcohol, and
immediately wipe with a second clean cloth before
the solvent dries. Use an abrasive cloth to remove
any surface oxides or contaminants. Clean the tube
end back to approximately 12 mm.
2. Repeat the cleaning operation. Ensure that tube’s
inner diameter is similarly cleaned.

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OPERATING MANUAL
3.5.2 Shielding and backing gas
Select proper shield gas/gas mix for optimum results.
100% argon is normally used for TIG welding. In certain
cases, you can benet from using a mixed gas, such as 95%
argon, 5% hydrogen.This mixed gas gives better control of
the weld puddle and lower heat input. Adding hydrogen
or helium increases the arc voltage and creates a "stier",
more focused arc column.
Industrial grade inert gas is sucient for most stainless
steel welds. Use a higher purity grade for high quality
welds on easily oxidizable alloys.
The purpose of purging is to replace unwanted air and
other vapor contaminants from the root pass by a gas
that prevents oxidation during welding. Oxidation can
produce a variety of problems, such as root oxidation
(sugar), incomplete fusion, porosity and changes in weld
chemistry, which can aect weld mechanical and corrosion
resistance properties adversely.
Use purging when welding stainless steel, nickel alloys,
and most nonferrous base metals. Argon is commonly
used.
The “chamber” created around the tube joint by the
installation of the weld head is ooded with inert gas
that both protects the weld puddle from oxidation and
the tungsten electrode. The gas hose material used
in the weld heads is specically designed to prevent
atmospheric moisture from contaminating the shielding
gas by permeation.
The gas regulator/ow meter should be set for 4
bar (60 PSI) and a suitable ow rate. Recommended gas
ow rate is 3 to 5 l/min for backing gas and 5-10 l/min
for shielding gas. Set pre-purge time so that backing gas
volume is about 10 times the volume to be put inside the
tube.
You can apply separate backing gas for root
protection. When using backing gas, also use dual ow-
meter regulator that allows having two independently
regulated (shielding and backing gas) circuits from one gas
bottle.
3.6 Instructions for welding
Use the following 5-step procedure to start welding:
1. Select and install suitable collets.
2. Mount weld head around the tube.
3. Pre-purge the tube ID with shielding gas.
4. Select the program you want to use.
5. Start welding by pressing the Start button.

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OPERATING MANUAL
3.7 Weld head control panel
W009315
A
B
C
D
A. Stop: immediately terminate the weld cycle and all
functions of the weld head.
B. Start Weld: initiate the weld program. LED light
beside the button is lit during the weld cycle. This is
also a soft way to stop welding.
C. Home position: welding can be started only when
the rotor gear is in its home position. It also allows
easy installation and removal of the workpiece.
1. Press the Home button to move the rotor gear
to the home position.
2. A red LED ignites next to this button, when the
rotor gear reaches its home position.
D. Rotation forward or reverse: with these buttons you
can move the rotor gear to either direction when
welding arc is not on. This is useful when mounting
or replacing the electrode or checking its condition.
3.8 Controller unit control panel
D
E
B
C
AF
G
I
H
A. Color LCD display: shows the setup values,
parameters and the soft key functions.
B. Stop: terminates the weld cycle and all weld head
functions.
C. Start Weld/Start Downslope: starts welding or
initiates downslope if welding is in progress.
D. USB port: connect memory stick to back up
programs and copy them from one power source
to another, to download QC programs, and to save
welding parameters and print them on a PC.
E. Cursor up: highlight the item above on display.
F. Cursor down: highlight the item below on display.
G. Enter: activate the highlighted item.
H. Control knob: increase/decrease the value of the
selected item.
I. Soft keys (4): select menu items shown on the
display depending on the operation mode (Setup,
Programming, Operation etc.)

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A7 TIG Orbital System 150© Kemppi Oy 2016 1615
OPERATING MANUAL
3.8.1 Start-up
When the control is rst turned on the main display will
remain o except for backlighting. After approximately
12 seconds the model, S/N, software release date, and last
calibration date appear on the display.
3.8.2 Main screen/Menu
Four soft keys on the main screen allow access to:
1. Library of existing procedures
2. Help with detailed explanation of highlighted item
3. Menu that provides access to various functions and
system conguration
4. New to create a new weld program.
Library
Programs are listed. Use the up/down cursor to scroll
through programs. Select program with Select (soft key).
Library displays the following choices:
• Weld Number XX
• Run
• Review Parameters
• Review Notes
• Edit Weld
Scroll through the list to make your selection.
To run, review, and edit existing program in Library
Move cursor to desired program and press Select.
Only weld numbers 001 to 099 are in use to store
programs in internal memory. Weld number 100 and above
are used when exporting weld programs to another power
source.
To run a weld in Library
1. Move cursor to Run (highlighted in red). Press
Select.
Also use cursor and Select to Review Parameters, Review
Notes, and Edit Weld.

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A7 TIG Orbital System 150© Kemppi Oy 2016 1615
OPERATING MANUAL
2. Press Start Weld to initiate weld or press Purge to
pull in gas solenoid if you want to use a longer
purge time. (For example, to purge gas lines when
rst connecting the weld head to the power
source.)
Menu
Use the Up/Down cursor to select from software
accessories:
• Maintenance Menu
• Copy Welds
• Delete Welds
• Print Welds
• QC Set-up
• Options
New
Create procedures using either the Auto program or
standard manual entry.
Navigating
• Select and proceed through a task using four soft
keys (see Main screen/ Menu). The selected item
is highlighted in red. To select an item, use the
up/down keys to highlight the selection in red
(move the cursor).
• To change a numerical value, select Yes/No, or
select an item from a drop-down menu using the
control knob.
• To move to the next screen, press the Next soft
key.
• Certain items are selected using Enter: for
example, the digit to be changed (00.00) or the
text labeling subroutine.

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A7 TIG Orbital System 150© Kemppi Oy 2016 1615
OPERATING MANUAL
3.8.3 Using Auto program
You can automatically select certain default values by
using Autoprogram. For example, to always use four
levels. To change these default values, you must edit the
weld program after it has been generated.
1. Select Yes with the control knob. Press Next.
2. If Password Protection has been applied, you will
be asked for your password to continue.
3. Select Weld Number using the control knob.
4. Press Next when nished.
5. Use Back to move to previous screen.
1. Use the cursor to select each line (highlighted in
red).
2. Use the control knob to select Head Model and
Material.
3. Use Enter and the control knob to select and
change each digit of O.D. and Wall Thickness.
4. Press Next when nished.
Use cursor to select line and the control knob to modify
Next Weld to Run. You have two choices:
1. Repeat the weld program. At the completion of a
weld, the same program is automatically loaded so
that you don’t need to re-enter the weld number.
2. Run a dierent weld program to create work cycles.
Press Next when nished.