OPERATING MANUAL 1920630 1712 EN Robot Gun Mount T1
CONTENTS Robot Gun Mount T1.. . . . . . . . . . . . . . . . . . . . . . . . ................................................. 3 Preface. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................. 3 Identification.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................. 4 CE marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROBOT GUN MOUNT T1 2. This document provides product information for the Kemppi Robot Gun Mount T1 unit. 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. Kemppi Robot Gun Mount T1 is used in industry and in the trade for connecting the gun neck to a robot equipped with central media guidance. It is available for gas-cooled guns (A7 MIG Gun 500-g) and liquid-cooled guns (A7 MIG Gun 500-w) by means of different adapter flanges. These instructions describe Kemppi Robot Gun Mount T1 only. The Kemppi robot mount must only be operated as supplied or equipped with authentic Kemppi spare parts.
.4 Signs used in the documentation 5.6 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 Cables Note: These 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 This chapter contains the technical data for the gun mount. 6.5 General data 6.1 Ambient conditions The table below presents the general torch data in line with EN 60 974-7.
6.6 Product-specific gun data 6.8 The type plate The following table applies to the entire Kemppi gun system, including gun neck, gun mount and cable assembly. The table below presents product-specific gun data in line with EN 60 974-7. Robot Gun Mount T1 is identified by a sticker or a Kemppi logo. When contacting the service staff, please remember to check the production stamp near the Kemppi logo.
8. DELIVERY SCOPE The delivery for a gas-cooled gun includes the following components: • Kemppi Robot Gun Mount T1 • Operating instructions • Screwdriver for hexagon-head screws, wrench size 2.5 • Sealing grease, silicone-free, 10 g can • Certificate of conformity • Cylinder-head screws, M4×10 (6 pcs.) The delivery for a water-cooled gun includes the following components: • Kemppi Robot Gun Mount T1 • Operating instructions • Certificate of conformity • Cylinder-head screws, M4×10 (6 pcs.
11. ROBOT GUN MOUNT T1 INSTALLATION The Kemppi Robot Gun Mount T1 unit is used for accommodating the welding guns in the exact position needed. The mount is fastened to the robot with cylinder-head screws and a robot flange. In order to cover the required performance ranges, there are two distinct mount versions available, the gas-cooled A7 MIG Gun 500-g and the water-cooled A7 MIG Gun 500-w.
.2 Fastening robot mount T1 to the robot Proceed as follows: 1. The parts of the system are depicted in the figure below. Figure 5: Fastening robot mount T1 to the robot Ensure correct positioning of the cylindrical pin (6). It specifies the reference position, relative to the robot. 2. 1 2 5 3 Mount robot flange (2) on the robot (5), using six cylinder screws (4), with max. tightening torque M = 3.5 Nm. Mount the robot mount (1) on the robot flange (2), using six cylinder screws (7), with max.
11.3 Mounting the corrugated hose clamp 11.3.1 Motoman® models 11.3.2 ABB®, Reis®, and OTC® models This section describes how to mount the corrugated hose clamp on Motoman® robots. This section describes how to mount the corrugated hose clamp on ABB®, Reis®, and OTC® models. The parts of the system are depicted in the figure below. The figure below refers to ABB® models.
11.4 Mounting the hose assembly on the robot Figure 8: Mounting the A7 MIG gun cable assembly 2 When mounting liquid-cooled A7 MIG Gun 500-w and cable assemblies, make sure that the mounting bores for the water nipples and the O-rings are lubricated. • When mounting liquid-cooled A7 MIG Gun 500-w and cable assemblies, make sure that the water nipples in the welding gun coupling for the A7 MIG Gun 500-w and cable assembly are inserted correctly into the cable assembly adapter.
5. 6. Screw the pull-in tool (1) into the cable assembly connection (4) as far as it will go. Pull the cable assembly through the 5th and 6th axes of the robot into the robot mount as far as it will go, using the pull-in tool. Figure 9: Movement allowance 1 2 3 7. Secure the fastening screw (14), with max. tightening torque M = 7.5 Nm. Observe the forced positioning. Only if the cable assembly connection (4) has been correctly inserted can it be attached with the fastening screw (14). 8. 9. 1. 2.
11.5 Mounting the liner 11.7 Attaching the A7 MIG W gun neck New liners have to be shortened to the actual length of the cable assembly. • For handling the liners, please observe the enclosed wire guide liner mounting instructions. • Strip 350 mm of the insulation sheathing of the liner from the front end after determining the correct length. This section describes how to attach the A7 MIG W gun neck. Figure 11: Attaching the A7 MIG W gun neck 11.
14. MAINTENANCE AND CLEANING The device may only be operated by qualified personnel. Because the robot mount is integrated into the gun’s welding process, the operation steps are performed after the relevant gun has been installed. Please observe the operating instructions for the A7 MIG Gun 500-g or the A7 MIG Gun 500-w welding guns, as appropriate. 13. UNMOUNTING Unmounting may only be carried out by specialist personnel.
14.1 Cleaning robot mount T1 with A7 MIG Gun 500-g Figure 12: Cleaning robot mount T1 with A7 MIG Gun 500-g 4 5 8 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 1 2 3 7 6 Bellows Cover ring O-ring, 28×1.5 2 set screws Robot mount T1 Screw Washer Fastening screw Threaded sleeve Proceed as follows: 1. 2. Clean (5) with compressed air. Unscrew the threaded sleeve (9), and pull it off, together with the bellows (1). 3. Turn the cover ring (2) to the right as far as it will go, and remove it. 4.
14.2 Cleaning robot mount T1 with A7 MIG Gun 500-w Proceed as follows: This section describes how to clean robot mount T1 with A7 MIG Gun 500-w. Pull off the retaining ring (13), together with the bellows (14). Check the O-ring (1) for wear, and replace it if necessary. Before replacing, grease the O-rings (1) with sealing grease (included in the delivery). 3. Remove the screw (10), washer (11), and fastening screw (12), and clean them, as a single assembly, with compressed air. 4.
15. TROUBLESHOOTING Risk of injury due to unexpected start-up In the event of any doubts or problems, please contact your retailer or the manufacturer. Please also consult the operating instructions for the other welding components, such as the power supply and air pressure line. Problem Cause Solution Emergency stop signal Cable assembly connected incorrectly See Section 11.
16. REMOVING THE MOUNT Unmounting may only be carried out by specialist personnel. Please make sure that the shutdown procedures are strictly observed before the unmounting work begins. Ensure this also for the components integrated into the welding system. 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.
Robot gun mount Product code Robot Gun Mount T1 W SP600588 Robot Gun Mount T1 G SP600589 Accessories Product code Pull-in tool SP600602 OPERATING MANUAL 17. CODES FOR ORDERING The pull-in tool accessory serves for the correct mounting of cable assemblies. The O-rings at the rod of the pull-in tool indicate the mounting positions of cable assembly versions A7 MIG Gun 500-g and A7 MIG Gun 500-w. The pull-in tool must only be used for Robot Gun Mount T1.
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