Kemppi A7 Cooler Bedienungsanleitung

1920720

1636

A7 MIG WelderA7 Cooler

OPERATING MANUAL

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

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.

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

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

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.

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

A7 Cooler© Kemppi Oy 2016 1636

OPERATING MANUAL

SF 51/SF 54

WIRE INCH

weld

data

m/min

SETUP

MMA

MIG

MMA

PANEL

SF 51

W001318

DYNAMICS

ARC FORCE

GAS TEST

ARC FORCE

DYNAMICS

GAS TEST

ARC FORCE

DYNAMICS

SF 52W/SF 53W and MS 200/MS 300

POWER

m/min

MINILOG

POWER

GAS TEST

DYNAMICS

WIRE INCH

weld

data

m/min

SETUP

W001319

LOCAL

REMOTE

A B

GAS TEST

DYNAMICS

WIRE INCH

weld

data

m/min

SETUP

W001319

LOCAL

REMOTE

After completing the preparations explained above, the device is ready for welding.

Before welding, read the operating instructions.

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.

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.

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

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