All-inclusive welding solution for robotic applications And you know.
2 3 12 9 7 5 4 8 11 1 10 6 1 Power source 7 Wire conduit 2 Wire feeder 8 Wire spool set 3 Wire feeder roller kit 9 Wire feeder mounting bracket 4 Interconnection cables 10 WiseFusion 5 Interconnection cable brackets 11 Cleaning Station 6 Earth return cable 12 Welding gun package 2
All-inclusive welding solution for robotic applications Fast and easy to adopt for any robot brand KEY BENEFITS EXCELLENT PERFORMANCE Delivers up to 380 amperes at full 100 % duty cycle. Excellent arc behaviour and welding quality, also with CO 2 shielding gas. Adds costefficiency to robotic welding. MORE WELD WITH WISEFUSION Gives better fusion of materials resulting in proper penetration, increased welding speed and less distortion on the workpiece. Improves productivity and quality. COMPLETE PACKAGE Contains everything in the same package: the power source, wire feeder, cables, brackets and the welding gun. Lowers overall investment costs. is a synergic MIG/MAG welding system for robotic welding applications. It is designed and manufactured by the Finnish provider of quality welding equipment, Kemppi Oy the number one pioneer in the energy-efficient welding inverter technology in the world. In its class, the represents notably high quality standards, as it uses partly the same technology innovations as Kemppi s top-class robotic welding solution, the A7 MIG Welder. also enjoys special features for improving welding productivity in robotic applications, for example readiness for using Kemppi s WiseFusion function, which affects the welding arc by making the arc more focused. This gives better fusion of materials resulting in proper penetration, increased welding speed and less distortion on the workpiece. With total of 90 memory channels for storing welding parameter settings, the offers great ease of use. Each welding task can be stored in its own memory channel, which can be called from the robot when ever needed. Fast and simple. BENEFITS World-famous Kemppi quality Reliability provided by Kemppi s high-technology innovations Fast, easy and inexpensive to get up and running Low overall investment costs Fast and easy parameter setting with 90 memory channels Added welding quality and productivity with WiseFusion function Extensive table of DeviceNet I/O signals for communiction with the robot Complete welding package for the common robotic applications 3
KEY BENEFITS WISEFUSION WiseFusion optimized welding function produces a very narrow and energy dense welding arc making welding faster and heat input lower. Focused penetration area allows the welding of narrow and deep grooves. WiseFusion results in excellent penetration without a risk of undercut. Narrower arc also facilitates weld pool control in position welding. WiseFusion ensures optimum arc length eliminating the need for constant parameter settings. Adaptive and automatic arc length regulation maintains the arc always within the short circuit boundaries and raises your arc-on time. MORE WELD WITH WISEFUSION Gives better fusion of materials resulting in proper penetration, increased welding speed and less distortion on the workpiece. Improves productivity and quality. LOWER HEAT INPUT Than in traditional MIG/MAG welding processes, delivering savings in rework costs. BENEFITS Higher welding speed Lower heat input resulting in less distortion and better mechanical properties of the weld Possibility to weld narrower and deeper grooves Excellent weld pool control in position welding Easy to weld in all positions Automatic arc length control granting always the right parameters Easy to use Uniform weld quality 1-MIG VS 1-MIG with WiseFusion 4 WiseFusion
1 A3 POWER SOURCE 400 Synergic MIG/MAG welding automation system, especially well-suited for cost-effective retrofit cases and heavy duty applications. A3 Power Source is available in digital models for integration with different robotic control systems. TECHNICAL SPECIFICATIONS Ordering code 6201403 Supply voltage 3~ 50/60 Hz 400 V, -15 % +20 % Mains connection cable H07RN-F 4G6 (5 m) Maximum supply current 23 A Effective supply current 21 A Fuse 35 A delayed Efficiency (100 % duty cycle) 87 % Power factor (at max. current) 0.9 Minimum short circuit power Ssc of supply network 4.7 MVA Idle power 25 W Rated power 80 % ED 19.5 kva 100 % ED 18.5 kva Primary current 50 % ED I1max 28 A 100 % ED I1 25.5 A No-load voltage (peak) U0 = 85 V 95 V Open circuit voltage (average) 50 V Welding voltage range 10 V - 46 V Output capacity 40 C 80 % ED 400 A 100 % ED 380 A Supply voltage 50 V DC Fuse 6.3 A delayed Operating temperature range -20 C +40 C Storage temperature range -40 C +60 C External dimensions LxWxH 590 x 230 x 500 mm Weight 36 kg Degree of protection IP21S EMC class A DEVICE NET CABLE Ordering code W015563 DEVICENET CABLE 5M (ROBOT CONNECTION) STAND FOR POWER SOURCE Ordering code 6185295 For easy transport and keeping floor free under welder 5
2 A3 WIRE FEEDER 25-RH-EUR Wire feeder for automated welding with a reliable 4-roll wire feed mechanism and full metal feed rolls. 25-RH-EUR can be mounted on the back of the robot arm or integrated with any mechanized welding system. A separate mounting bracket is required for mounting the wire feeder on robot. Wire feeder with Euro connector is available in right hand version. TECHNICAL SPECIFICATIONS Ordaring code 6203403 Operating voltage (safety voltage) 50 V DC Rated power 100 W Load capacity 80 % ED 600 A 100 % ED 500 A Wire feed mechanism 4-roll, single motor Gun connection Euro Filler wires ø Fe, Ss 0.6 1.6 mm ø Flux-cored wire 0.8 1.6 mm ø Al 1.0 1.6 mm ø CuSi 0.8 1.2 mm Operating temperature range -20 C... +40 C Storage temperature range -40 C... +60 C External dimensions LxWxH 269 x 175 x 169 mm Weight 4.5 kg Degree of protection IP21S EMC class A 6
3 FEED ROLL KITS FOR A3 WIRE FEEDER U = U Groove V = Plain V Groove VK = Knurled V Groove T = Trapezoid Groove HD = Heavy Duty kit (contains metal feed rolls) MC/FC = Metal/Flux Cored Ordering code Description F000350 FE (MC/FC) V0.8-0.9 HD DURATORQUE KIT #3 F000351 FE (MC/FC) V1.0 HD DURATORQUE KIT #3 F000352 FE (MC/FC) V1.2 HD DURATORQUE KIT #3 F000353 FE (MC/FC) V1.6 HD DURATORQUE KIT #3 F000354 SS (FE) V0.8-0.9 HD DURATORQUE KIT #3 F000355 SS (FE) V1.0 HD DURATORQUE KIT #3 F000356 SS (FE) V1.2 HD DURATORQUE KIT #3 F000357 SS (FE) V1.6 HD DURATORQUE KIT #3 F000358 MC/FC VK1.0 HD DURATORQUE KIT #3 F000359 MC/FC VK1.2 HD DURATORQUE KIT #3 F000360 MC/FC VK1.4-1.6 HD DURATORQUE KIT #3 F000361 MC/FC VK2.0 HD DURATORQUE KIT #3 F000362 AL U1.0 HD DURATORQUE KIT #3 F000363 AL U1.2 HD DURATORQUE KIT #3 F000364 AL U1.6 HD DURATORQUE KIT #3 4 INTERCONNECTION CABLES The interconnection cable set contains several cables and hoses. The cable set is used for delivering the welding power, shielding gas, cooling liquid, and control signals from the welding power source to the wire feeder. Interconnection cable sets are available in spiral sleeve. Ordering code SP801064A SP801065A Description INTERCONNECTION 70mm2 CABLE 5M INTERCONNECTION 70mm2 CABLE 10M 7
5 INTERCONNECTION CABLE BRACKETS Ordering code SP008072 Metal attacment piece, two cable ties, for zipper bag 6 EARTH RETURN CABLE Ordering code Description Additional info SP801062A GROUND 70MM2 CABLE 5M Dix connector for the power source, 5 m, 70 mm 2 SP801063A GROUND 70MM2 CABLE 10M Dix connector for the power source, 10 m, 70 mm 2 7 WIRE CONDUIT FOR WIRE SPOOLS High quality wire conduit delivers the filler wire smoothly from wire spool to wire feeder. Male connectors on both ends fit to Kemppi feeder and Kemppi wire spool support. Please note that female snap connector for wire spool holder or wire drum is not included in the order code but has to be ordered separately. In case of stainless steel or aluminium, a separate chili liner is also required. WIRE CONDUITS (STANDARD LENGTH) Ordering code Description SP801058A WIRE CONDUIT 1,8M SP801059A WIRE CONDUIT 3,0M SP801060A WIRE CONDUIT 5,0M SP801061A WIRE CONDUIT 8,0M 8
8 WIRE SPOOL SET 8.1 WIRE SPOOL STAND SET WIRE SPOOL HOLDER Suitable for standard 15 kg wire coil. NOTE: Female connector for wire conduit not included. Must be ordered separately. Ordering code Description Additional info W007628 WIRE SPOOL SUPPORT RIGHT wire spool holder W007629 WIRE SPOOL SUPPORT LEFT wire spool holder PROTECTIVE COVER FOR WIRE SPOOL Ordering code SP007940 Plastic cover for wire spool holder FLOOR STAND FOR WIRE SPOOL HOLDER Ordering code W007356 Floor stand for wire spool holder 8.2 ROBOT MOUNTED WIRE SPOOL HOLDER SET Ordering code Description Additional info SP600773A WIRE SPOOL STAND SET Compatible with Fanuc M-10iA/M-20iA, M-10ID, Kawasaki BN006N/BN006L and Yaskawa MA1440/MA2010 9
9 WIRE FEEDER MOUNTING BRACKETS Brackets for mounting the wire feeder on the robot s 3rd axis. The design is robot model specific. Order code includes metal plates. Insulation rings and screws are not included if order code begins with W. Ordering code Description Additional info SP800872 DT400 BRACKET KUKA KR6 R1820 HW KUKA KR6 R1820 HW SP801006 DT400 BRACKET KUKA KR 5-2 ARC HW KUKA KR5 ARC SP800991 DT400 BRACKET ASSM_FANUC 100IC Fanuc 100iC W014886 DT400 BRACKET ASSM. IRB 1520ID ABB IRB 1520 ID W014755 DT400 BRACKET ASSM_KAWASAKI BA006N/L Kawasaki BA006N W014755 DT400 BRACKET ASSM_KAWASAKI BA006N/L Kawasaki BA006L SP800810 DT400 BRACKET KUKA KR10 R1420 / KR6 R1820 KUKA KR 10 R1420 SP800810 DT400 BRACKET KUKA KR10 R1420 / KR6 R1820 KUKA KR 6 R1820 SP800711 DT400 BRACKET ABB IRB1600 ABB IRB 1600 10 WISE PROCESSES Ordering code A3500000 Description WiseFusion 10
11 CLEANING STATION SP600614A ROBOT GUN CLEANING STATION 350A/500A SP600615A ROBOT GUN CLEANING STATION STAND 350A/500A SP600616A Reamer tool FOR GUN NECK 500-G 500A SP600617A Reamer tool FOR GUN NECK 350-G 350A 11
NON-HOLLOW WRIST HOLLOW WRIST 16 16 5 9 8 1 2 3 4 7 6 15 15 CONSUMABLES 13 14 12 11 10 12 Robotic gun packages
Robotic gun packages for A perfect gas cooled welding system for robotic arc welding consists of a gun neck with a contact tip holder, a gas nozzle and a cable assembly. Robotic gun can be mounted on a suitable Kemppi Gun Mount. Accurate TCP location contributes to constant and reliable welding results. Robust design constructed from centralized inner tube & stainless steel made outer tube guarantees best possible usability during daily operations and minimizes the risk of damages to system in case of collisions. Low maintenance need and easy to change components increase system availability. Engineered designs are available by request. 1 2 Gun package, non-hollow wrist Shock sensor 6 7 Gun package, hollow wrist Shock sensor 10 11 Tip holder Insulator 3 Gun mount 8 Flange adapter 12 Orifice 4 5 Flange adapter Cable assembly 9 Cable assembly 13 14 Nozzle Contact tip 15 Neck 16 Wire liners Robotic gun packages 13
GUN FOR NON HOLLOW WRIST ROBOT (T2) 1 COMPLETE GUN PACKAGE SP600800A GUN PACK G EURO 350 1M T2 350A SP600805A GUN PACK G EURO 500 1M T2 500A 2 SHOCK SENSOR SP600750A COLLISION SENSOR T2 350A/500A 3 GUN MOUNT SP600751A ROBOT GUN MOUNT T2 350A/500A 4 FLANGE ADAPTER Ordering code Description Robot model SP801050A FLANGE T2 KR 10 R1420 KUKA KR 10 R1420 SP801051A FLANGE T2 KR 6 R1820 KUKA KR 6 R1820 SP801052A FLANGE T2 IRB 1600 ABB IRB 1600 5 CABLE ASSEMBLY Ordering code Description Robot model SP600760A CABLE ASSEMBLY T2 G EURO L=1,05M KR 10 R1420 KUKA KR 10 R1420 SP600761A CABLE ASSEMBLY T2 G EURO L=1,1M KR 6 R1820 KUKA KR 6 R1820 SP600762A CABLE ASSEMBLY T2 G EURO L=0,85M IRB 1600 ABB IRB 1600 14 Robotic gun packages
GUN FOR HOLLOW WRIST ROBOT (T1) 6 COMPLETE GUN PACKAGE SP600801A GUN PACK G EURO 350 1M T1 350A SP600804A GUN PACK G EURO 500 1M T1 500A 7 SHOCK SENSOR SP600752A COLLISION SENSOR T1 350A/500A 8 FLANGE ADAPTER Ordering code Description Robot model SP801053A FLANGE GUN MOUNT T1 KR5 ARC KUKA KR5 ARC SP801054A FLANGE GUN MOUNT T1 100iC FANUC 100iC SP801055A FLANGE GUN MOUNT T1 IRB 1520 ID ABB IRB 1520 ID SP801056A FLANGE GUN MOUNT T1 BA006N KAWASAKI BA006N SP801057A FLANGE GUN MOUNT T1 BA006L KAWASAKI BA006L 9 CABLE ASSEMBLY Ordering code Description Robot model SP600763A CABLE ASSEMBLY T1 G EURO L=1,0M KR5 ARC KUKA KR5 ARC SP600764A CABLE ASSEMBLY T1 G EURO L=0,95M 100iC FANUC 100iC SP600765A CABLE ASSEMBLY T1 G EURO L=1,1M IRB 1520 ID ABB IRB 1520 ID SP600766A CABLE ASSEMBLY T1 G EURO L=1,05M BA006N KAWASAKI BA006N SP600767A CABLE ASSEMBLY T1 G EURO L=1,4M BA006L KAWASAKI BA006L Robotic gun packages 15
CONSUMABLES FOR GUN 10 TIP HOLDER SP600742A CONTACT TIP ADAPTER M6 350-G 350A SP600743A CONTACT TIP ADAPTER M6 500-G 500A 11 INSULATOR SP9580268A INSULATING RING 350-G 350A SP9580269A INSULATING RING 500-G 500A 12 ORIFICE 4294881A GAS DIFFUSER 350-G 350A 4294882A GAS DIFFUSER 500-G 500A 13 NOZZLE SP600744A GAS NOZZLE CONICAL 350-G 13 350A SP600745A GAS NOZZLE CONICAL 350-G 16 350A SP600746A GAS NOZZLE CONICAL 500-G 16 500A SP600747A GAS NOZZLE CONICAL 500-G 19 500A 16 Robotic gun packages
14 CONTACT TIP 9580286A CONTACT TIP 0.8/D8.7 M6 350A/500A 9580287A CONTACT TIP 0.9/D8.7 M6 350A/500A 9580288A CONTACT TIP 1.0/D8.7 M6 350A/500A 9580289A CONTACT TIP 1.2/D8.7 M6 350A/500A 9580290A CONTACT TIP 1.6/D8.7 M6 350A/500A 9580281A CONTACT TIP 1.4/D8.7 M6 350A/500A 15 NECK SP600610A GUN NECK 350/500-G 31 350A/500A SP600611A GUN NECK 350/500-G 35 350A/500A 16 LINERS Ordering code SP600618A SP600619A SP600620A SP600768A SP600769A SP600770A SP600771A SP600772A Description LINER STEEL RED 0.9-1.2/1,8M ROBOT EU LINER STEEL RED 0.9-1.2/2.5M ROBOT EU LINER STEEL RED 1,2-1.6/1,8M ROBOT EU LINER STEEL RED 1,2-1.6/2,5M ROBOT EU LINER CARBON RED 0.9-1.2/2,0M ROBOT EU ALU LINER CARBON RED 0.9-1.2/2,5M ROBOT EU ALU LINER CARBON RED 1,2-1.6/2,0M ROBOT EU ALU LINER CARBON RED 1,2-1.6/2,5M ROBOT EU ALU Robotic gun packages 17
A3 MIG WELDER EXAMPLE SETUP Gas cooled set for a hollow wrist robot POWER SOURCE SETUP Code A3 POWER SOURCE 400 6201403 WIRE FEEDER SETUP A3 WIRE FEEDER 25-RH-EUR 6203403 FE (MC/FC) V1.2 HD DURATORQUE KIT #3 F000352 WIRE SPOOL STAND SET SP600773A CABLE SET INTERCONNECTION 70mm2 CABLE 5M GROUND 70MM2 CABLE 5M WIRE CONDUIT 1,8M SP801064A SP801062A SP801058A GUN FOR HOLLOW WRIST ROBOT (T1) GUN PACK G EURO 500 1M T1 INCLUDING: COLLISION SENSOR T1 GUN NECK 350/500-G 31 CONTACT TIP ADAPTER M6 500-G INSULATING RING 500-G GAS DIFFUSER 500-G GAS NOZZLE CONICAL 500-G 16 CONTACT TIP 1.2/D8.7 M6 LINER STEEL RED 0.9-1.2/1,8M ROBOT EU FLANGE GUN MOUNT T1 BA006N CABLE ASSEMBLY T1 G EURO L=1,05M BA006N ROBOT GUN CLEANING STATION ROBOT GUN CLEANING STATION STAND REAMER TOOL FOR GUN NECK 500-G SP600804A SP600752A SP600610A SP600743A SP9580269A 4294882A SP600746A 9580289A SP600618A SP801056A SP600766A SP600614A SP600615A SP600616A 18 A3 MIG welder example setup
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WWW.KEMPPI.COM Kemppi is the pioneering company within the welding industry. It is our role to develop solutions that make you win business. Headquartered in Lahti, Finland, Kemppi employs over 600 welding experts in 17 countries and has a revenue of more than 110 MEUR. Our offering includes welding solutions - intelligent equipment, welding management software and expert services - for both demanding industrial applications and ready-to-weld needs. Local expertise is available via our global partner network covering over 60 countries. Kemppi India Private Limited Lakshmi Towers 2/770 First Street Neelankarai 600 041 Chennai India Kemppi India Private Limited Robotic Welding Application Center Plot. P84, D II Block, MIDC, Chinchwad, Pune Maharstra 411019 India