Abicor Binzel iROB 501 PRO 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®501 PRO
EN Robot welding system with Controller KINETIC
wire feed control unit

EN - 2
iROB®501 PRO
Table of contents
1 Identification.................................................................................................................................EN-5
1.1 Marking.................................................................................................................................EN-5
1.2 Nameplate ............................................................................................................................EN-5
1.3 Signs and symbols used.......................................................................................................EN-6
1.4 Classification of the warnings..............................................................................................EN-7
2 Safety ..............................................................................................................................................EN-7
2.1 Designated use .....................................................................................................................EN-7
2.2 Responsibilities of the user ...................................................................................................EN-7
2.3 Warning and information signs...........................................................................................EN-8
2.4 Safety instructions for the electrical power supply ............................................................EN-8
2.5 Personal protective equipment ............................................................................................EN-8
2.6 Emergency information ........................................................................................................EN-9
3 Scope of delivery........................................................................................................................EN-9
4 Product description ................................................................................................................. EN-10
4.1 Welding power source structure and function .................................................................EN-11
4.1.1 Control elements .................................................................................................. EN-12
4.2 Wire feed control unit structure and function.................................................................. EN-17
4.3 Structure and function of the wire feed systems.............................................................. EN-17
4.4 Wi-Fi router and control app (optional) .......................................................................... EN-19
4.5 Technical data for the welding power source................................................................. EN-20
4.6 Technical data for the wire feed control unit................................................................... EN-21
4.6.1 Controller KINETIC wire feed control unit......................................................... EN-21
4.6.2 Push Feeder KINETIC.......................................................................................... EN-21
4.6.3 Pull Feeder KINETIC............................................................................................EN-22
4.6.4 Wire Buffer KINETIC........................................................................................... EN-22
4.6.5 Pull Feeder KINETIC cable assembly ................................................................EN-22
4.7 Connections ....................................................................................................................... EN-23
5 Transport and installation.................................................................................................... EN-23
6 Commissioning.......................................................................................................................... EN-24
6.1 Establishing the power supply.......................................................................................... EN-24
6.2 Attaching and connecting the Push Feeder KINETIC.....................................................EN-25
6.3 Shortening the wire guide for the cable assembly......................................................... EN-25
6.4 Moving the robot into the maintenance position............................................................EN-26
6.5 Attaching the Wire Buffer KINETIC to the robot ............................................................EN-26
6.6 Mounting the Pull Feeder KINETIC.................................................................................. EN-27
6.7 Setting up the buffer box ..................................................................................................EN-28
6.8 Connecting the Pull Feeder KINETIC cable assembly ...................................................EN-28
6.9 Connecting the intermediate cable assembly.................................................................EN-30
6.10 Connecting the wire conduit............................................................................................. EN-31
6.11 Connecting the coolant connections................................................................................EN-32
6.12 Attaching the intermediate cable assembly to the robot ...............................................EN-32
6.12.1 Attaching the neckliner........................................................................................EN-32
6.13 Attaching/replacing the welding torch ........................................................................... EN-33
6.14 Establishing a connection to the welding robot..............................................................EN-33
7 Operation.................................................................................................................................... EN-34
7.1 Feeding in the welding wire ............................................................................................. EN-34
7.1.1 Adjusting the Pull Feeder KINETIC contact pressure........................................ EN-37
7.2 Administrative settings ....................................................................................................... EN-38
7.2.1 Password-protecting the welding parameters ................................................... EN-38
7.2.2 Activating the control panel lock........................................................................ EN-39
7.3 Overview of welding parameters and processes........................................................... EN-40
7.3.1 Overview of welding parameters ......................................................................EN-40
7.3.2 Overview of welding procedures....................................................................... EN-40
7.4 Preparing the welding process.........................................................................................EN-43
7.4.1 Setting the welding procedure ........................................................................... EN-43
7.4.2 Setting the welding sequence.............................................................................EN-44
7.5 Effects of the welding parameter settings........................................................................ EN-47
7.6 Examples of welding parameter settings......................................................................... EN-47
7.6.1 Example parameters for CO2 ...................................................................................................EN-47
7.6.2 Example of parameters for CO2 and flux-cored wire......................................EN-50

iROB®501 PRO
EN - 3
7.6.3 Example of parameters for MAG short arc welding........................................ EN-50
7.6.4 Example of parameters for MAG pulse welding...............................................EN-51
7.6.5 Example of parameters for MIG pulse aluminum welding.............................. EN-55
7.6.6 Example of parameters for MIG aluminum short arc welding........................ EN-55
7.7 Additional functions........................................................................................................... EN-56
7.7.1 Setting the arc characteristic .............................................................................. EN-56
7.7.2 Adjusting the penetration control....................................................................... EN-56
7.7.3 Adjusting the move frequency............................................................................ EN-56
7.7.4 Setting kinetic move............................................................................................. EN-56
7.8 Setting internal functions................................................................................................... EN-57
7.8.1 Making settings.................................................................................................... EN-57
7.8.2 Description of the internal functions................................................................... EN-58
7.9 Managing the job memory .............................................................................................. EN-73
7.9.1 Saving jobs .......................................................................................................... EN-73
7.9.2 Changing the job................................................................................................. EN-73
7.9.3 Recalling a saved job ..........................................................................................EN-74
7.9.4 Deleting a job.......................................................................................................EN-74
7.10 Carrying out the welding process.....................................................................................EN-75
7.10.1 Starting the welding process...............................................................................EN-75
7.10.2 Adjusting parameters during the welding process............................................EN-75
7.11 Restoring factory settings...................................................................................................EN-76
7.12 Creating a data backup ....................................................................................................EN-76
7.12.1 Welding parameter/internal function settings .................................................. EN-77
7.12.2 Simplified data log function................................................................................ EN-79
7.12.3 Fault log function ................................................................................................. EN-79
7.12.4 Backup operations .............................................................................................. EN-80
7.12.5 Importing backup data ........................................................................................EN-81
7.13 Checking the software version......................................................................................... EN-82
8 Decommissioning..................................................................................................................... EN-83
9 Maintenance and cleaning .................................................................................................. EN-83
9.1 Maintenance and cleaning intervals............................................................................... EN-84
9.2 Cleaning the device.......................................................................................................... EN-85
9.3 Maintenance work on the wire feed control unit ........................................................... EN-86
9.3.1 Switching off the main switch............................................................................. EN-86
9.4 Maintenance work on the Push Feeder KINETIC........................................................... EN-86
9.4.1 Replacing the conveyor roller ............................................................................ EN-86
9.5 Maintenance work on the Pull Feeder KINETIC .............................................................EN-87
9.5.1 Replacing the neckliner........................................................................................EN-87
9.5.2 Replacing the conveyor roller ............................................................................ EN-88
9.5.3 Replacing the wire guide nozzle ....................................................................... EN-89
9.5.4 Replacing the pressure roll ................................................................................. EN-90
9.6 Maintenance work on the Wire Buffer KINETIC.............................................................EN-91
9.6.1 Replacing the wire guide.....................................................................................EN-91
9.6.2 Replacing the wire guide and guide rollers in the Wire Buffer KINETIC........EN-91
10 Faults and troubleshooting ................................................................................................. EN-93
10.1 General faults .................................................................................................................... EN-93
10.2 Faults on the control panel ................................................................................................EN-94
10.3 Fault with Wire Buffer KINETIC‘s automatic position adjustment ..................................EN-97
10.4 Faults on the wire feed control unit.................................................................................. EN-98
10.4.1 Read out assistance code................................................................................... EN-98
11 Disassembly............................................................................................................................. EN-106
12 Disposal ..................................................................................................................................... EN-106
12.1 Disposal of materials.......................................................................................................EN-106
12.2 Disposal of consumables................................................................................................ EN-106
12.3 Packaging ........................................................................................................................ EN-106
13 IFR-800 fieldbus connection tool ..................................................................................... EN-107
13.1 Configuration................................................................................................................... EN-107
13.2 Specification .................................................................................................................... EN-107
13.3 Processing time for communication data........................................................................EN-110
13.4 Application specifications................................................................................................EN-111
13.4.1 List of I/O data ................................................................................................... EN-111
13.4.2 Simplified table for output data ........................................................................EN-113

EN - 4
iROB®501 PRO
13.4.3 Example of setting output data..........................................................................EN-115
13.4.4 Details of I/O data.............................................................................................EN-116
13.4.5 Functions.............................................................................................................EN-123
13.4.6 Control timing.....................................................................................................EN-125
14 Accessories ...............................................................................................................................EN-126
15 Spare parts and consumables..........................................................................................EN-126

iROB®501 PRO 1 Identification
EN - 5
1 Identification
The iROB®501 PRO robot welding system is used for automated MIG/MAG welding and comprises the
following modules.
— iROB®501 welding power source
— Controller KINETIC wire feed control unit
— Pull Feeder KINETIC with iCAT mini robot mount
— Push Feeder KINETIC
— Wire Buffer KINETIC
If the welding power source is equipped with the optional iCOOL 1200 cooling unit, separate operating
instructions are included for this module.
The Controller KINETIC wire feed control unit is permanently integrated into the iROB®501 welding power
source and enables the mX Kinetic welding procedure by balancing the Push Feeder KINETIC and Pull
Feeder KINETIC modules. The Pull Feeder KINETIC and Push Feeder KINETIC modules are used for
the automatic feeding of welding filler material. The Wire Buffer KINETIC is used as a signal generator for
the Controller KINETIC wire feed control unit to enable a balanced wire feed.
The device may be operated only with original spare parts. These operating instructions describe the
iROB®501 PRO robot welding system only.
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
Fig. 1 iROB®501 nameplate
Fig. 2 Controller KINETIC nameplate

EN - 6
1 Identification iROB®501 PRO
The device is labeled using nameplates.
► 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. 3 Push Feeder KINETIC nameplate
Fig. 4 Pull Feeder KINETIC nameplate
Fig. 5 Wire Buffer KINETIC 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®501 PRO 2 Safety
EN - 7
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.
► Do not use or store the device outdoors where it is wet.
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 - 8
2 Safety iROB®501 PRO
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.
► Read and observe the operating instructions.
► Wear eye protection.
Warning against hot surfaces. Risk of burns.
► Do not touch hot surfaces.
► Wear protective gloves.
Electrical voltage caution. Danger of electric shock.
► Only a trained electrician should open the device.
► Interrupt the electrical power supply before opening the device.
Electrical voltage caution. Danger of electric shock.
► Do not touch live parts such as the welding wire and drive unit or any metal parts that
touch the welding wire.
Caution: moving parts.
► Keep away from moving parts.
► Keep hands, loose clothing and tools away during operation.
Property damage due to improper use.
► Do not expose the device to strong vibrations or impact in the marked areas.
Damage to material due to electrostatic discharge on contact.
► Have the device grounded by a qualified electrician before startup.
Material damage due to electrical voltages.
► Do not expose the device to high electrical voltages in the marked areas.

iROB®501 PRO 3 Scope of delivery
EN - 9
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®501 welding power source
— 1× KINETIC system wire feed control system (installed in the welding power source)
— 1× Pull Feeder KINETIC with cable assembly and iCAT mini robot mount
— 1× Push Feeder KINETIC
— 1× Wire Buffer KINETIC
— 1× operating instructions for the iROB®501 PRO robot welding system.
— 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.
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.

EN - 10
4 Product description iROB®501 PRO
4 Product description
Fig. 6 iROB®501 PRO structure (example)
APull Feeder KINETIC with cable assembly and
iCAT mini robot mount
BWire Buffer KINETIC
CWire feed control unit KINETIC system
DiROB®501 welding power source
EiCOOL 1200 cooling unit
FPush Feeder KINETIC
DA B
F
C
E

iROB®501 PRO 4 Product description
EN - 11
4.1 Welding power source 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. Use of the Penetration Control function makes it
possible to automatically adjust the wire feed speed so that the welding current remains constant even if the
free welding wire end varies.
Fig. 7 iROB®501 structure and function
AControl panel
BMain switch
CNot assigned
DVoltage test lead connection
EPower supply connection (welding torch side)
FWire feed control unit
GCooling unit (optional)
HDriving carriage (optional)
IWorkpiece connection
JNot assigned
KMains 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 Clean Less spatter in the short arc due to modified bead separation. . Higher
welding speed for large tolerances, flat and uniform seam geometry.
mX Kinetic Reduced porosity (Al, galvanized material, primer)
Excellent gap bridging; controlled heat input . High melting rate with
low heat input .
mX Move DC Focus on CrNi and Al
Controlled heat input by pulsing at two power levels. TIG-like seam
surface.
Penetration Control Controlled penetration. High welding speed with reduced risk of
undercuts.
B
A
C
E
G
I
J
H
K
D
F

EN - 12
4 Product description iROB®501 PRO
4.1.1 Control elements
The control elements may vary depending on the product type.
Fig. 8 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<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<Penetration control> button
T<Move frequency> button
U<Cooling unit on/off> button (optional)
V<Synergy mode ON/OFF> button
W<Weld data capture> button
X<Load> button
Y<Save> button
Z<Enter> button
AA<Warning/temperature> LED
ABUSB port
ACService interface
ADIndicator LEDs
Fig. 9 LED overview on page EN-16
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 W
T U V
X
Y
Z
AA AD AD

iROB®501 PRO 4 Product description
EN - 13
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<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 - 14
4 Product description iROB®501 PRO
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®501 PRO 4 Product description
EN - 15
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<Penetration control> button Activate the Penetration Control function
The wire feed speed automatically adjusts so that the welding
current remains constant even if the free welding wire end varies.
This function is available when "steel", "steel flux-cored wire",
"stainless steel" or "stainless steel flux-cored wire" is selected.
LED on: penetration control switched on.
LED off: penetration control switched off.
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<Weld data capture> button No function
X<Load> button Loads the welding parameters stored in the job memory.
7.9 Managing the job memory on page EN-73
Creates a data backup on a USB storage device.
7.12.4 Backup operations on page EN-80
Tab. 1 Control elements
Pos. Name Function

EN - 16
4 Product description iROB®501 PRO
The LEDs on the control panel have the following meanings:
Y<Save> button Saves the set parameters in the job memory.
7.9 Managing the job memory on page EN-73
Imports a data backup from a USB storage device.
7.12.5 Importing backup data on page EN-81
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-93
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. 9 LED overview
AWarning LED
BLED for temperature
CLED for amperes
DLED for wire feed speed
ELED for time
FLED for pulse frequency
GLED for volts
HLED for arc length and/or voltage correction
ILED ratio of upper/lower value of wire feed speed with
mX Move DC
JJob No. LED
KLED shielding gas post-flow
LLED for end crater filling parameter
MLED for main welding parameter
NLED for start welding parameter
OLED shielding gas pre-flow
Tab. 1 Control elements
Pos. Name Function
A
m/min
sec
Hz
±
V
IE
IS
%
Job-No.
O
A
N L K
B
M
C D E F
G
H
I
J

iROB®501 PRO 4 Product description
EN - 17
4.2 Wire feed control unit structure and function
With mX kinetic welding, the wire feed control unit enables low-spatter welding at a high speed with low
heat input. The ignition process is optimized for low spatter and the high-quality welding with bead size
control enables a high-quality welding result. The arc is controlled in real time.
4.3 Structure and function of the wire feed systems
Push Feeder KINETIC
The Push Feeder KINETIC is part of the wire feeder system. The Push Feeder KINETIC has a 2-roll drive and
is solely used for wire feeding. The 2-roll drive feeds the welding wire at a constant wire speed. The speed
is controlled by the Controller KINETIC Wire feed control unit.
Fig. 10 Movement principle with the mX Kinetic welding procedure
Wire feed Wire retraction
Repetition
Arc Short circuit
Fig. 11 Push Feeder KINETIC structure
ASpring lock
BPressure lever
CWire feed-in trigger
DMotor
EPressure roll
FGuide adapter
GConveyor roller
HDrive gear
IMotor control lead port
JEncoder control lead port
KWire guide
G
E
F
C
J
B
K
A
I
D
H

EN - 18
4 Product description iROB®501 PRO
Pull Feeder KINETIC
The Pull Feeder KINETIC is part of the wire feeder system. The Pull Feeder KINETIC’s torch interface is
compatible with welding torches in the ABIROB® W series.
Fig. 12 Pull Feeder KINETIC structure
AWelding torch/cable assembly interface
BFront cover
CiCAT mini robot mount
DMotor cover
BA
D
C

iROB®501 PRO 4 Product description
EN - 19
Wire Buffer KINETIC
An encoder in the Wire Buffer KINETIC sends the wire feed control unit a signal to synchronize the wire
feeder units, thereby ensuring that the welding process is optimally controlled.
4.4 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-126
Fig. 13 Wire Buffer KINETIC structure
AWire Buffer KINETIC
BBuffer box
CCover flap
DWelding power cable connector
EPull Feeder KINETIC cable assembly connector
FWire conduit connector
GWire retraction trigger
HGas test trigger
IWire feed-in trigger
A E
GHI F
CA D
B
Fig. 14 Wi-Fi router
AWi-Fi router
A

EN - 20
4 Product description iROB®501 PRO
4.5 Technical data for the welding power source
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®501 PRO
Mains voltage 400 V ±15%
Number of phases 3 phases
Rated frequency 50/60 Hz
Max. current consumption 36 A
Max. power consumption 25 kVA, 22.9 kW
Fuse on mains side 32 A; slow-blow
Zmax mains supply ≤ 0.038 Ω
Adjustable range 30 A to 500 A
Working voltage 12 V to 45 V
Idle power consumption 44 V
Idle voltage 80 V maximum
Duty cycle 80% (+40°C) 400 A/34 V pulse
Duty cycle 60% (+40°C) 500 A/39 V DC
Protection type IP 23
Welding torch cooling type Liquid-cooled
Total weight with cooling unit and wire
feed control unit
137 kg
(cooling unit 31 kg)
(wire feed control unit 23 kg)
Weight without cooling unit and wire feed
control unit
83 kg
Dimensions (L × W × H) of the entire device
with the cooling unit and wire feed control
unit
395 mm × 710 mm × 1158 mm
Dimensions (L × W × H) without the cooling
unit and wire feed control unit
395 mm × 710 mm × 760 mm
Static characteristic Constant voltage characteristic