Abicor Binzel iROB 401 AC/DC User manual

T E C H N O L O G Y F O R T H E W E L D E R ´ S W O R L D .
www.binzel-abicor.com
EN Original operating instructions
iROB® 401 AC/DC
EN Welding power source

EN - 2
iROB®401 AC/DC
Table of contents
1 Identification.................................................................................................................................EN-4
1.1 Marking .............................................................................................................................................EN-4
1.2 Nameplate.........................................................................................................................................EN-4
1.3 Signs and symbols used ...................................................................................................................EN-4
1.4 Classification of the warnings ..........................................................................................................EN-5
2 Safety ..............................................................................................................................................EN-5
2.1 Designated use..................................................................................................................................EN-5
2.2 Responsibilities of the user................................................................................................................EN-5
2.3 Warning and information signs .......................................................................................................EN-6
2.4 Safety instructions for the electrical power supply.........................................................................EN-6
2.5 Personal protective equipment.........................................................................................................EN-6
2.6 Emergency information.....................................................................................................................EN-6
3 Scope of delivery........................................................................................................................EN-6
4 Product description ....................................................................................................................EN-7
4.1 Structure and function.......................................................................................................................EN-7
4.2 Control elements ...............................................................................................................................EN-8
4.3 Wi-Fi router and control app (optional)....................................................................................... EN-13
4.4 Technical data ................................................................................................................................ EN-14
4.5 Connections.................................................................................................................................... EN-15
5 Transport and installation.................................................................................................... EN-15
6 Commissioning.......................................................................................................................... EN-16
6.1 Establishing the power supply ...................................................................................................... EN-16
6.2 Establishing a connection to the welding robot .......................................................................... EN-16
7 Operation.................................................................................................................................... EN-17
7.1 Administrative settings.................................................................................................................... EN-17
7.1.1 Password-protecting the welding parameters.............................................................................. EN-17
7.1.2 Activating the control panel lock .................................................................................................. EN-18
7.2 Overview of welding parameters and processes ....................................................................... EN-19
7.2.1 Overview of welding parameters................................................................................................. EN-19
7.2.2 Overview of welding procedures................................................................................................. EN-20
7.3 Preparing the welding process ..................................................................................................... EN-21
7.3.1 Setting the welding procedure...................................................................................................... EN-21
7.3.2 Setting the welding sequence .......................................................................................................EN-22
7.4 Effects of the welding parameter settings .................................................................................... EN-24
7.5 Examples of welding parameter settings ..................................................................................... EN-25
7.5.1 Example of CO2 welding parameters .........................................................................................EN-25
7.5.2 Example of welding parameters with CO2 and flux-cored wire...............................................EN-28
7.5.3 Example of welding parameters with MAG short arc welding ................................................. EN-28
7.5.4 Example of welding parameters with MAG pulse welding ....................................................... EN-29
7.5.5 Example of welding parameters with MIG pulse aluminum welding ....................................... EN-33
7.5.6 Example of welding parameters with MIG aluminum short arc welding ................................. EN-33
7.6 Additional functions ....................................................................................................................... EN-34
7.6.1 Setting the arc characteristic......................................................................................................... EN-34
7.6.2 Adjusting the EN ratio ................................................................................................................... EN-34
7.6.3 Adjusting the move frequency....................................................................................................... EN-35
7.7 Setting internal functions................................................................................................................ EN-35
7.7.1 Making settings ..............................................................................................................................EN-35
7.7.2 Description of the internal functions ............................................................................................. EN-36
7.8 Managing the job memory ........................................................................................................... EN-47
7.8.1 Saving jobs ..................................................................................................................................... EN-47
7.8.2 Changing the job ........................................................................................................................... EN-48
7.8.3 Recalling a saved job .................................................................................................................... EN-48
7.8.4 Deleting a job................................................................................................................................. EN-49
7.9 Carrying out the welding process ................................................................................................EN-50
7.9.1 Starting the welding process......................................................................................................... EN-50
7.9.2 Adjusting parameters during the welding process......................................................................EN-50
7.10 Restoring factory settings............................................................................................................... EN-51
7.11 Creating a data backup................................................................................................................ EN-51
7.11.1 Welding parameter/internal function settings............................................................................. EN-52
7.11.2 Simplified data log function .......................................................................................................... EN-54

iROB®401 AC/DC
EN - 3
7.11.3 Fault log function............................................................................................................................ EN-54
7.11.4 Backup operations......................................................................................................................... EN-55
7.11.5 Importing backup data.................................................................................................................. EN-56
7.12 Checking the software version...................................................................................................... EN-57
8 Decommissioning..................................................................................................................... EN-57
9 Maintenance and cleaning .................................................................................................. EN-58
9.1 Maintenance and cleaning intervals ........................................................................................... EN-59
9.2 Cleaning the device....................................................................................................................... EN-59
10 Faults and troubleshooting ................................................................................................. EN-60
10.1 General faults................................................................................................................................. EN-60
10.2 Faults on the control panel.............................................................................................................EN-61
11 Disassembly............................................................................................................................... EN-64
12 Disposal ....................................................................................................................................... EN-64
12.1 Disposal of materials ..................................................................................................................... EN-64
12.2 Disposal of consumables .............................................................................................................. EN-64
12.3 Packaging....................................................................................................................................... EN-64
13 IFR-800 fieldbus connection tool ....................................................................................... EN-65
13.1 Configuration ................................................................................................................................. EN-65
13.2 Specification................................................................................................................................... EN-65
13.3 Processing time for communication data ..................................................................................... EN-68
13.4 Application specifications ............................................................................................................. EN-68
13.4.1 List of I/O data .............................................................................................................................. EN-69
13.4.2 Simplified table for output data.....................................................................................................EN-71
13.4.3 Example of setting output data..................................................................................................... EN-73
13.4.4 Details of I/O data.........................................................................................................................EN-74
13.4.5 Functions ......................................................................................................................................... EN-80
13.4.6 Control timing................................................................................................................................. EN-82
14 Accessories ................................................................................................................................. EN-83

EN - 4
1 Identification iROB®401 AC/DC
1 Identification
The iROB®401 AC/DC welding power source is used for automated MIG/MAG welding. The device may
be operated only with original spare parts. These operating instructions describe the iROB®401 AC/DC
welding power source only.
When used in these operating instructions, the terms "device", "product", and "welding power source"
always refer to the iROB®401 AC/DC welding power source.
If the welding power source is equipped with the optional iCOOL 1200 cooling unit, separate operating
instructions are included for this module.
1.1 Marking
This product fulfills the requirements that apply to the market to which it has been introduced.
A corresponding marking has been affixed to the product, if required.
1.2 Nameplate
The device is labeled by means of a nameplate.
► For inquiries, please have at hand the device type, device number, and year of construction as
indicated on the nameplate.
1.3 Signs and symbols used
The following signs and symbols are used in the operating instructions:
Fig. 1 Nameplate
General instructions.
Steps to be carried out in succession.
Lists.
Cross-reference symbol indicating detailed, supplementary, or further information.
Caption, item description.
1
A

iROB®401 AC/DC 2 Safety
EN - 5
1.4 Classification of the warnings
The warnings used in the operating instructions are divided into four different levels and shown prior to
potentially dangerous work steps. Depending on the type of danger, the following signal words will be used:
2 Safety
This chapter describes the essential safety requirements and warns of residual hazards that should be kept
in mind to operate the product safely. Non-observance of the safety instructions may result in risks to the life
and health of personnel as well as cause environmental or material damage.
► Observe the document entitled "Safety Instructions".
2.1 Designated use
The device described in these operating instructions may be used only for the purpose and in the manner
described in these operating instructions. The device is solely used as a welding power source for
MIG/MAG welding. Any other use is considered improper. Unauthorized conversions or modifications are
not allowed.
► Do not exceed the maximum load data specified in the documentation. Overloads lead to destruction.
► Do not make any structural modifications to the product.
2.2 Responsibilities of the user
► Ensure that only suitably qualified personnel perform work on the device or system.
Suitably qualified personnel are:
— 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 been trained accordingly;
— those who are able to recognize possible risks because of their special training, knowledge, and
experience.
► Keep non-suitably qualified people out of the work area.
DANGER
Describes an imminent threatening danger. If not avoided, it may cause severe injuries or death.
WARNING
Describes a potentially dangerous situation. If not avoided, this may result in death or serious injuries.
CAUTION
Describes a potentially harmful situation. If not avoided, this may result in slight or minor injuries.
NOTICE
Describes the risk of impairing work results, material damage, or irreparable damage to the device or
equipment.
WARNING
Risk of injury due to electromagnetic fields
The device can produce electromagnetic fields that could impact the proper function of cardiac
pacemakers and implanted defibrillators.
► Do not use the device if you have a pacemaker or an implanted defibrillator.
► The device may be used only in industrial zones according to DIN EN 61000-6-3.

EN - 6
3 Scope of delivery iROB®401 AC/DC
2.3 Warning and information signs
The following warning, notice and mandatory signs can be found on the product:
These markings must always be legible. They may not be covered, obscured, painted over, or removed.
2.4 Safety instructions for the electrical power supply
► Ensure that the power supply cable is not damaged, for example, by being driven over, crushed or torn.
► Check the power supply cable for damage and wear at regular intervals.
► If it is necessary to replace the power supply cable, use only ABICOR BINZEL spare parts.
► Only a qualified electrician should replace the power supply cable and the mains plug.
► Splash-water protection and mechanical stability must be ensured when replacing the mains plug of the
power supply cable.
2.5 Personal protective equipment
► Wear your personal protective equipment (PPE).
► Ensure that others in close proximity are also wearing personal protective equipment.
Personal protective equipment consists of protective clothing, eye protection, protective gloves, and safety
shoes.
2.6 Emergency information
► In the event of an emergency, immediately disconnect the following supplies:
— Electrical power supply
— Gas supply
► Extinguish burning oil or emulsions using a CO2 or powder fire extinguisher.
3 Scope of delivery
The following components are included in the scope of delivery:
— 1× iROB®401 AC/DC welding power source
— 1× operating instructions for the iROB®401 AC/DC welding power source
— 1× "Safety Instructions" document
Optional:
— 1× iCOOL 1200 cooling unit (installed in the welding power source)
— 1× Wi-Fi router for using the iROB®POWER App control app
— 1× driving carriage
— 1× base
— 1× operating instructions for the iCOOL 1200 Cooling unit
► 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.
► For more information about points of contact, consultation, and orders, visit www.binzel-abicor.com.
Although the items delivered are carefully checked and packaged, it is not possible to fully rule out the risk
of transport damage.
Goods-in inspection
► Use the delivery note to check that everything has been delivered.
► Check the delivery for damage (visual inspection).
Complaints
► If goods are damaged, contact the final carrier.
► Keep the packaging for possible checks by the carrier.
► Read and observe the operating instructions.

iROB®401 AC/DC 4 Product description
EN - 7
Returns
► Use the original packaging and packing material for returns.
► If you have questions concerning packaging and safety during shipment, contact your supplier, carrier,
or transport company.
4 Product description
4.1 Structure and function
The device is a component of an automatic welding system. The built-in microprocessor facilitates complete
control of all welding functions. The device is suitable for the following welding procedures/functions:
All welding parameters can be saved to the integrated job memory. In synergy mode, the welding voltage
is automatically adjusted to the set welding current. The parameter setting function can be used to finely
adjust the automatically determined welding voltage.
Fig. 2 iROB®401 AC/DC structure and function
AControl panel
BMain switch
CNot assigned
DVoltage test lead connection
EPower supply connection (welding torch side)
FCooling unit (optional)
GDriving carriage (optional)
HWorkpiece connection
INot assigned
JMains control LED
mX Standard DC Standard welding procedures without pulses. From short arc with low
energy input to high power spray arc. Suitable for all base materials,
cored wires, and shielding gases.
mX Pulse DC Pulse welding process for different penetration profiles. Standard and
high-performance settings for all base materials, flux cored wires, and
shielding gases.
mX Move DC Focus on CrNi and Al
Controlled heat input by pulsing at two power levels. . TIG-like seam
surface.
mX Pulse AC Alternating current pulse welding procedure for optimum weld
penetration control and gap bridging with thin sheet applications.
mX Move AC Focus on CrNi and Al
Controlled heat input thanks to AC pulses at two power levels. TIG-like
seam surface.
B
A
C
E
G
H
I
J
D
F

EN - 8
4 Product description iROB®401 AC/DC
4.2 Control elements
The control elements may vary depending on the product type.
Fig. 3 Control elements
ALeft digital display
BRight digital display
C<Parameter setting> knob
D<Toggle welding current/wire feed speed> button
E<Toggle voltage> button
F<Parameter selection> button
G<Function> button
H<Shielding gas check> button
I<Wire feed> button
J<Welding speed> selection button
K<Welding procedure> selection button
L<Shielding gas type> selection button
M<Welding wire material> selection button
N<Welding wire diameter> selection button
O<Operating mode> selection button
P<Tack time> button
Q<Arc dynamics> button
R<Release start welding/end crater parameter> button
S<Weld data capture> button
T<Move frequency> button
U<Cooling unit on/off> button (optional)
V<Synergy mode ON/OFF> button
W<EN ratio> button
X<Load> button
Y<Save> button
Z<Enter> button
AA<Warning/temperature> LED
ABUSB port
ACService interface
ADIndicator LEDs
Fig. 4 LED overview on page EN-12
Tab. 1 Control elements
Pos. Name Function
ALeft digital display During welding, the welding current is displayed and
the <A> LED illuminates.
When making settings, the set value is displayed and the
corresponding LED illuminates.
BRight digital display The welding voltage is displayed during welding.
When making settings, the set value is displayed and the
corresponding LED illuminates.
O
AC
AB
CBA
N M L K J
DE
F
G
H
I
P
Q R S
T U V
X
Y
Z
AA AD AD
W

iROB®401 AC/DC 4 Product description
EN - 9
C<Parameter setting> knob Adjusts the selected parameter value (welding current, welding
voltage, or wire feed speed).
D<Toggle welding current/wire
feed speed> button
Selects the welding current and wire feed speed.
The value is displayed in the left digital display and can be
adjusted via the parameter setting function. The mode can be
switched by pressing the button.
E<Toggle voltage> button Selects the welding voltage.
The value is displayed in the right digital display and can be
adjusted via the parameter setting function. If synergy mode has
been selected for adjusting the voltage, the displayed value can
be switched between the absolute value and the correction value
by pressing the button. In synergy mode, the voltage is adjusted
according to the welding current. The basis of the characteristic
curve value is ± 0. This value is used for fine tuning.
F<Parameter selection> button Switches between the welding parameters (shielding gas pre-
flow time, starting current, main current, end current, and
shielding gas post-flow time).
During welding, the set value can be displayed on the digital
display.
G<Function> button Selects internal functions.
If the button is pressed for 1 second or longer, the LED illuminates
and the internal function mode is switched on.
H<Shielding gas check> button Allows shielding gas to flow.
When the button is pressed, the LED illuminates and shielding gas
is emitted. After 2 minutes, the shielding gas flow stops
automatically. When the button is pressed again, the LED
extinguishes and the shielding gas flow stops.
I<Wire feed> button Feeds the welding wire.
When the button is pressed, the LED illuminates and welding wire
is fed. The wire feed speed can be adjusted via the <Parameter
setting> knob. If an analog remote control is connected, the wire
feed speed can be adjusted via the current setting on the analog
remote control.
J<Welding speed>
selection button
Selects the desired welding speed.
The selection option depends on the installed options.
The LED for the selected welding speed illuminates. Some
combinations of welding wire diameter, welding wire material,
shielding gas type, and welding procedure are not sensible. If an
impermissible combination is selected, the LED flashes.
Tab. 1 Control elements
Pos. Name Function

EN - 10
4 Product description iROB®401 AC/DC
K<Welding procedure>
selection button
Selects the desired welding procedure.
The selection option depends on the installed options.
The LED for the selected welding procedure illuminates.
Some combinations of welding wire diameter, welding wire
material, welding speed, and shielding gas type are not sensible.
If an impermissible combination is selected, the LED flashes.
L<Shielding gas type>
selection button
Selects the desired shielding gas type.
The selection option depends on the installed options.
The LED for the selected shielding gas type illuminates. Some
combinations of welding wire diameter, welding wire material,
welding speed, and welding procedure are not sensible. If an
impermissible combination is selected, the LED flashes.
M<Welding wire material>
selection button
Selects the desired welding wire material.
The selection option depends on the installed options.
The LED for the selected welding wire material illuminates. Some
combinations of welding wire diameter, welding speed, shielding
gas type, and welding procedure are not sensible. If an
impermissible combination is selected, the LED flashes.
N<Welding wire diameter>
selection button
Selects the desired welding wire diameter.
The selection option depends on the installed options.
The LED for the selected welding wire diameter illuminates.
Some combinations of welding wire material, welding speed,
shielding gas type, and welding procedure are not sensible. If an
impermissible combination is selected, the LED flashes.
O<Operating mode>
selection button
No function.
P<Time> button No function.
Tab. 1 Control elements
Pos. Name Function

iROB®401 AC/DC 4 Product description
EN - 11
Q<Arc dynamics> button Switches the arc characteristic from soft (+10) to hard (−10).
When the button is pressed, the LED illuminates and the
<Parameter setting> knob can be used to adjust the parameters.
The current characteristic is shown in the right digital display.
R<Release start welding/end
crater parameter> button
Enables the activation of start welding/end crater parameters
when the "two-step" operating mode is selected in automatic
mode (internal functions F45–47).
When the button is pressed, the LED illuminates and the
activation of start welding/end crater parameters is enabled.
S<Weld data capture> button No function.
T<Move frequency> button Defines the double pulse frequency if mX Move DC welding
procedure is selected.
When the button is pressed, the LED illuminates and the
<Parameter setting> knob can be used to adjust the frequency.
U<Cooling unit on/off> button Switches the optional cooling unit on or off.
The unit is switched on/off when the button is pressed for
3 seconds.
LED on: cooling unit is switched on.
LED off: cooling unit is switched off.
V<Synergy mode ON/OFF>
button
Defines the welding voltage.
LED on:
Synergy mode ON: the welding voltage is automatically
adjusted according to the set welding current. Arc length
correction is carried out via the parameter setting.
LED off:
Synergy mode OFF: power and voltage are set independent
of each other.
W<EN ratio> button Defines the EN ratio if mX Pulse AC or mX Move AC has been
selected.
When the button is pressed, the LED illuminates and the
<Parameter setting> knob can be used to adjust the EN ratio.
The EN ratio is shown in the right-hand digital display.
X<Load> button Loads the welding parameters stored in the job memory.
7.8 Managing the job memory on page EN-47
Creates a data backup on a USB storage device.
7.11.4 Backup operations on page EN-55
Tab. 1 Control elements
Pos. Name Function

EN - 12
4 Product description iROB®401 AC/DC
The LEDs on the control panel have the following meanings:
Y<Save> button Saves the set parameters in the job memory.
7.8 Managing the job memory on page EN-47
Imports a data backup from a USB storage device.
7.11.5 Importing backup data on page EN-56
Z<Enter> button Performs the administrative functions such as button lock,
password, and assignment of welding parameters to memory
locations.
If the button is pressed for 3 seconds or more, button lock is
activated.
AA LED warning/temperature The LED illuminates or blinks as soon as an error occurs or if the
device overheats.
10 Faults and troubleshooting on page EN-60
AB USB port Data can be read from or stored to a USB storage device via the
port.
AC Input for service The interface is used exclusively for service purposes.
Fig. 4 LED overview
AWarning LED
BLED for temperature
CLED for amperes
DLED for wire feed speed
ELED for time
FLED for pulse frequency
GLED DC idle voltage
HLED for volts
ILED for arc length and/or voltage correction
JLED ratio of upper/lower value of wire feed speed with
mX Move DC and mX Move AC
KJob No. LED
LLED shielding gas post-flow
MLED for end crater filling parameter
NLED for main welding parameter
OLED for start welding parameter
PLED shielding gas pre-flow
Tab. 1 Control elements
Pos. Name Function
P
A
OM L
B
N
C D E F
H
I
J
K
G

iROB®401 AC/DC 4 Product description
EN - 13
4.3 Wi-Fi router and control app (optional)
If the device is equipped with an optional Wi-Fi router, all device functions can also be controlled and
programmed via the optional iROB®POWER App control app.
14 Accessories on page EN-83
Fig. 5 Wi-Fi router
AWi-Fi router
A

EN - 14
4 Product description iROB®401 AC/DC
4.4 Technical data
A
A duty cycle of 60% means that the device rests for 4 minutes after 6 minutes of welding with the
specified current.
Tab. 2 Ambient conditions for transport and storage1
1According to EN IEC 60974-1
Ambient temperature −20°C to +55°C
Relative humidity 20% to 80% (non-condensing)
Tab. 3 Ambient conditions for operation1
1According to EN IEC 60974-1
Ambient temperature −10°C to +40°C
Relative humidity 20% to 80% (non-condensing)
Max. tilt angle 10°
Tab. 4 Technical data
iROB®401 AC/DC
Mains voltage 400 V ±15%
Number of phases 3 phases
Rated frequency 50/60 Hz
Max. current consumption 31 A
Max. power consumption 21.7 kVA, 21.5 kW
Fuse on mains side 32 A; slow-blow
Welding current range 30 A to 400 A
Working voltage 12 V to 35 V
Idle power consumption 44.2 W
Idle voltage 92 V maximum
Duty cycle 40% (+40°C) DC 400 A/34 V
Duty cycle 100% (+40°C) DC 350 A/31.5 V
Duty cycle 40% (+40°C) DC Pulse 400 A/34 V
Duty cycle 100% (+40°C) DC Pulse 283 A/28.2 V
Duty cycle 60% (+40°C) AC Pulse 350 A/31.5 V
Duty cycle 100% (+40°C) AC Pulse 300 A/29 V
Protection type IP 23
Welding torch cooling type Air-cooled
Liquid-cooled (with optional cooling unit)
Total weight with cooling unit 114 kg
(cooling unit 31 kg)
Weight without cooling unit 83 kg
Dimensions (L × W × H) of entire device with
cooling unit
395 mm × 710 mm × 1158 mm
Dimensions (L × W × H) of the entire device
without cooling unit
395 mm × 710 mm × 760 mm
Static characteristic Constant voltage characteristic

iROB®401 AC/DC 5 Transport and installation
EN - 15
4.5 Connections
5 Transport and installation
The device can be transported with a lifting tool.
► Fix the device to the attachment points.
► Slowly lift the device and make sure that it remains balanced during transport.
► Install the device accordingly and lock the casters (for optional driving carriage).
Fig. 6 Connections on the back
AData cable for WLAN module (optional)
BFieldbus interface (e.g. Ethernet IP)
CPower supply for WLAN module (optional)
DWelding torch control lead connection
EMPP control lead connection
A
E
B
D
C
WARNING
Risk of injury due to improper transport and installation
In the event of improper transportation and positioning, the device could topple over or fall. This may
result in serious injuries.
► Check and wear your personal protective equipment.
► Ensure that all supply lines and cables do not encroach into the area in which employees are working.
► Place the device on a suitable base (flat, solid, dry) on which it will not topple over.
► Note the weight of the device when lifting it.
4.4 Technical data on page EN-14
► Use an appropriate lifting tool with load handling attachment for transporting and installing
the device.
► Avoid abrupt lifting and setting down.
► Do not lift the device over persons or other devices.
► Use the attachment points provided.
NOTICE
Material damage resulting from improper transportation and positioning
Improper transport or installation can cause the device to tip or fall over. This can result in material
damage and irreparable damage to the device.
► Protect the device against weather conditions, such as rain and direct sunlight.
► Protect the device from welding spatter when welding.
► Protect the device from direct jets of sparks when grinding.
► Ensure that the device does not make contact if you pass over edging.
► Use the device only in dry, clean and well-ventilated rooms.
► Maintain a minimum distance of 30 cm from the wall when installing the device to ensure that it
is sufficiently ventilated.

EN - 16
6 Commissioning iROB®401 AC/DC
6 Commissioning
6.1 Establishing the power supply
► Note the safety instructions.
2.4 Safety instructions for the electrical power supply on page EN-6
For the mains voltage and the fuse protection, please refer to:
4.4 Technical data on page EN-14
► Comply with the required cable cross-sections.
► Connect the ground line as close as possible to the welding point.
► Do not swap out the power cable.
► If cables must be extended, use only original cables.
► Connect the device to the power supply at the terminals provided.
6.2 Establishing a connection to the welding robot
13 IFR-800 fieldbus connection tool on page EN-65
WARNING
Electric shock due to improperly installed electrical power supply
If the electrical power supply and ground connection are improperly installed, fatal electric shocks
may occur.
► Only a trained electrician should carry out work on electrical components.
► If you want to operate the device in a very humid environment or on conductive material, install
a residual current circuit breaker in the power supply.
► Protect the power supply line to the device with suitable fuses that comply with regulations.
► Ground the device according to the applicable regulations.
► Do not ground the device together with other devices and machines.
WARNING
Electric shock due to defective cables
The use of damaged or improperly installed cables may result in a potentially fatal electric shock.
► Check all live cables and connections for proper installation and damage.
► Have any damaged, deformed, or worn parts replaced by a qualified electrician only.
► Only operate the device with an undamaged power supply cable.
► Do not swap out the power supply cable.
WARNING
Risk of injury due to fire
A fire may occur due to improper use or connection. This may result in serious burns.
► Ensure that the operating voltage specified on the nameplate is suitable for the mains voltage.
► Ensure that the ventilation slots are not blocked.

iROB®401 AC/DC 7 Operation
EN - 17
7 Operation
7.1 Administrative settings
7.1.1 Password-protecting the welding parameters
Activating this function protects against the following operating errors on the welding power source control
panel:
— Changing the welding parameters (it is still possible to check the settings)
— Operating the <Parameter selection> button and the <Parameter setting> knob
If the password function is activated, it remains active even after the device is switched on again via internal
functions.
Assigning a password
The password must be a three-digit number. "000" is not accepted as a password.
► Make a note of the password and keep it in a safe place.
A forgotten password can only be reset by ABICOR BINZEL.
► To cancel password setting, set the main switch to <0>.
NOTICE
Material damage due to exceeding the maximum duty cycle
If the device is operated for longer than the maximum duty cycle, it may be overloaded and irreparably
damaged.
► Only operate the device up to the maximum permissible duty cycle.
4.4 Technical data on page EN-14
► Observe the maximum duty cycle for welding components.
1Set the main switch to <I>.
The mains control LED lights up.
<HELLO> appears on both digital displays.
1Set the main switch to <0>.
2Press and hold the <Function> and <Enter> buttons
simultaneously and set the main switch back to <I>.
Keep both buttons pressed until <PAS → Loc> are
displayed alternately in the left digital display.
3Release the buttons when <Loc> is displayed.
If a password has not yet been assigned, <Loc> is displayed.
Continue with step (5).
If a password has already been assigned, <Loc> flashes.
Continue with step (4).
4To change the password, first enter the old password as
described below and press <Enter>.
If the number matches the stored password, both digital
displays show <good>. The new password can be entered
as described below.
5Set the hundreds digit with the <Parameter setting> knob.
F
+
A
m/min.
sec.
Hz
±
V
%
JOB.No.
A
m/min.
sec.
Hz
±
V
%
JOB.No.

EN - 18
7 Operation iROB®401 AC/DC
Activating password protection
Canceling password protection
7.1.2 Activating the control panel lock
The control panel lock function prevents the welding parameters from being changed by mistake. The control
panel lock only permits wire feed and retraction movements, shielding gas tests, and parameter saving.
Switching off the device does not cancel the control panel lock. Resetting the welding parameters and the
internal functions deactivates the control panel lock.
6Press the <Parameter selection> button.
The tens digit starts to flash.
7Set the tens and ones digits in the same way with the
<Parameter setting> knob.
8Check the password and press <Enter> twice.
The password is saved.
+
1Press and hold <Enter> for more than 3 seconds.
Password protection is active.
1Press and hold <Enter> for at least 3 seconds.
<PAS → Loc> flashes alternately in the left digital display.
2Set the hundreds digit with the <Parameter setting> knob.
3Press the <Parameter selection> button.
The tens digit starts to flash.
4Set the tens and ones digits in the same way with the
<Parameter setting> knob.
5Press <Enter>.
If the number matches the stored password, both digital
displays show <good> and password protection is removed.
If the number does not match the stored password, <bAd> is
displayed on the left digital display.
► Use the <Parameter setting> knob to re-enter the
password as described above.
A
m/min.
sec.
Hz
±
V
%
JOB.No.
A
m/min.
sec.
Hz
±
V
%
JOB.No.
A
m/min.
sec.
Hz
±
V
%
JOB.No.

iROB®401 AC/DC 7 Operation
EN - 19
The parameter protection function can be used to give only a selected group of persons permission to
change parameters. The parameter protection function can only be canceled by entering a password.
7.1.1 Password-protecting the welding parameters on page EN-17
7.2 Overview of welding parameters and processes
7.2.1 Overview of welding parameters
► Press and hold <Enter> for at least 3 seconds.
The control panel lock is activated.
In the event of an operating error, the LED above the <Enter> button flashes.
► Press and hold <Enter> again for at least 3 seconds.
The control panel lock is deactivated.
The LED above the <Enter> button is extinguished.
(3 sec.)
(3 sec.)
Tab. 5 welding parameters
welding parameters Adjustable range Starting value Description
Shielding gas pre-flow time 0 to 10 s 0.1 s Defines the duration of the gas flow
prior to the start of welding.
Start welding
parameter
Main welding
parameter
End crater filling
parameter
Power supply 20 to 400 A 150 A Start welding parameter:
Defines the welding current/voltage
immediately after welding starts.
Main welding parameter:
Defines the welding current/voltage
during welding.
End crater filling parameter:
Defines the welding current/voltage at
the end of welding.
Voltage
(manual)
10 to 40 V 23.5 A
Voltage
(arc length
correction)
−10 to 10 0
Shielding gas post-flow time 0 to 10 s 0.4 s Defines the duration of the gas flow
after the arc is extinguished.
Tack time 0.1 to 10 s 3 s Defines the duration of the tack time.
(Not in automatic mode.)
Arc characteristic −10 to 10 0 Varies the arc characteristic from soft
(+10) to hard (−10).
Memory location number in the job
memory
1 to 100 1 Memory location number for welding
parameter sets.
mX Move DC frequency 0.5 to 32.0 Hz 3.0 Hz Sets the frequency during mX Move DC
welding.
EN ratio −50 to 50 0 Sets the EN ratio for AC welding.
Tab. 6 Functions
Function Adjustable parameters
Shielding gas type CO2 MAG (18% CO2)
MAG (8% CO2)
MIG (2% O2)
MIG (2.5% CO2)
MIG (100% Ar)
Welding wire material Steel, steel flux-cored wire, stainless steel, ferritic stainless steel,
stainless steel flux-cored wire, CuSi, CuAl, AlMg5, AlSi5/12,
Ni base, titanium
Welding procedure mX Standard DC, mX Pulse DC, mX Move DC,
mX Pulse AC, mX Move AC
Welding wire diameter (mm) 0.8/1.0/1.2/1.6
Start parameter ON/OFF
Voltage adjustment Arc length correction/manual

EN - 20
7 Operation iROB®401 AC/DC
7.2.2 Overview of welding procedures
The possible combinations of welding procedures are listed in the following tables and can be selected by
the connected robot via the interface. If an impermissible combination is selected, this is indicated in the
right/left blinking digital display <−>.
The welding procedures produce high-quality welding results only with the specified shielding gases and
shielding gas combinations. Changes to the shielding gases and shielding gas combinations always affect
the welding results.
Tab. 7 Welding procedure
Welding procedure Shielding gas type Welding wire
material
Welding wire
diameter (mm)
Welding speed
mX Standard DC 82% Ar + 18% CO2Fe 1.0/1.2 High/standard
98% Ar + 2% O2CrNi 1.0/1.2 High/standard
97.5% Ar + 2.5% CO2CrNi 1.0/1.2 High/standard
CrNi(Ferr) 1.0/1.2 High/standard
mX Pulse DC 82% Ar + 18% CO2Fe 1.0/1.2 High/standard
98% Ar + 2% O2CrNi 1.0/1.2 High/standard
97.5% Ar + 2.5% CO2CrNi 1.0/1.2 High/standard
CrNi(Ferr) 1.0/1.2 High/standard
100% Ar AlSi5/12 1.2/1.6 High/standard
AlMg5 1.0/1.2/1.6 High/standard
CrNi 1.0/1.2 High/standard
CuSi3 0.8/1.0/1.2 High/standard
mX Move DC 82% Ar + 18% CO2Fe 1.0/1.2 High/standard
98% Ar + 2% O2CrNi 1.0/1.2 High/standard
97.5% Ar + 2.5% CO2CrNi 1.0/1.2 High/standard
CrNi(Ferr) 1.0/1.2 High/standard
100% Ar AlSi5/12 1.2/1.6 High/standard
AlMg5 1.0/1.2/1.6 High/standard
mX Pulse AC 82% Ar + 18% CO2Fe 1.0/1.2 High/standard
98% Ar + 2% O2CrNi 1.0/1.2 High/standard
97.5% Ar + 2.5% CO2CrNi 1.0/1.2 High/standard
CrNi(Ferr) 1.0/1.2 High/standard
100% Ar AlSi5/12 1.2/1.6 High/standard
AlMg5 1.0/1.2/1.6 High/standard
CrNi 1.0/1.2 High/standard
CrNi(Ferr) 1.0/1.2 High/standard
CuSi3 0.8/1.0/1.2 High/standard
mX Move AC 82% Ar + 18% CO2Fe 0.8/1.0/1.2/1.6 High/standard
92% Ar + 8% CO2Fe 0.8/1.0/1.2 High/standard
98% Ar + 2% O2CrNi 0.8/1.0/1.2/1.6 High/standard
CrNi(Ferr) 0.8/1.0/1.2 High/standard
97.5% Ar + 2.5% CO2CrNi 0.8/1.0/1.2/1.6 High/standard
CrNi(Ferr) 0.8/1.0/1.2 High/standard
100% Ar AlSi5/12 1.2/1.6 High/standard
AlMg5 1.0/1.2/1.6 High/standard