OPERATING MANUAL 1920660 1616 EN Robot Gun Cleaning Station
CONTENTS 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 6. The Robot Gun Cleaning Station. . ................................................. 3 Preface. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................. 3 Identification.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................. 4 CE marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THE ROBOT GUN CLEANING STATION This document provides product information for the Kemppi Robot Gun Cleaning Station. 2. PREFACE Congratulations on your purchase of this product. Used correctly, Kemppi products can significantly increase the productivity of your welding and provide many years of economical service. This operation manual contains important information on the use, maintenance, and safety of your Kemppi product.
IDENTIFICATION 5. The Robot Gun Cleaning Station is used in industry and in the trade for automatic cleaning of the gas nozzle interior of MIG/MAG welding guns. The cleaning station helps to extend the service life of the welding gun and the maintenance intervals. These instructions describe the Robot Gun Cleaning Station product only. The Robot Gun Cleaning Station must be operated only as supplied or equipped with authentic Kemppi spare parts. 4.
.6 Emergency instructions Items in the manual that require particular attention, to minimize damage and personal injury, are indicated with a three-level notification and warning system. Read these sections carefully, and follow the instructions. In the event of an emergency, immediately interrupt the following: • The power supply • The flow of compressed air Note: Note items give the user a useful piece of information.
5.8 Product safety If improperly used, the device can present risks to people and physical property. • Use the device in line with its designated use only. • Do not convert or modify the device to enhance its performance without appropriate authorization. • Using clean water, rinse work pieces that have been degreased with chlorinated solvents, to prevent the risk of phosgene gas forming. Do not place degreasing baths containing chlorine in the vicinity of the welding area.
TECHNICAL DATA Figure 1: Version with a long support 1. 2. 3. 4. Figure 2: Version with a short support 1. 2. 3. 4. Cleaning unit Collecting tray Bottle-holder for anti-spatter bottle Support stand with base plate © Kemppi Oy 2016 7 Cleaning unit Collecting tray Bottle-holder for anti-spatter bottle Support stand with flange plate Robot Gun Cleaning Station OPERATING MANUAL 6.
6.4 The electrical clamping block This section describes suitable ambient conditions for the Robot Gun Cleaning Station. This section describes the Robot Gun Cleaning Station’s electrical clamping block.
6.5 The compressed-air motor 6.8 The type plate This section describes the Robot Gun Cleaning Station’s compressed-air motor. The Robot Gun Cleaning Station unit is labeled with a nameplate on the back as shown in the figure. Pneumatic motor’s nominal speed with oiled air approx. 650 rpm at 6 bar Air consumption approx. 400 l/min Repository volume (anti-spatter fluid) 1l Air supply connection internal width 6 mm Max. torque 8 Nm Figure 3: The type plate 6.
7. DELIVERY SCOPE 8. The standard delivery includes the following components: • The Robot Gun Cleaning Station components described in this manual • A connection set with non-return valve (may be pre-assembled) • Anti-spatter fluid (1-liter bottle) • Operating instructions • Support stand with base plate STORAGE The physical conditions for storage in a closed room are -10 °C to 55 °C. OPERATING MANUAL The equipment parts and wear parts are ordered separately.
FUNCTIONAL DESCRIPTION For cleaning, the torch is clamped with the cylindrical part of the gas nozzle in the clamping device. The milling cutter, which is configured to match the gas nozzle and torch geometry, moves into the gas nozzle’s interior by means of a stroke movement and removes adhered welding spatter. At the same time, the gas nozzle interior may be blasted with compressed air through the cable assembly (optional).
9.4 Sub-assembly accessories and options The wire-cutting device sub-assembly is depicted in the figure below. This section describes the sub-assembly accessories and options.
10. INSTALLING THE ROBOT GUN CLEANING STATION Figure 7: Installing the Robot Gun Cleaning Station Proceed as follows: 1. Risk of injury due to unexpected start-up For the entire duration of maintenance, servicing, unmounting, and repair work, the following instructions must be adhered to: • Switch off the power supply. • Cut off the compressed air supply. • Pull the power plug. Connect the two hoses (4 and 8) to the applicable bottles to put the injection unit of the welding torch into operation.
10.1 Connecting to electricity Figure 8: Connection for compressed air, DN10 This section describes how to connect the Robot Gun Cleaning Station to electricity. 1. Connect the cleaning station of the welding torch to the power supply through an integrated plug connection. Ready-to-use control leads are available in lengths of 5 and 10 m (optional). For electrical connection, check device type NPN resp. PNP. The necessary control signals too are transmitted through this plug.
10.2 Installing the injection unit This section describes how to install the Robot Gun Cleaning Station’s injection unit. Proceed as follows: The injection unit’s parts are depicted in the figure below. The numbering in the steps of the procedure refers to this figure. Figure 11: Rubber gasket Before you operate the device, mount the rubber gasket, fitting the gas nozzle of the welding torch. Figure 10: Injection unit 1. 2. 3. Mark the gas nozzle diameter of the welding torch. Loosen the cover (1).
This section describes how to adjust the anti-spatter fluid. Proceed as follows: 1. The parts of the system are depicted in the figure below. 2. Figure 12: Adjusting the anti-spatter fluid Hereby, the rubber gasket is "opened." The immersion depth of the welding torch is limited by the stroke of the injection unit. 3. Move the gas nozzle, with the front side toward the thrust ring. Move the welding torch further down to activate the injector function. Pay attention to the max.
10.4 Installing the wire-cutting device The parts of the system are depicted in the figure below. Figure 14: Installing the wire-cutting device Proceed as follows: 1. 2. For better access, loosen the protection plate and move it backwards. Move the welding torch to the cutting position. Pay attention to the desired stick-out length. 3. 4. Move the free wire end to the fixed cutter (at the lower cutting edge).
10.5 Attaching the cutting prism The parts of the system are depicted in the figure below. Figure 15: Installing the wire-cutting device Proceed as follows: 1. Mount the clamping prism (1) in the clamping device (5) from above. See that a clamping prism (1) that fits the gas nozzle diameter is mounted. You can find the diameter of the prism marked on the prism. 2. Attach the clamping prism with the cylinder screw (3) (tightening torque: 20 Nm). 6. 7.
This section describes how to set up the clamping position. The parts of the system are depicted in the figure below. Figure 18: Setting up the clamping position The clamping position in the direction of the milling cutter axis should be in the cylindrical part of the gas nozzle. The clamping position (5) can vary, depending on the gas nozzle type. 10.8 Setting up the compressed-air motor Set up the compressed-air motor with the aid of the figure below. Figure 19: Setting up the compressed-air motor 1.
10.9 Adjusting the height Proceed as follows: 1. The parts of the system are depicted in the figure below. Figure 20: Height adjustment 2. 3. 4. 1. 2. 3. 4. 5. Loosen the clamping screws, M8×45 (6), using an Allen key (8). Meanwhile, hold the compressed-air motor (8). Move the compressed-air motor (8) to the upper stroke position, as shown in Figure 20 (A) (the compressed-air motor can be moved into the upper stroke position manually).
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10.12 Connecting the pneumatic system For the supply, a compressed-air hose with a min. internal diameter of 6 mm is required; it is fastened to the housing by means of a screw connection (not included in the delivery). A compressed-air shutoff valve in the supply line is recommended. This allows the Robot Gun Cleaning Station to be depressurized quickly and simply, for carrying out any installation and maintenance work.
This section describes how to use the Robot Gun Cleaning Station. As the Robot Gun Cleaning Station is integrated into a welding system, the operating instructions for the welding components, such as the welding torch and robot control, must be observed during operation. Make sure that the Robot Gun Cleaning Station unit is operated with the delivered protective device only. Proceed as follows: 1. 2. 3. Switch on the robot control. Start the welding process. Stop the welding process.
14. TROUBLESHOOTING If the measures described below are not successful, please consult your dealer or the manufacturer.
15. UNMOUNTING Unmounting may only be carried out by specialist personnel. Please make sure that the shutdown procedures are strictly observed before the unmounting is started. Make sure to include also the components integrated into the welding system. Risk of injury due to unexpected start-up OPERATING MANUAL For the entire duration of maintenance, servicing, unmounting, and repair work, the following instructions must be adhered to: • Switch off the power supply. • Cut off the compressed air supply.
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