ABICOR xFUME AF500 User manual
EN - 2
xFUME® ABIROB® AF500
Table of contents
1 Identification.................................................................................................................................EN-3
1.1 Marking .............................................................................................................................................EN-3
1.2 Signs and Symbols Used..................................................................................................................EN-3
2 Safety ..............................................................................................................................................EN-3
2.1 Designated use..................................................................................................................................EN-3
2.2 Obligations of the operator .............................................................................................................EN-3
2.3 Basic safety instructions....................................................................................................................EN-4
2.4 Safety instructions for electrical components..................................................................................EN-4
2.5 Safety instructions for welding .........................................................................................................EN-4
2.6 Safety instructions for extraction (according to ISO 21904)........................................................EN-5
2.7 Safety instructions for personal protective equipment ...................................................................EN-5
2.8 Classification of the warnings ..........................................................................................................EN-5
3 Scope of Delivery........................................................................................................................EN-5
3.1 Emergency information.....................................................................................................................EN-6
4 Product Description....................................................................................................................EN-6
4.1 Setup and functional description .....................................................................................................EN-7
4.2 Technical Data...................................................................................................................................EN-8
5 Putting into operation...............................................................................................................EN-9
5.1 Setting up the torch neck ............................................................................................................... EN-10
5.2 Setting up the cable assembly ...................................................................................................... EN-10
5.3 Attaching the machine-side connector ..........................................................................................EN-11
5.4 Setting the shielding gas volume ...................................................................................................EN-11
5.5 Introducing the wire ........................................................................................................................EN-11
6 Operation.................................................................................................................................... EN-12
6.1 Carrying out the welding process ................................................................................................ EN-12
7 Decommissioning..................................................................................................................... EN-12
8 Maintenance and cleaning .................................................................................................. EN-12
8.1 Cleaning the wire guide................................................................................................................ EN-13
8.2 Mounting and shortening the liner ............................................................................................... EN-13
8.3 Cleaning the torch neck................................................................................................................. EN-14
9 Troubleshooting ....................................................................................................................... EN-14
10 Disassembly............................................................................................................................... EN-15
11 Disposal ....................................................................................................................................... EN-15
11.1 Disposing of materials ................................................................................................................... EN-15
11.2 Disposing of consumables............................................................................................................. EN-15
xFUME® ABIROB® AF500 1 Identification
EN - 3
1 Identification
The xFUME® ABIROB® AF500 welding torch system is used in the industry and in the trade for shielding
gas welding using inert (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.
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.
1.2 Signs and Symbols Used
The following signs and symbols are used in the operating instructions:
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, and
environmental damage or material damage.
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 used to extract welding fumes and dust that is
generated during welding. The device can be used to extract welding fumes that contain CMR substances
and to extract welding fumes that do not contain CMR substances. When extracting welding fumes that
contain CMR substances, the welding torch must be operated together with a suitable W3-certified fume
extraction system. Any other use is considered improper. Unauthorized modifications or changes to enhance
the performance are not permitted.
► Do not exceed the maximum load data as defined by the documentation supplied. Excessive loads lead
to irreparable damage.
► Do not make any constructive changes to this product.
► Do not use or store the device outdoors where it is wet.
► During welding work outdoors, use suitable protection against the weather conditions.
2.2 Obligations of the operator
► Ensure that only qualified personnel are permitted to perform work on the device or system.
Authorized 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 untrained persons out of the work area.
General instructions.
Action(s) to be carried out in succession.
Lists.
Cross-reference symbol refers to detailed, supplementary or further information.
Caption, item description.
1
A
EN - 4
2 Safety xFUME® ABIROB® AF500
2.3 Basic safety instructions
The product has been developed and manufactured in accordance with state-of-the-art technology and the
recognized safety standards and directives. Inevitable technical residual risks to the user, third parties,
devices, or other material property are posed by the product. This document describes the essential safety
requirements and warns of residual hazards that should be kept in mind to operate the product safely.
Detailed product information and product-specific safety instructions are found in the separate operating
instructions and in other product-specific documentation. Non-observance of the safety instructions may
result in risks to the life and health of personnel, and environmental damage or material damage. The
manufacturer will accept no liability for damage caused by non-observance of the documentation.
► Before using the system for the first time, please read the provided documentation carefully.
► Do not operate the product unless it is functioning properly and ensure compliance with all documents.
► Before carrying out specific work, for example, commissioning, operation, transport and maintenance,
read the documentation carefully.
► Use suitable means to protect yourself and bystanders from the hazards listed in the documentation.
► Store the documentation within easy reach of the device for reference and enclose all documents when
passing on the product.
► Consult the documentation for additional welding components.
► Information about how to handle gas cylinders can be found in the instructions provided by the gas
manufacturer and the relevant local regulations, e.g., regulations that apply to compressed air.
► Observe the local accident prevention regulations.
► Only trained specialists should commission, operate, and service the device. Qualified personnel are
persons who, based on their special training, knowledge, experience and due to their knowledge of the
relevant standards, are able to assess the tasks assigned to them and identify possible dangers.
► Keep the work area in order. Ensure good lighting of the work area.
► Switch off the power supply, gas supply, and compressed air supply, and disconnect the mains
connection for the entire duration of maintenance, commissioning, and repair activities.
► For disposal, observe the local regulations, laws, provisions, standards and directives.
2.4 Safety instructions for electrical components
► Check electric tools for damage and for its proper functioning in accordance with its designated use.
► Do not expose electric tools to rain and avoid a moist or wet environment.
► Protect yourself from electric shock by using insulating mats and wearing dry clothing.
► Do not use the electric tools in areas subject to fire or explosion hazards.
2.5 Safety instructions for welding
► Arc welding may cause damage to the eyes, skin and hearing. Note that other hazards may arise when
the device is used with other welding components. Therefore, always wear the prescribed personal
protective equipment as defined by local regulations.
► Any metal vapors, especially lead, cadmium, copper and beryllium are harmful. Ensure sufficient
ventilation or extraction. Do not exceed the current occupational exposure limits (OEL).
► To prevent the formation of phosgene gas, rinse workpieces that have been degreased with chlorinated
solvents using clean water. Do not place degreasing baths containing chlorine in the vicinity of the
welding area.
► In connection with various welding torches, there may be other hazards, for example those caused by:
electrical current (power supply, internal circuit), welding spatter with regard to combustible or
explosive materials, UV radiation from the arc, smoke and vapors.
► Adhere to the general fire protection regulations and remove flammable materials from the vicinity of
the welding work area prior to starting work. Provide appropriate fire extinguishing equipment in the
workplace.
xFUME® ABIROB® AF500 3 Scope of Delivery
EN - 5
2.6 Safety instructions for extraction (according to ISO 21904)
► 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 system 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 volume flow at the suction nozzle using the ABICOR BINZEL suction test pipe.
► Check the extraction hoses at regular intervals, at least once a week, for damage and contamination.
► Note that if additional hoses or hoses from other manufacturers 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 extraction torch.
► Replace the extraction-specific wear parts at regular intervals. The replacement interval required
depends on the application conditions.
► Opening the air regulator is only intended to briefly reduce the volume flow at the suction nozzle. Close
the air regulator immediately afterwards. The air regulator must be closed to ensure efficient capture of
fumes.
► Observe the instructions on the adapter label for connecting components.
► When welding under particularly oily ambient conditions, creepage distances consisting of metal
oxides from the welding fume can form locally on fume-carrying surfaces, which are potentially
electrically conductive. Therefore, clean the welding fume-carrying surfaces on the fume extraction torch
regularly.´
2.7 Safety instructions for personal protective equipment
► Do not wear loose fitting clothing or jewelry.
► Use a hair net for long hair.
► Wear safety goggles, protective gloves and, if required, a breathing mask when the device is in use and
when welding.
2.8 Classification of the warnings
The warnings used are divided into four different categories and are indicated prior to potentially dangerous
work steps.
Depending on the type of danger, the following signal words will be used:
3 Scope of Delivery
The following components are included in the scope of supply:
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 or material damage and indicates irreparable damage to the device or
equipment.
EN - 6
4 Product Description xFUME® ABIROB® AF500
— 1x xFUME® ABIROB® AF500 welding torch system
— 1x torch-sided cable support with integrated switch housing cover
— 1x machine-side cable support with central connector
— 1x operating instructions
The xFUME® ABIROB® AF500 requires additional, welding-task dependent components for the initial set-
up. These including the following:
— 1x torch mounting bracket (required for attachment to the robot/cobot)
— 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.
► 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
► Check for order completeness by checking the delivery note.
► Check the delivered goods for damage (visual inspection).
Claim process
► If goods are damaged, contact the final carrier.
► Keep the packaging for possible checks by the carrier.
Returns
► Use original packaging and packing material for returns.
► If you have questions concerning the packaging or how to secure the device, contact your supplier,
carrier or transport company.
3.1 Emergency information
► In the event of an emergency, immediately disconnect the following supplies: electrical power supply,
compressed air supply, coolant supply and shielding gas supply.
► Consult the documentation for welding components.
4 Product Description
WARNING
Hazards caused by improper use
If improperly used, the device can present risks to persons, animals, and material property.
► 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.
xFUME® ABIROB® AF500 4 Product Description
EN - 7
4.1 Setup and functional description
The xFUME® ABIROB® AF500 provides an arc for welding when supplied with the appropriate
consumables. The welding wire required for welding is fed through the welding torch system all the way to
the contact tip. The contact tip transmits the welding current to the welding wire, producing an arc between
the welding wire and the workpiece. The arc and the molten pool are protected by the inert gas (MIG) and
the active gas (MAG).
The standard torch neck types are available in the geometries straight, 22°, and 45° bends. The uniform
interface at the connection module makes all torch necks compatible with one another.
The connection module establishes the connection between the welding torch and the cable assembly. The
mounting flange is used to attach the welding torch system to the robot. The air-cooled cable assembly
provides the welding torch with all the components required for welding, e. g. the welding current, shielding
gas and air. A fume hose is included but must be connected to an extractor for at source fume extraction.
Tab. 1 Torch system
ASwan neck
BFume Shroud
CTorch mounting flange
DCable assembly
A
D
B
C
EN - 8
4 Product Description xFUME® ABIROB® AF500
4.2 Technical Data
The volume the torch-integrated extraction system collects depends on many factors, such as the position of
the suction nozzle, the welding geometry and the gas emission rate of the welding process. Under optimal
conditions, over 95 % of the welding fumes can be captured in accordance with ISO 21904-3.
Tab. 2 Ambient conditions for transport and storage
Temperature
(storage in a closed environment)
−10 °C to +40 °C
Temperature
(transport)
−25 °C to +55 °C
Relative humidity Up to 90 % at +20 °C
Tab. 3 Ambient conditions during operation
Temperature −10 °C to +40 °C
Relative humidity Up to 90 % at +20 °C
Tab. 4 General torch data according to EN 60 974-7
xFUME® ABIROB® AF500
Type of voltage DC
Polarity of the wire electrode for DC Usually positive
Wire types Commercially available round wires
Type of use Automatic
Voltage rating Peak value of 141 V
Protection type of the device connections
(EN 60529)
IP3X
Shielding gas (EN ISO 14175) CO2 and mixed gas M21
Tab. 5 Product-specific torch data (EN 60974-7 and EN ISO 21904-1)
xFUME® ABIROB® AF500
Type of Cooling Air
Load1
1 For pulse arcs, the load data are reduced by up to 35 %.
CO2500 A
M21 450 A
DC 100 %
Wire Ø 0.8–1.6 mm
Gas flow rate 10–30 l/min
Volume flow2
(for induced speed 0.35 m/s)
2 When used with welding fume extraction systems of the XFume series.
Suction nozzle 103.9 m3/h
Connector 118.3 m3/h
Required vacuum at the
connector
(for induced speed 0.35 m/s)
11 kPa
Torch neck type Swan neck
Torch mount type Solid
xFUME® ABIROB® AF500 5 Putting into operation
EN - 9
5 Putting into operation
Tab. 6 Torch neck geometry
xFUME® ABIROB® AF500
cx X1 X2 Y1 Y2 TCP (X) Y
0 ° 189.7 mm 204.8 mm – – 14.2”/360 mm –
22 ° 181.5 mm 195.4 mm 44.1 mm 49.8 mm 14.2”/360 mm 5.7”/145.6 mm
45 ° Contact Sales Contact Sales Contact Sales Contact Sales 15.75”/400 mm –
Fig. 1 Torch neck geometry
Fig. 2 Torch neck diameter
AØ 26.5 mm BØ 18 mm
Y2
X1
X2
Y1
cx
A B
CAUTION
Risk of injury due to unexpected start
If power is supplied during maintenance, cleaning or disassembly, parts can start running unexpectedly
and lead to injuries.
► Switch off the device.
► Close all supply lines.
► Disconnect the electrical power supply.
EN - 10
5 Putting into operation xFUME® ABIROB® AF500
5.1 Setting up the torch neck
1Screw the replaceable tip adapter (D) onto the torch neck (G) using the multi-wrench (J).
2Screw the contact tip (B) into the tip adapter (D) and tighten using the multi-wrench (J).
3Grease the torch neck O-rings.
4Insert the torch neck (G) into the connection module (H) until reaching the stop.
5Screw the bayonet nut (F) onto the connection module (H) locking the 3 pins in place.
6Insert the fume tube (E) into the bayonet nut (F) until reaching the stop.
7Screw the suction nozzle (C) into the fume tube (E) hand tight.
8Screw the gas nozzle (A) onto the tip adapter (D) hand tight.
5.2 Setting up the cable assembly
► Select the correct wire type and appropriate wire guide for your application.
► For information on cutting the wire to size and correctly assembling the wire guide, see the following
section:
8 Maintenance and cleaning on page EN-12
Fig. 3 Setting up the torch neck
AGas nozzle
BContact tip
CSuction nozzle
DTip adapter
EFume tube
FBayonet nut
GTorch neck
HConnection module
IKey
JMulti-wrench
A
I
BC D E F G H
J
Tab. 7 Liner type
Steel and stainless steels Spiral liners
Aluminum, copper, nickel and stainless steels PA liners
xFUME® ABIROB® AF500 5 Putting into operation
EN - 11
1Lay out the cable assembly (B) straight and attach to the handle (A),(F).
2Attach control cable (E).
3Insert power pin (D) into the wire feeder.
4Connect the extraction hose to the suction connector (C).
5.3 Attaching the machine-side connector
1Check once again whether the wire guide has been fitted correctly.
2Join the power pin (D) to the wire feeder.
5.4 Setting the shielding gas volume
The type and amount of shielding gas used depend on the welding task and the gas nozzle geometry.
1To prevent the shielding gas supply from becoming clogged by impurities, briefly open the cylinder valve
before connecting the cylinder. This will expel any impurities that may be present.
2Make all shielding gas connections gas-tight.
3Connect the shielding gas cylinder to the wire feeder.
4Set the gas quantity on the shielding gas cylinder’s pressure reducer.
5.5 Introducing the wire
1Each time the wire is replaced, ensure that the start of the wire is free of burrs and not bent.
2Insert the wire in the wire feeder as specified by the manufacturer.
3Press the button <zero-current wire feed> on the wire feeder.
Fig. 4 Setting up the cable assembly
AClamp
BCable assembly
CSuction connector
DPower pin
EControl cable
FHandle
A
E
B C D
F
EN - 12
6 Operation xFUME® ABIROB® AF500
6 Operation
6.1 Carrying out the welding process
1Open the shielding gas cylinder.
2Switch on the power source.
7 Decommissioning
1Stop the welding process.
2Wait until the shielding gas post-flow time has passed.
3Switch off the power source.
4Close the shielding gas cylinder valve.
8 Maintenance and cleaning
WARNING
Shortness of breath and poisoning caused by inhaling phosgene gas
When welding workpieces that have been degreased with chlorinated solvents, phosgene gas is formed.
It can damage the respiratory tract when inhaled.
► Do not inhale fumes and vapors.
► Check and wear your personal protective equipment.
► Ensure a sufficient supply of fresh air.
► Rinse the workpieces with clean water prior to welding.
► Do not place degreasing baths containing chlorine in the vicinity of the welding area.
WARNING
Risk of burns from sparks
During welding activities, sparks, glowing workpieces or hot slag can produce flames. This may result in
serious burns.
► Check the work area for flashpoints.
► Check and wear your personal protective equipment.
► Provide appropriate fire extinguishing equipment in the workplace.
► Allow workpieces to cool down after welding.
► Prior to performing welding work, properly fasten the ground clamp to the workpiece or welding
table.
WARNING
Risk of arc eye
The arc produced by welding can damage the eyes.
► Check and wear your personal protective equipment (eye protection).
CAUTION
Risk of injury due to unexpected start
If power is supplied during maintenance, cleaning or disassembly, parts can start running unexpectedly
and lead to injuries.
► Switch off the device.
► Close all supply lines.
► Disconnect the electrical power supply.
xFUME® ABIROB® AF500 8 Maintenance and cleaning
EN - 13
1Remove weld spatter.
2Check that all threaded fittings are tight.
8.1 Cleaning the wire guide
1Unscrew the cable assembly on the machine side and lay it out straight.
2Unscrew the nut and pull out the liner.
3Clean the wire conduit from both sides with compressed air.
4Slide the adjusted liner into the wire conduit and secure with a nut.
8.2 Mounting and shortening the liner
New and unused liners must be shortened to the actual length of the cable assembly.
1Lay out the cable assembly (C) straight.
2Disconnect the central connector (B) from the feed unit.
3Screw on the retaining sleeve (A).
4Replace the old liner (E) with a new one and insert the stripped side into the central connector (B).
5Place the retaining sleeve (A) inverted by 180 ° onto the new liner (E) (side without thread).
WARNING
Electric shock due to defective cables
Damaged or improperly installed cables can lead to fatal electric shock.
► Check all live cables and connections for proper installation and damage.
► Damaged, deformed or worn parts should only be replaced by a qualified electrician.
WARNING
Risk of injury caused by parts swirling around
The use of compressed air for cleaning purposes can cause device parts to come loose and cause
serious injuries.
► When cleaning the wire guide with air, wear suitable protective clothing, in particular safety goggles.
Fig. 5 Mounting and shortening the liner
ARetaining sleeve
BCentral connector
CCable assembly
DNut
ELiner
FCollet
A
D
BC
F
E
EN - 14
9 Troubleshooting xFUME® ABIROB® AF500
6Cut off the overlapping liner (E) flush with the retaining sleeve (A).
7Screw the collet (F) onto the liner (E) as far as it will go.
Use the sight bore on the collet (F) to check the position of the wire guide.
8Slide the collet (F) and liner (E) into the central connector (B) as far as they will go.
9Screw the threaded side of the retaining sleeve (A) into the central connector (B) and tighten.
10 Use the nut (D) to secure the cable assembly (C) to the central connector (B).
8.3 Cleaning the torch neck
To increase the system availability of the welding robot, ABICOR BINZEL offers automated torch cleaning.
1Remove the gas nozzle.
2Remove the weld spatter and spray with ABICOR BINZEL anti-spatter fluid.
3Check the wear parts for visible damage and replace them if necessary.
4Replace the equipment kit when worn or soiled.
5Clean the separating point and O-rings with silicone-free seal grease.
6Check the TCP after each use or after a collision in the WH alignment jig.
9 Troubleshooting
CAUTION
Risk of injury and device damage when handled by unauthorized persons
Improper repair work and modifications to the product may lead to serious injuries and damage to the
device. The product warranty will be rendered invalid if work is carried out on the product by
unauthorized persons.
► Consult the documentation for the welding components.
Tab. 8 Troubleshooting
Fault Cause Troubleshooting
Torch neck gets hot. Contact tip loose. ► Check and tighten.
Contact tip loose on torch side and toward
the workpiece.
No trigger function. Control lead interrupted/defective. ► Check/repair.
Wire burned solid in the contact tip. Wrong parameters set. ► Check and correct setting.
Contact tip worn out. ► Replace.
Irregular wire feed. Liner clogged. ► Clean both directions with compressed
air or replace if necessary.
► Replace the contact tip.
Contact tip and wire diameter not aligned.
Wrong contact pressure set on the wire
feeder.
► Correct as specified by the
manufacturer.
Spatter bridge between the contact tip and
the gas nozzle.
► Clean and spray the gas nozzle interior.
Arc between the gas nozzle and the
workpiece.
Contact tip not tailored to the wire diameter
or contact tip worn out.
► Check the contact tip.
Erratic arc. Wrong welding parameters set. ► Correct the welding parameters.
Wire guide unit worn out. ► Replace the wire guide.
Strong weld spatter build-up in the gas
nozzle.
► Clean the gas nozzle.
Pore formation. Insufficient or no gas coverage. ► Check the gas cylinder contents and
pressure setting.
Air current blows shielding gas away. ► Use partitions to shield the welding
area.
xFUME® ABIROB® AF500 10 Disassembly
EN - 15
10 Disassembly
1Disconnect the cable assembly from the wire feeder.
2Remove the parts to be disconnected (change body, bracket, torch neck).
11 Disposal
11.1 Disposing of materials
This product is mainly made of metallic materials that can be melted in steel and iron works and are thus
almost infinitely recyclable. The plastic materials used are labeled in preparation for their sorting and
separation for later recycling.
11.2 Disposing of consumables
Oil, greases and cleaning agents must not contaminate the ground or enter the sewage system. These
substances must be stored, transported and disposed of in suitable containers. Contaminated cleaning tools
(brushes, rags, etc.) must also be disposed of in accordance with the information provided by the
consumables’ manufacturer.
► Observe the relevant local regulations and disposal instructions in the safety data sheets specified by
the manufacturer of the consumables.
The disposal of dust collecting bags and disposal bags is subject to special waste regulations. The dust must
not enter sewage systems or be disposed of together with normal household waste.
► Observe the local and official regulations.
CAUTION
Risk of injury due to unexpected start
If power is supplied during maintenance, cleaning or disassembly, parts can start running unexpectedly
and lead to injuries.
► Switch off the device.
► Close all supply lines.
► Disconnect the electrical power supply.
Equipment marked with this symbol is covered by European Directive 2012/19/EU on
waste electrical and electronic equipment (WEEE).
► Do not dispose of electrical and electronic equipment with household waste.
► Disassemble electrical equipment prior to proper disposal.
10 Disassembly on page EN-15
► Collect components of electrical separately and recycle in an environmentally
responsible manner.
► Observe local regulations, laws, provisions, standards and guidelines.
► Please consult your local authority for information about collection and return of
electrical devices.
Table of contents
