Kemppi AX MIG Welder User manual

AX MIG Welder
Operating manual - EN
AX MIG Welder
© Kemppi 11921900 / 2318

AX MIG Welder
Operating manual - EN
CONTENTS
1. General 5
1.1 Equipment description 7
1.2 X5 Power Source 400 and 500 9
1.3 R500 wire feeders 11
1.3.1 Wire feed mechanism 13
1.3.2 Wire feeder peripheral connector 14
1.3.3 Wire feeder control cable connector 14
1.4 AX MIG Welder interconnection cable 16
1.5 RCM (Robot Connectivity Module) 18
1.6 Cooling unit (optional) 20
2. Installation 21
2.1 Installing power source mains plug 22
2.2 Connecting to AX Manager user interface 23
2.3 Installing equipment on stand (optional) 24
2.4 Installing cooling unit (optional) 25
2.5 Installing RCM on power source (optional) 28
2.6 Mounting wire feeder on robot arm 30
2.7 Removing and attaching RCM top cover 31
2.8 Routing cables into RCM 33
2.9 Connecting PE (protective earth) wire (optional) 35
2.10 Installing fieldbus module (optional) 36
2.11 Removing fieldbus module 38
2.12 Installing add-on cards (optional) 40
2.12.1 Add-on card combinations for external device control 40
2.12.2 Add-on card combinations for digital robot control 44
2.13 Connecting touch sensor fast output (optional) 45
2.14 Connecting backup power supply (optional) 46
2.15 Connecting door switch (optional) 47
2.16 Connecting stop switch (optional) 48
2.17 Connecting cables to wire feeder 49
2.18 Connecting cables to power source and RCM 51
2.19 Installing wire guide tubes 52
2.20 Removing wire guide tubes 55
2.21 Installing feed rolls 57
2.22 Removing feed rolls 59
2.23 Mounting welding gun 61
2.24 Installing wire 62
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2.25 Installing gas bottle 66
2.26 How to get welding programs 68
2.27 Fieldbus control tables 69
2.27.1 AX MIG 1: AX MIG Welder default fieldbus control table 70
2.27.2 KEMPPI 1: KempArc Pulse compatibility fieldbus control table 75
2.27.3 KEMPPI 4: A7 MIG Welder compatibility fieldbus control table 77
2.27.4 KEMPPI 6: A7 MIG Welder WeldEye compatibility fieldbus control table 80
2.27.5 Control information 84
2.27.6 Status information 85
2.28 Timing diagrams 88
2.28.1 Welding start and stop timing 88
2.28.2 Memory channel change timing 89
2.28.3 Wire inch timing 89
2.28.4 Touch sensor timing 90
2.28.5 Stop switch response timing 91
3. Operation 92
3.1 Preparing welding system for use 93
3.1.1 Filling cooler and circulating coolant 93
3.1.2 Calibrating welding cable 94
3.2 Using AX Manager 96
3.2.1 Home 98
3.2.2 Memory channels 100
3.2.3 Users 102
3.2.4 Weld Assist 102
3.2.5 Welding parameters 106
3.2.6 WPS 112
3.2.7 Info view 118
3.2.8 Tools 119
3.2.9 Robot status 119
3.2.10 Network settings 121
3.2.11 Device settings 123
3.2.12 Robot settings 125
3.2.13 Fieldbus settings 127
3.2.14 Logbook 131
3.2.15 Weld history 132
3.2.16 Applying welding programs 133
3.2.17 Weld data 135
3.3 Additional guidance to functions and features 137
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3.3.1 1-MIG 137
3.3.2 WiseFusion feature 137
3.3.3 WisePenetration+ feature 137
3.3.4 WiseSteel feature 138
3.3.5 Pulse welding 138
3.3.6 WiseRoot+ process 139
3.3.7 WiseThin+ process 139
3.3.8 MAX Cool process 140
3.3.9 MAX Position process 140
3.3.10 MAX Speed process 141
3.3.11 Digital Welding Procedure Specification (dWPS) 141
3.3.12 WeldEye ArcVision 141
3.3.13 Through Arc Seam Tracking (TAST) 142
3.3.14 USB backup and restore 143
3.3.15 USB update 143
4. Maintenance 145
4.1 Daily maintenance 146
4.2 Periodic maintenance 147
4.3 Service workshops 148
4.4 Troubleshooting 149
4.4.1 Error codes 150
4.5 Installing and cleaning power source air filter (optional) 154
4.6 Disposal 156
5. Technical data 157
5.1 X5 power sources 158
5.2 R500 wire feeders 167
5.3 RCMs 168
5.4 Cooling unit 169
5.5 Add-on cards 170
5.6 AX MIG Welder ordering info 171
5.7 Wire feeder consumables 172
5.8 Touch sensing voltage levels 175
5.9 Appendix: System integration checklist 176
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AX MIG Welder
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1. GENERAL
These instructions describe the integration and use of AX MIG Welder equipment. The equipment consists of a welding
power source, wire feeder, RCM (Robot Connectivity Module) and cooling unit (optional) designed for robotic MIG/MAG
welding. The user interface, AX Manager, can be accessed with an internet browser.
AX MIG Welder can be integrated with all major robot brands. For robot-specific information, refer to the robot man-
ufacturer's operating instructions.
The AX MIG Welder integration consists of the following general steps:
1. Install the hardware
>> Make sure all components are intact.
>> Install the power source mains plug and cooling unit, if any.
>> Attach all necessary components to the robot and welding cell.
>> Connect cables.
>> Turn on the welding system.
>> Install wire guide tubes and wire feed rolls.
2. Connect to the AX Manager user interface (refer to "Connecting to AX Manager user interface" on page23)
3. Configure the system
>> Configure the network, device, robot and fieldbus settings.
>> Create memory channels (apply welding programs).
>> Make a system backup, if necessary.
The integration steps are listed in more detail here: "Appendix: System integration checklist" on page176.
Important notes
Read the instructions through carefully. For your own safety, and that of your working environment, pay particular atten-
tion to the safety instructions delivered with the equipment.
Items in the manual that require particular attention in order to minimize damage and harm are indicated with the
below symbols. Read these sections carefully and follow their instructions.
Note: Gives the user a useful piece of information.
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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.
Kemppi symbols: Userdoc.
General notices:Userdoc.
DISCLAIMER
While every effort has been made to ensure that the information contained in this guide is accurate and com-
plete, no liability can be accepted for any errors or omissions. Kemppi reserves the right to change the spe-
cification of the product described at any time without prior notice. Do not copy, record, reproduce or transmit
the contents of this guide without prior permission from Kemppi.
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1.1 Equipment description
AX MIG Welder has multiple power source and two wire feeder options to choose from.
X5 power sources (400 A):
•X5 Power Source 400
>> Standard power source with support for automatic 1-MIG process as well as MAX Speed and MAX Cool pro-
cesses
•X5 Power Source 400 Pulse
>> Pulse power source with support for automatic 1-MIG process, pulse and double pulse processes, and all MAX
processes
•X5 Power Source 400 Pulse+
>> Pulse power source with support for automatic 1-MIG process, pulse and double pulse processes, and all Wise
and MAX processes
•X5 Power Source 400 MV Pulse+
>> Multi-voltage pulse power source with support for automatic 1-MIG process, pulse and double pulse processes,
and all Wise and MAX processes.
X5 power sources (500 A):
•X5 Power Source 500
>> Standard power source with support for automatic 1-MIG process as well as MAX Speed and MAX Cool pro-
cesses
•X5 Power Source 500 Pulse
>> Pulse power source with support for automatic 1-MIG process, pulse and double pulse processes, and all MAX
processes
•X5 Power Source 500 Pulse+
>> Pulse power source with support for automatic 1-MIG process, pulse and double pulse processes, and all Wise
and MAX processes
For the power source part descriptions, refer to "X5 Power Source 400 and 500" on page9.
R500 wire feeders:
•R500 Wire Feeder EUR
•R500 Wire Feeder EUR+
>> Includes connections for using compressed air for gun cleaning
>> Includes gas sensor
>> Includes voltage sensing cable connection required for the WiseThin+ and WiseRoot+ processes.
For the wire feeder part descriptions, refer to "R500 wire feeders" on page11.
Robot Connectivity Modules:
•RCM
•RCM+
>> Includes wireless connectivity features.
For the RCM part descriptions, refer to "RCM (Robot Connectivity Module)" on page18.
X5 cooling unit:
•X5 Cooler 1400, 1.4 kW
For the cooling unit part descriptions, refer to "Cooling unit (optional)" on page20.
Welding guns:
For information on welding guns, refer to the gun manufacturer's operation instructions.
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AX MIG Welder
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Robot gun mounts:
For information on robot gun mounts, refer to the gun mount manufacturer's operation instructions.
Welding programs:
For information on selecting welding programs, contact your local Kemppi dealer.
Optional accessories:
•Gun cleaning station
•Stand for X5 power source
•Wire feeder mounting brackets
•Wire spool holder
•Protective cover for wire spool
•Floor stand for wire spool holder.
For more information on optional accessories, refer to the product catalog at Kemppi.com or contact your local Kemppi
dealer.
EQUIPMENT IDENTIFICATION
Serial number
Serial number of the device is marked on the rating plate or in another distinctive location on the device. It is
important to make correct reference to the serial number of the product when ordering spare parts or making
repairs for example.
Quick Response (QR) code
Device-related information or a web link to such information may be found in the form of a QR code on the
device. The code can be read, for example, with a mobile device camera and a QR code application.
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AX MIG Welder
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1.2 X5 Power Source 400 and 500
This section describes the structure of X5 Power Source 400 and X5 Power Source 500 models.
Front
1. Indicator panel *
2. Transportation handle (not intended for mechanical lifting)
3. Front locking interface (locking e.g. on top of the cooling unit)
Indicator panel *
1. VRD (Voltage Reduction Device) indicator
VRDis used only in manual welding in MMA mode.
2. High temperature indicator (overheating)
>> The LED is yellow when the unit is overheating.
If the power source overheats, a thermal cutoff switches the unit off and does not allow it to be used until it has
cooled down.
3. Power on/off indicator
>> The LED is green when the unit is on.
4. Coolant temperature warning
>> The LED is yellow when the cooler is overheating.
If the coolant liquid overheats, a thermal cutoff switches the welding system off and does not allow it to be used
until the coolant liquid has cooled down.
5. Coolant circulation warning
>> The LED is green when the coolant circulation is working normally.
>> The LED is red when there is a problem in the coolant circulation.
If the circulation of the coolant liquid is obstructed, a thermal cutoff switches the welding system off. Check and fix
the error before using the welding system again.
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Rear
1. Power switch
2. Voltage sensing cable connector (Pulse+ power sources only)
3. Control cable connector
4. Control cable connector
5. Mains cable
6. Rear locking interface
>> For locking e.g. on top of the cooling unit
7. Earth return cable connector, minus (-) connector
8. Welding current cable connector, plus (+) connector.
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1.3 R500 wire feeders
This section describes the structure of R500 Wire Feeder EUR and R500 Wire Feeder EUR+.
R500 Wire Feeder EUR, front
1. Euro connector for welding cable connection
2. Peripheral connector for welding gun auxiliary products
3. Welding current cable connector, positive (+) connector
R500 Wire Feeder EUR, rear
4. Control cable connector
5. Shielding gas hose connector
6. Wire conduit connector.
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R500 Wire Feeder EUR+, front
1. Euro connector for welding cable connection
2. Compressed air outlet connection (for gun cleaning only)
3. Peripheral connector for welding gun auxiliary products
4. Welding current cable connector, positive (+) connector.
R500 Wire Feeder EUR+, rear
5. Control cable connector
6. Voltage sensing cable connector for interconnection cable (required for WiseThin+ and WiseRoot+ processes)
7. Voltage sensing cable connector for work piece (required for WiseThin+ and WiseRoot+ processes)
8. Compressed air inlet connection (for gun cleaning only)
9. Wire conduit connector
10. Shielding gas hose connector.
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R500 Wire Feeder EUR and R500 Wire Feeder EUR+, top
11. Gas test button
12. Air blow button (usable in R500 Wire Feeder EUR+ only)
13. Wire inch backward button
>> Drives the filler wire backward (with arc off)
14. Wire inch forward button
>> Drives the filler wire forward (with arc off).
1.3.1 Wire feed mechanism
1. Pressure rolls and pressure roll mounting pins
2. Pressure handles
3. Pressure roll locking arms
4. Inlet guide tube
5. Middle guide tube locking clip
6. Middle guide tube
7. Outlet guide tube
8. Rear drive roll and drive roll mounting cap
9. Front drive roll and drive roll mounting cap.
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For installing the feed rolls, refer to "Installing feed rolls" on page57.
For installing the wire guide tubes, refer to "Installing wire guide tubes" on page52.
1.3.2 Wire feeder peripheral connector
This section describes the order and purpose of the pins in the peripheral connector used for connecting welding gun
auxiliary products.
A. Reserved for future use
B. Reserved for future use
C. Supply (+24 V)
>> for a collision sensor with LED status indicators
D. Wire inch input
>> for a welding gun's wire inch button
E. Collision sensor input
>> for a collision sensor (only the gun mounts T1 and T2 feature a collision sensor)
F. Touch sensor output (+50...+200 V)
>> for touch sensing with gas nozzle (ensure that your gun supports touch sensing with gas nozzle)
G. Reserved for future use
H. Supply GND
>> for a welding gun's wire inch button
>> for a collision sensor
I. Reserved for future use
J. Reserved for future use.
1.3.3 Wire feeder control cable connector
This section describes the purpose and order of the pins in the wire feeder's control cable connector.
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A. Power supply GND
B. Data in/out
C. Power supply (+48 V)
D. Wire feeder ID (1 / 2)
E. Touch sensor voltage (+50...+200 V)
F. Reserved for future use
G. Reserved for future use.
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AX MIG Welder
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1.4 AX MIG Welder interconnection cable
The AX MIG Welder interconnection cables come in multiple different lengths and configurations to suit your equipment
setup.
For installing cables, refer to "Connecting cables to power source and RCM" on page51 and "Connecting cables to wire
feeder" on page49.
Power source end of interconnection cable
1. Voltage sensing cable (required for WiseThin+ and WiseRoot+ processes)
2. Shielding gas hose
3. Welding current cable
4. Wire feeder control cable.
Power source end of interconnection cable - water cooling
1. Voltage sensing cable (required for WiseThin+ and WiseRoot+ processes)
2. Shielding gas hose
3. Cooling liquid hoses (inlet/outlet)
4. Welding current cable
5. Wire feeder control cable.
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Wire feeder end of interconnection cable
1. Voltage sensing cable (required for WiseThin+ and WiseRoot+ processes)
2. Shielding gas hose
3. Welding current cable
4. Wire feeder control cable.
Wire feeder end of interconnection cable - water cooling
1. Voltage sensing cable (required for WiseThin+ and WiseRoot+ processes)
2. Shielding gas hose
3. Welding current cable
4. Coolant hoses (inlet/outlet)
5. Wire feeder control cable.
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1.5 RCM (Robot Connectivity Module)
RCM handles the communication between the welding system and the robot.
For connecting cables, refer to "Connecting cables to power source and RCM" on page51.
1. Wire feeder control cable connector
2. Reserved for future use
3. Power source control cable connector
4. Reserved for future use
5. Touch sensor negative (-) connector
6. Cable inlet (with grommet)
7. Ethernet port
8. USB port
9. Cable inlet with cable clamp
10. Cover fixing screws
11. Alignment holes and screws (for securing the cover in place).
Inside RCM
1. S1 button (forced factory reset, refer to "Troubleshooting" on page149)
2. Indicator LEDs
3. Touch sensor status fast output terminal
4. Add-on card slots
5. Fieldbus module slot
6. Door switch terminal
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7. Stop switch terminal
8. Backup power supply terminal
9. Ethernet 1 (LAN 1)
10. Ethernet 2 (LAN 2).
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1.6 Cooling unit (optional)
Front
1. Cooler container cap
2. Cooling liquid level indicator
3. Front locking interface (for locking on the stand)
4. Front locking interface (for locking to the power source)
5. Rear locking interface (for locking to the power source)
6. Cooling liquid circulation button
>> Keeping the button pressed activates the pump and circulates the cooling liquid throughout the system. Once
released, the pump stops.
Rear
7. Coolant outlet connector (color-coded)
8. Coolant inlet connector (color-coded)
9. Rear locking interface (for locking on the stand)
10. Cooling unit to power source connectors
11. Additional strain relief mount.
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