Abicor Binzel xFUME ABIROB AF500 User manual

www.binzel-abicor.com
xFUME® ABIROB® AF500
Welding Torch Systems
EN Operating Instructions

xFUME®ABIROB®AF500
EN Translation of the original operating instructions
© The manufacturer reserves the right, at any time and without prior notice, to make such changes and
amendments to these operating instructions as become necessary due to misprints, inaccuracies or product
enhancements. Such changes will, however, be incorporated into subsequent editions of the operating
instructions.
All brand names and trademarks that appear in these operating instructions are the property of their
respective owners/manufacturers.
Our latest product documents as well as all contact details for the ABICOR BINZEL national subsidiaries
and partners worldwide can be found on our website at www.binzel-abicor.com.
1EN-3
1.1 EN-3
2EN-3
2.1 EN-3
2.2 EN-4
2.3 EN-4
2.4 EN-4
2.6
3
EN- 6
3.1
EN-5
3.2
3.3 EN-8
3.4
EN-8
4EN-9
4.1
4.2
5
EN-10
5.1
EN-11
5.2
EN-11
5.3
EN-11
5.4
EN-11
6
EN-12
6.1
6.2
Identification
Marking
Safety
Designated use
Obligations of the operator
Personal protective equipment (PPE)
Classification of the warnings
Safety Instructions
Emergency information
Product description
Technical data
Abbreviations
Nameplate
Signs and symbols used
Scope of delivery
Transport
Storage
Functional description
Torch neck
Connection module
Bracket
Cable assembly
Putting into operation
Setting up the ABIROB®A torch
neck
Setting up the cable assembly
6.3
EN-15
6.4
6.5
7
7.1
EN-17
8
EN-18
9
9.1
EN-18/19
9.2
9.3
EN-20
10
EN-20
11
12
12.1
12.2
12.3
Attaching the machine-side
connector
Connecting the control lead
Setting the shielding gas volume
Introducing the wire
Operation
Welding process
Putting out of operation
Maintenance and cleaning
Cleaning the liner
Shortening the liner
Cleaning the torch neck
Troubleshooting
Disassembly
Disposal
Materials
Consumables
Packaging
2.5
EN--9
EN- 6/7
EN-10
EN-10
EN-13
EN-14
EN-12
EN-14
EN-14
EN-16
EN-15
EN-16
EN-17
EN-21
EN-21
EN-21
EN Translation of the original operating instructions

1Identification
1Identification
1.1 Marking
This product fulfills the requirements that apply to the market to which it has been introduced. A corresponding
marketing has been affixed to the product, if required.
2 Safety
Please observe the attached ''Safety Instructions'' document.
2.1 Designated Use
•The device described in these instructions may be used only for the purpose and in the manner described in
these instructions. In doing so, observe the operating, maintenance, and servicing conditions.
•Any other use is considered improper.
•Unauthorized modifications or changes to enhance the performance are not permitted.
2.2 Obligations of the Operator
EN 3
• Only the following personnel may work on the device:
• those who are familiar with the basic regulations on occupational safety and accident prevention;
• those who have been instructed on how to handle the device;
• those who have read and understood these operating instructions;
• those who have read and understood the chapter entitled “Safety Instructions”;
• those who have been trained accordingly;
• those who are able to recognize possible risks because of their special training, knowledge, and
experience.
• Keep other people out of the work area.
• Observe the occupational health and safety regulations of the relevant country.
• Observe the regulations on occupational safety and accident prevention.
The xFUME® ABIROB® AF500 welding torch system is used in the industry and in the trade for shielding gas
welding using inhert (MIG) or active (MAG) gases. This version is air cooled and can be used in all welding
positions.
These operating instructions only describe the xFUME® ABIROB® AF500 welding torch system. The welding
torch system may only be operated with original ABICOR BINZEL spare parts.
xFUME®ABIROB®AF500

2 Safety
To avoid danger to the user, these instructions recommend the use of personal protective equipment (PPE).
•This consists of protective clothing,safety goggles, a class P3 respiratory mask, protective gloves, and safety
shoes.
The warning signs used in the operating instructions are divided into four different levels and are shown prior to
specific work steps. Arranged in descending order of importance, they have the following meaning:
DANGER
Describes imminent threatening danger. If not avoided, it will result in fatal or extremely critical
injuries.
WARNING
Describes a potentially dangerous situation. If not avoided, it may result in serious injuries.
CAUTION
Describes a potentially harmful situation. If not avoided, it may result in slight or minor injuries.
NOTICE
Describes the risk of impairing work results or the risk that the work may result in material
damage to the equipment.
2.4 Classifications of Warnings
2.5 Safety Instructions for extraction
•Ensure that all components have been properly installed on the fume extraction torch.
•Ensure that the fume extraction torch is connected to the fume extraction unit prior to use.
•Use the fume extraction torch only with a fume extraction system that has been approved for use in the
respective country.
•Observe the local occupational health and safety regulations and guidelines.
•Check the negative pressure at the rear extraction port using the ABICOR BINZEL pressure gauge,
and adjust the extraction unit as needed to reach the target on the flow requirement label.
•Check the extraction hoses at regular intervals, at least once a week, for damage and contamination.
EN 4
xFUME®ABIROB®AF500
2.3 Personal Protective Equipment (PPE)

2 Safety
•Note that if additional hoses or hoses from other manufactures are used, pressure loss in the fume
extraction torch can result.
•Note that the applied vacuum depends on the geographic altitude of the operation site.
•Observe the warning signals and indicators on the fume extraction system. Warning signals and indicators
can imply a saturated filter or a problem with/damage to the fume torch.
•Replace the extraction-specific wear parts at regular intervals. The replacement interval required depends
on the application conditions.
•Open the handle regulator for only a moment and close is quickly after opening it. The air regular must be
closed to ensure efficient capture of fumes.
•Observe the instructions on the adapter label for connecting components.
•When used with welding fume extraction systems of the xFUME® series.
The degree to which welding fumes are captured during torch integrated extraction depends on many
factors, such as the position of the suction nozzle, the welding geometry, and the rate of smoke emission
during the welding process. Under optimal conditions, over 95% of the welding fumes can be captured in
accordance with ISO 21904-3.
2.6 Emergency Information
In case of emergency, immediately disconnect the following supplies:
•Electrical power supply
•Compressed air supply
•Gas supply
Further measures can be found in the operating instructions for the power source or the documentation for other
peripheral devices.
EN 5
xFUME®ABIROB®AF500

3 Product Description
Hazards caused by improper use
If improperly used, the device can present risks to persons, animals, and material
property.
WARNING
•Use the device according to its designated use only.
•Do not convert and modify the device to enhance its performance without
authorization.
•Only qualified personnel are permitted to perform work on the device or
system.
3 Product Description
3.1 Technical Data
Ambient temperature of welding -10 °C to + 40 °C
Relative humidityUp to 90 % at 20 °C
Tab. 1 Ambient conditions during operation
Storage in a closed enviornment, ambient temperature
Ambient Temperature for shipment
Relative Humidity Up to 90% at 20°C
Tab. 2 Ambient conditions for transport and storage
-10 °C to + 40 °C
-25 °C to + 55 °C
Type of voltage DC
Polarityof the electrodes Usually positive
Wire types Commercially available round wires
Type of use Automatic
Voltage rating Peak value of 141 V
Protection type ofthe machine-side connections IP3X (EN 60 529)
Shielding gas (EN ISO 1417 5) CO2 andmixed gas M21
Tab. 3Generial torch data according to EN 60 974-7
EN 6
xFUME®ABIROB®AF500

3 Product Description
EN 7
Tab. 4Product specific torch data as laid out in EN 60974-7
1 for pulse arcs, the load data are reduced by up to
35%
Fig. 1 Torch neck dimensions
DESCRIPTION SWANNECK TCP (X) Y
Solid Torch Mount 180 Degree 14.2”/360mm -
Solid Torch Mount 22 Degree 14.2”/360mm 5.7”/145.6mm
Solid Torch Mount 45 Degree * 15.75”/400mm -
*Coming Soon
xFUME®ABIROB®AF500

3 Product Description
EN 8
Fig. 2 Length xFUME ®ABIROB® AF500 torch neck
3.2 Abbreviations
DC Direct current
DC Duty cycle
MIG Metal inert Gas
MAG Metal active Gas
MAC Maximum allowable concentration of harmful substances at the workplace
Voltage rating Classification of the insulation resistance, voltage strength and protection type
TCP Tool Center Point
Tab. 6 Abbreviations
3.3 Nameplate
xFUME®ABIROB®AF500

3 Product Description
EN 9
The welding torch system xFUME® ABIROB® AF500 is identified by a sticker on the machine side
connection housing. When making any inquiries, please remember the following information:
•Certificate of conformity, production stamp or product label on the torch neck, for example xFUME®
ABIROB® AF500 , information on sticker.
When making inquiries, please note the following information:
•Certificate of conformity, production stamp or product label on the torch neck, for example xFUME®
ABIROB® AF500 22 °, information on the sticker
3.4 Signs and Symbols Used
Symbol Description
Bullet symbol for instructions and lists
Cross reference symbol refers to detailed, supplementary or
further information
1Step(s) described in the text to be carried out in succession
•
4 Scope of Delivery
•Torch-sided cable support with integrated switch housing cover
•Machine-side cable support with central connector
•Operating instructions
The xFUME®ABIROB®AF500 required additional, welding-task dependent components for the initial set-up. These including the following:
Tab. 7 Scope of delivery
•Torch Mounting Bracket (required for attachment to the robot/cobot)
•Equipment parts and wear parts (order separately)
•Fume extractor
The cable assemblies for the xFUME® ABIROB® AF500 welding torch system are available in standard
lengths of 9, 12, and 15 ft. as well as customer-specific lengths.
Order the equipment parts and wear parts separately. The order data and ID numbers for the equipment
parts and wear parts can be found in the current catalog. Contact details for advice and orders can be found
online at www.binzel-abicor.com.
The following signs and symbols are used in the operating instructions:
xFUME®ABIROB®AF500

4 Scope of Delivery
EN 10
4.1 Transport
Although the items delivered are carefully checked and packaged, it is not possible to fully exclude the risk of
transport damage.
4.2 Storage
Physical storage conditions in a closed environment:
Tab. 2 Ambient conditions for transport and storage on page EN-5
Goods inspection Use the delivery note to check that everything has been delivered.
Check the delivery for damage (visual inspection).
In case of complaints If the delivery has been damaged during transportation, contact the last
carrier immediately. Retain the packaging for potential inspection by the
carrier.
Packaging for return Where possible, use the original packaging and the original packaging
material. If you have any questions concerning the packaging and/or how
to secure an item during shipment, please consult your supplier.
Tab. 8 Transport
5 Functional description
The functioning xFUME®ABIROB® AF500 welding torch system comprises the following components:
Fig. 3 ABIROB® AF500 torch system
xFUME®ABIROB®AF500
Torch Mounting
Bracket

5 Functional Description
The standard torch neck types xFUME® ABIROB®AF500 360, A500 are available in the geometries
straight, 22°, and 45° bends. The uniform interface at the connection module makes all torch necks
compatible with one another.
5.2 Connection module
The connection module establishes the connection between the welding torch and the cable assembly.
5.3 Mounting Bracket
The mounting bracket is used to attach the xFUME® ABIROB®AF500 welding torch system to the robot.
5.4 Cable assembly
The air-cooled cable assembly provides the welding torch with all the components required for
welding, e. g. the welding current, shielding gas and air. A fume hose is included but must be connected to an
extractor for at source fume extraction.
EN 11
Together, the components form a fully-functional entity that provides an arc for welding when
supplied with the appropriate consumables. The welding wire required for welding is fed through the
xFUME® ABIROB®AF500 welding torch system all the way to the contact tip. The contact tip
transmits the welding current to the welding wire, producing an arc between the welding wire and
the workpiece. The arc and the molten pool are protected by the inert gas (MIG) and the active gas
(MAG).
5.1 Torch neck
xFUME®ABIROB®AF500

6 Putting into operation
DANGER
Risk of injury due to unexpected start
The following instructions must be adhered to during all maintenance, servicing, assembly, disassembly and repair work:
• Switch off the power source.
• Close off the compressed air supply.
• Close off the gas supply.
• Disconnect all electrical connections.
NOTICE
• Note the following instructions:
3 Product description on page EN-5
6 Putting into operation
6.1 Setting up the xFUME® ABIROB® AF500 torch neck
EN 12
1. Screw the replaceable tip adapter (4) onto the torch neck (7) using the wrench (9).
2. Screw the contact tip (2) into the tip adapter (4) and tighten using the wrench (9).
3. Grease the torch neck 0 rings and insert the torch neck (7) into the connection module (8) until reaching the stop.
4. Insert the torch neck (7) into the connection module (8) until reaching the stop.
5. Screw the bayonet nut (6) onto the connection module (8) locking the 3 pins in place.
6. Insert the fume tube (5) into the bayonet nut (6) until reaching the stop.
7. Screw the suction nozzle (3) into the fume tube (5) hand tight..
8. Screw the gas nozzle (1) onto the tip adapter (4) hand tight.
Fig. 4Setting up the torch neck
xFUME®ABIROB®AF500
910
Connection Module
Grease

6.2 Setting up the cable assembly
Fig. 5Setting up the cable assembly
NOTICE
• Select the correct wire type and appropriate wire guide for your application.
• For information on cutting the wire guide to size and correctly assembling it, please see the following
section:
9 Maintenance and cleaning on page EN-18
•Spiral liners = for steel and stainless steels
• PA liners = for aluminum, copper, nickel and stainless steels
6 Putting into operation
EN 13
1 Clamp
2 Handle
3 Control Cable
4 Cable Assembly
5 Suction Connector
6 Power Pin
1. Lay out the cable assembly (4) straight and attach to the handle (1 & 2)
2. Attach control cable (3).
3. Insert power pin (6) into the wire feeder.
4. Connect the etraction hose to the suction connector (5).
xFUME®ABIROB®AF500

6 Putting into operation
6.4 Setting the shielding gas volume
Fig. 5 Setting up the cable assembly on page EN-13
Check once again whether the wire guide has been fitted correctly.
Join the power pin (6) to the wire feeder.
6.3 Attaching the machine-side connector
1 Connect the shielding gas cylinder to the wire feeder.
2 Set the gas quantity on the shielding gas cylinder’s pressure reducer.
6.5 Introducing the wire
1 Insert the wire in the wire feeder as specified by the manufacturer. 2 Press the
‘zero-current wire feed’ button on the wire feeder.
NOTICE
• The type and amount of shielding gas used depend on the welding task and the gas nozzle geometry.
• To prevent the shielding gas supply from becoming clogged by impurities, briefly open the cylinder valve
before connecting the cylinder. This will expel any impurities that may be present.
• Make all shielding gas connections gas-tight.
NOTICE
• Each time the wire is replaced, ensure that the start of the wire is free of burrs and not bent.
EN 14
xFUME®ABIROB®AF500

7 Operation
7.1 Welding process
1 Open the shielding gas cylinder. 2
Switch on the power source.
DANGER
Shortness of breath and poisoning caused by inhaling phosgene gas When welding workpieces
that have been degreased with chlorinated solvents, phosgene gas is formed.
• Do not inhale fumes and vapors.
• Ensure a sufficient supply of fresh air.
• Rinse the workpieces with clean water prior to welding.
• Do not place degreasing baths containing chlorine in the vicinity of the welding area.
DANGER
Risk of burns
During welding activities, sparks, glowing workpieces or hot slag can produce flames.
• Check the work area for flashpoints.
• Provide appropriate fire extinguishing equipment in the workplace.
• Allow workpieces to cool down after welding.
• Prior to performing welding work, properly fasten the ground clamp to the workpiece or welding table.
WARNING
Arc eye
The arc produced by welding can damage the eyes.
• Check and wear your personal protective equipment.
NOTICE
• Only qualified personnel are permitted to perform work on the device or system.
• Ensure that all required parameters have been set.
7 Operation
EN 15
xFUME®ABIROB®AF500

8 Putting out of operation
8 Putting out of operation
1 Wait until the shielding gas post-flow time has passed. 2 Close the
shut-off valve for the gas supply.
3 Switch off the power source.
9 Maintenance and cleaning
Despite the above, scheduled maintenance and cleaning are prerequisites for a long service life and fault-free
operation.
1 Remove weld spatter.
2 Check that all threaded fittings are tight.
ABICOR BINZEL offers factory repair s ervices.
NOTICE
• When decommissioning the system, ensure that the procedures for switching off the welding components
are observed.
DANGER
Risk of injury due to unexpected start
The following instructions must be adhered to during all maintenance, servicing, assembly, disassembly and
repair work:
• Switch off the power source.
• Close off the compressed air supply.
• Close off the gas supply.
• Switch off the entire welding system.
• Disconnect all electrical connections.
DANGER
Electric shock
Dangerous voltage due to defective cables.
• Check all live cables and connections for proper installation and damage.
• Replace any damaged, deformed or worn parts.
NOTICE
• The specified maintenance intervals are guidance values and refer to single-shift operation.
• Only qualified personnel are permitted to perform work on the device or system.
• Check and wear your personal protective equipment.
EN 16
xFUME®ABIROB®AF500

9 Maintenance and cleaning
9.1 Cleaning the wire guide
1 Unscrew the cable assembly on the machine side and lay it out in a stretched position. 2 Unscrew the nut
and pull out the spiral liner or PA liner.
3 Clean the wire conduit from both sides with compressed air.
4 Slide the adjusted spiral liner or PA liner into the wire conduit and secure with a nut.
9.2 Shortening the spiral liner
1 Lay out the cable assembly (3) in a stretched position. 2 Disconnect
the central connector (2) from the feed unit. 3 Screw on the retaining
sleeve (1).
4 Replace the old spiral liner (6) with a new one and insert the stripped side into the central
connector (2).
WARNING
Risk of injury
Serious injuries may be caused by parts swirling around.
• When cleaning with compressed air, wear suitable protective clothing, in particular safety goggles.
NOTICE
• New and unused spiral liners or PA liners must be shortened to the actual length of the cable assembly.
1 Retaining sleeve 2
Central connector
3 Cable assembly 4
Nut
5 Collet
6 Spiral liner
Fig. 6Shortening the spiral liner
1 2
5
6
3
4
EN 17
xFUME®ABIROB®AF500

10 Troubleshooting
5 Place the retaining sleeve (1) inverted by 180° onto the new spiral liner (6) (side without
thread).
6 Cut off the overlapping spiral liner (6) flush with the retaining sleeve (1).
7 Screw the collet (5) onto the spiral liner (6) as far as it will go.
Use the sight bore on the collet (5) to check the position of the wire guide.
8 Slide the collet (5) and spiral liner (6) into the central connector (2) as far as they will go. 9 Screw the
threaded side of the retaining sleeve (1) into the central connector (2) and
tighten.
10Use the nut (3) to secure the cable assembly (4) to the central connector (2).
9.3 Cleaning the torch neck
To increase the system availability of the welding robot, ABICOR BINZEL offers automated torch cleaning.
1 Remove the gas nozzle.
2 Remove the weld spatter and spray with ABICOR BINZEL anti-spatter fluid.
3 Check the wear parts for visible damage and replace them if necessary.
4 Replace the equipment kit when worn or soiled.
5 Clean the separating point and O-rings with silicone-free seal grease.
6 Check the TCP after each use or after a collision in the WH alignment jig.
10 Troubleshooting
Please observe the attached ‘Warranty’ document. In the event of any doubts and/or problems, please contact
your retailer or the manufacturer.
DANGER
Risk of injury and device damage when handled by unauthorized persons Improper repair
work and modifications to the product may lead to serious injuries and damage to the device. The product
warranty will be rendered invalid if work is carried out on the product by unauthorized persons.
•
Only qualified personnel are permitted to perform work on the device or system.
NOTICE
• Consult the documentation for the welding components.
EN 18
xFUME®ABIROB®AF500
DANGER

10 Troubleshooting
Fault Cause Troubleshooting
Torch neck gets hot
• Contact tip loose • Check and tighten
• Contact tip loose on torch side and
toward the workpiece
• Check and tighten
No trigger function • Control lead interrupted/defective • Check/repair
Wire burned solid in the contact
tip
• Wrong parameters set • Check and correct setting
• Contact tip worn out • Replace
Irregular wire feed
• Spiral liner/PA liner clogged • Clean both directions with compressed air
or replace if necessary
• Contact tip and wire diameter not aligned • Replace the contact tip
• Wrong contact pressure set on the wire feeder • Correct as specified by the manufacturer
Arc between the gas nozzle
and the workpiece
• Spatter bridge between the contact tip and
the gas nozzle • Clean and spray the gas nozzle interior
Erratic arc
• Contact tip not tailored to the wire diameter
or contact tip worn out
• Check the contact tip
• Wrong welding parameters set
• Correct the welding parameters
• Wire guide unit worn out • Replace the wire guide
Pore formation
• Strong weld spatter build-up in the gas nozzle • Clean the gas nozzle
• Insufficient or no gas coverage • Check the gas cylinder contents and
pressure setting
• Air current blows shielding gas away • Use partitions to shield the welding area
Tab. 9 Troubleshooting
EN 19
xFUME®ABIROB®AF500

11 Disassembly
11 Disassembly
1 Disconnect the cable assembly from the wire feeder.
2 Remove the parts to be disconnected (change body, bracket, torch neck).
DANGER
Risk of injury due to unexpected start
The following instructions must be adhered to during all maintenance, servicing, assembly,
disassembly and repair work:
•Switch off the power source.
•Close off the compressed air supply.
•Close off the gas supply.
•Switch off the entire welding system.
•Disconnect all electrical connections.
NOTICE
•Only qualified personnel are permitted to perform work on the device or system.
•Consult the documentation for the welding components.
•Note the following instructions:
8 Putting out of operation on page EN-18
EN 20
xFUME®ABIROB®AF500