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