OPERATING MANUAL 1920620 1712 EN A7 MIG Gun 500-w
CONTENTS The A7 MIG Gun 500-w.. . . . . . . . . . . . . . . . . . . . ................................................. 3 Preface. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................. 3 Identification.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................. 4 CE marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THE A7 MIG GUN 500-W 2. This document provides product information on the Kemppi A7 MIG Gun 500-w. Kemppi MIG/MAG guns for automatic welding are designed for demanding professional use. They are suitable for use in all MIG units equipped with Kemppi robotic MIG wire feeders and power sources. PREFACE Congratulations on your purchase of this product. Used correctly, Kemppi products can significantly increase the productivity of your welding and provide many years of economical service.
IDENTIFICATION 5. The welding gun system Kemppi A7 MIG Gun 500-w is used in industry and in the trade for welding using inert gases (MIG) or active gases (MAG). This model is liquid-cooled and can be used in all welding positions. These operating instructions describe only the welding gun system A7 MIG Gun 500-w. The welding gun system may only be operated as supplied or with authentic Kemppi spare parts. SAFETY Read and follow the additional safety instructions enclosed. 5.
.4 Signs used in the documentation 5.6 Emergency instructions Items in the manual that require particular attention, to minimize damage and personal injury, are indicated with a three-level notification and warning system. Read these sections carefully, and follow the instructions. In the event of an emergency, immediately interrupt the following: • The power supply • The flow of compressed air Cables Note: These items give the user a useful piece of information.
5.8 Product safety If improperly used, the device can present risks to people and to physical property. • Use the device in accordance with its designated use only. • Do not convert or modify the device to enhance its performance without appropriate authorization. • Using clean water, rinse work pieces that have been degreased with chlorinated solvents, to prevent the risk of phosgene gas forming. Do not place degreasing baths containing chlorine in the vicinity of the welding area.
6. TECHNICAL DATA This chapter provides the technical data of the gun. The table below provides general torch data in line with EN 60 974-7. Length L (m) In line with the robot model Type of voltage DC Top of performance range (max.) 500 A Polarity of the electrodes Usually positive Coolant connection Plug-in nipple, NW 5 mm Wire types Commercially available round wires Cooling unit power Min.
DELIVERY SCOPE 8. The standard scope of delivery for the hose assembly includes the following components: • Kink protection on the torch neck side with an integrated switch cover • Kink protection on the machine side with a central plug • Operating instructions For the initial assembly, the following components are required, depending on the welding task at hand.
10. FUNCTIONAL DESCRIPTION Figure 2: Welding gun system A7 MIG Gun 500-w 2 The contact tip transmits the welding current to the welding wire, producing an arc between the welding wire and work piece. The light arc and the molten pool are protected by the inert gas (MIG) or active gas (MAG). 10.2 The connection module 10.1 The neck 10.3 The mount Figure 3: 500-w measurements The mount is used to attach the welding gun system to the robot via the Kemppi robot mount.
11. INSTALLING THE ROBOT GUN For the entire duration of maintenance, servicing, unmounting, and repair work, the following instructions must be adhered to: • Switch off the power supply. • Cut off the compressed air supply. • Pull the power plug. 11.1 Assembling the A7 MIG Gun 500-w neck This section describes how to assemble the A7 MIG Gun 500-w neck. Figure 4: A7 MIG Gun 500-w neck assembly Proceed as follows: 1. Read the safety instructions in this manual and the separate safety instructions. 2 2.
.2 Connecting the hose assembly to the gun 11.3 Equipping the cable assembly with a liner This section describes how to assemble the A7 MIG Gun 500-g neck. This section describes how to equip the cable assembly with a liner. Figure 5: Connecting the hose assembly to the gun Figure 6: Equipping the cable assembly with a liner 2 1 4 2 1 8 9 4 7 3 6 5 10 1. 2. 3. 4. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Gun neck Positioning pin Cable assembly Fastening nut of welding gun Proceed as follows: 1. 2.
11.4 Connecting the gun system to the wire feeder • Do not use any de-ionized or de-mineralized water as coolant or for tightness or flow tests. This may shorten the service life of your welding gun. • We recommend the use of a Kemppi-brand cooling liquid for liquid-cooled welding guns. This section describes how to connect the gun system to the wire feeder. Figure 7: Connecting the gun system to the wire feeder Figure 8: Connecting the coolant 4 8 5 5 2 4 3 Proceed as follows: 1. 2. 3.
11.6 Connecting the control line 11.7 Setting the shielding gas quantity The control line is normally delivered with a pre-soldered amphenol plug, which is compatible with the Kemppi wire feeder. Otherwise, choose a compatible plug for your wire feeder and solder it to the corresponding wires in accordance with the assignment plan. This section describes how to set the amount of shielding gas.
12. OPERATION Shortness of breath and poisoning caused by inhaling phosgene gas Glare affecting the eyes The arc produced by welding may damage the eyes. Phosgene gas is formed during the welding of work pieces that have been degreased with chlorine-containing solvents. Wear suitable protective clothing and eye protection. Do not inhale fumes and vapors.
12.3 Maintenance and cleaning Once a month, thoroughly clean the robot mount to remove all dirt and welding spatter. Risk of injury due to unexpected start-up For the entire duration of maintenance, servicing, unmounting, and repair work, the following instructions must be adhered to: • Switch off the power supply. • Cut off the compressed air supply. • Pull the power plug. Electric shock Dangerous voltages can be produced because of defective cables.
12.3.2 Shortening the wire liner 12.3.3 Cleaning the gun neck Unused wire liners or PA liners have to be shortened to the actual length of the hose assembly. Figure 10: Shortening the wire liner 2 3 1 4 6 5 1. 2. 3. 4. 5. 6. Support sleeve Central plug Hose assembly Retaining nut Collet chuck Liner Proceed as follows: This section describes how to clean the gun neck. 1. 2. 3. 4. Lay out the cable assembly (3) straight. Disconnect the central plug (2) from the feed unit.
12.3.4 Maintaining the coolant shutoff valve This section describes how to service the coolant shutoff valve. The system parts are depicted in the figure below: 1 8 2 3 5 6 4 7 Proceed as follows: 1. 2. 3. 4. 5. 6. 7. 8. 2 valves 2 pressure springs 2 set screws, M8×8 2 clamping screws, M4×5 Cable assembly 4 O-rings, 7×1 Max. screw-down depth 2 valve balls 1. 2. 3. 4. 5. 6. 7. 8. Loosen the clamping screw (4). Unmount the valves (1). Unscrew the set screws (3).
13. TROUBLESHOOTING Risk of injury due to unexpected start-up In the event of any doubts or problems, please contact your retailer or the manufacturer. Please also consult the operating instructions for the other welding components, such as the power supply and air pressure line. Problem Cause Solution Gun neck gets hot Contact tip not tightened Check and tighten Contact tip loose on the neck side.
14. UNMOUNTING Unmounting may only be carried out by specialist personnel. Please make sure that the shutdown procedures are strictly observed, before the unmounting work begins. Ensure this also for the components integrated into the welding system. Risk of injury due to unexpected start-up For the entire duration of maintenance, servicing, unmounting, and repair work, the following instructions must be adhered to: • Switch off the power supply. • Cut off the compressed air supply. • Pull the power plug.
15. PRODUCT CODES FOR ORDERING Gun neck Product code Item Type Product code Gun neck A7 MIG 500-w 0° * SP600550 CONTACT TIP ADAPTER M8 W500 (copper) SP600560 Gun neck A7 MIG 500-w 22° * SP600551 Contact tip adapter Gun neck A7 MIG 500-w 35° * SP600552 Contact tip Life + Wire Ø Hole Ø Gun neck A7 MIG 500-w 45° * SP600553 0.8 0.9 W007919 0.9 1.05 W007920 1.0 1.15 W006826 1.2 1.4 W006518 1.6 1.
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