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24

Robot Gun Cleaning Station

© Kemppi Oy 2016

1616

OPERA

TING M

ANU

AL

11.  USING THE ROBOT GUN CLEANING 

STATION

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.  Switch on the robot control.
2.  Start the welding process.
3.  Stop the welding process.

12.  WITHDRAWING THE ROBOT 

GUN CLEANING STATION FROM 

OPERATION

This section describes how to remove the Robot Gun 

Cleaning Station from service.

  As the Robot Gun Cleaning Station is integrated into a 

welding system, the details of its withdrawal from operation 

depend on the robot control. Please make sure that the 

shutdown procedures for all components integrated into 

the welding system are strictly observed. 

1.  Proceed as follows: Switch off the robot control.

13.  MAINTENANCE AND CLEANING

Scheduled maintenance and cleaning are prerequisites for 

a long service life and trouble-free operation. 

Once a month, thoroughly clean the robot mount to 

remove all dirt and welding spatter.

  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.

  Electric shock

Dangerous voltage can be produced because of defective 

cables.

•  Check all live cables and connections for proper 

installation.

•  Replace any parts that have suffered damage, 

deformation, or wear.

  The maintenance intervals listed are recommended 

values and assume single-shift operation.

•  Maintenance and cleaning work may only be 

carried out by qualified and trained specialists.

•  Always wear your personal protective clothing 

when performing maintenance and cleaning 

work.

•  When replacing the liquid-cooled A7 MIG Gun 

500-w hose assemblies, make sure that any 

coolant residues are removed from the robot 

mount.

•  The maintenance intervals listed are 

recommended values and assume single-shift 

operation.

The Robot Gun Cleaning Station unit is virtually 

maintenance-free. However, regularly cleaning and 

evaluating the mechanical parts that experience stress is 

necessary in order to maintain its value and to guarantee 

its full ability to function.

13.1  Weekly maintenance

1.  Check the condition of the milling cutter.
2.  Clean the clamping unit.
3.  Cleaning of the injection unit.
4.  Unmount the cover of the injection unit (1) and the 

thrust ring (3), and check the rubber gasket (1). See 
Section 8.2.

5.  Empty the waste container for wire rests.

13.2  Monthly cleaning

•  Clean the storage tank of the injection unit if it is 

very dirty. 

•  We recommend a monthly basic cleaning.

Summary of Contents for A7 Cooler

Page 1: ...1920660 1616 Robot Gun Cleaning Station EN OPERATING MANUAL ...

Page 2: ...n 11 9 1 The cleaning station sub assembly 11 9 2 The injection unit sub assembly 11 9 3 Wire cutting device sub assembly 12 9 4 Sub assembly accessories and options 12 10 Installing the Robot Gun Cleaning Station 13 10 1 Connecting to electricity 14 10 2 Installing the injection unit 15 10 3 Adjusting the anti spatter fluid 16 10 4 Installing the wire cutting device 17 10 5 Attaching the cutting ...

Page 3: ...ase read the manual carefully before using the equipment for the first time For your own safety and that of your work environment pay particular attention to the safety instructions in the manual For more information on Kemppi products contact Kemppi Oy consult an authorized Kemppi dealer or visit the Kemppi Web site www kemppi com The specifications presented in this manual are subject to change ...

Page 4: ...es of the user Keep the operating instructions within easy reach in the location of the device for reference and include the operating instructions when handing over the product Installation operation and maintenance work may only be carried out by qualified personnel Qualified personnel are persons who on account of their special training knowledge experience and familiarity with the relevant sta...

Page 5: ...nd respect them when installing operating and servicing the machine The welding arc and spatter The welding arc harms unprotected eyes Also be careful with reflected flashes from the arc The welding arc and spatter burn unprotected skin Use safety gloves and protective clothing Danger of fire or explosion Pay attention to fire safety regulations Remove flammable or explosive materials from the wel...

Page 6: ...isassembled bridged or otherwise bypassed During welding work outdoors use suitable protection against the weather conditions Check the electrical device for any damage and for proper functioning in accordance with its designated use Never expose the electrical device to rain and avoid damp or wet environments Protect yourself from electrical accidents by using insulating mats and wearing dry clot...

Page 7: ...gure 1 Version with a long support 1 Cleaning unit 2 Collecting tray 3 Bottle holder for anti spatter bottle 4 Support stand with base plate Figure 2 Version with a short support 1 Cleaning unit 2 Collecting tray 3 Bottle holder for anti spatter bottle 4 Support stand with flange plate ...

Page 8: ...distributor block Table 3 Pneumatic distributor block Compressed air connection G1 4 Internal width min Ø 6 mm Nominal pressure 6 bar Working pressure 6 8 bar Quality of compressed air ISO 8573 1 2010 min class 4 6 4 The electrical clamping block This section describes the Robot Gun Cleaning Station s electrical clamping block Table 4 Electrical clamping block Operating voltage internal operating ...

Page 9: ... injection unit Table 6 Injection unit Injection unit 1 liter bottle capacity Operating pressure max 6 bar Max actuation time 4 s Consumption of anti spatter fluid depends on the dosage setting 6 7 The wire cutting device This section describes the Robot Gun Cleaning Station s wire cutting device Table 7 Wire cutting device Cutting capacity at 6 bar Solid wire up to 1 6 mm Cutting time 1 0 seconds...

Page 10: ...rts and wear parts lists The contact information for consulting and for placing orders can be found on the Internet via www kemppi com 7 1 Transport The components are carefully checked and packed however damage may still occur during shipping Checking procedure on receipt of goods Check that the shipment is correct by referring to the shipping note In case of damage Check the package and componen...

Page 11: ...n optional anti spatter application 9 1 The cleaning station sub assembly The cleaning station sub assembly is depicted in the figure below 1 Motor cover 2 Compressed air motor with integrated stroke 3 Device cover 4 Injection unit 5 Collecting device 6 Anti spatter bottles with mounted bottle holder 7 Compressed air connection DN10 8 Electrical device connection 9 Wire cutting device 10 Clamping ...

Page 12: ...le 8 Sub assembly accessories Prism Anti twist fastening with a cylinder head screw M8 20 in the clamping device depending on the diameter of the gas nozzle Milling cutter Milling cutter dimensions determined on the basis of the gas nozzle and torch geometry for an immersion depth of up to 50 mm the cutter is available for all standard WH and robot torch versions Table 9 Sub assembly options Maint...

Page 13: ...below Proceed as follows 1 Connect the two hoses 4 and 8 to the applicable bottles to put the injection unit of the welding torch into operation All other connections for compressed air are pre mounted at the factory Ensure that the non return valve 6 is attached to the suction hose 4 2 Connect the device through the compressed air hose Figure 7 Installing the Robot Gun Cleaning Station 1 Return c...

Page 14: ...Connecting to electricity This section describes how to connect the Robot Gun Cleaning Station to electricity Proceed as follows 1 Connect the cleaning station of the welding torch to the power supply through an integrated plug connection The necessary control signals too are transmitted through this plug Figure 9 Electrical connection Operating voltage 1 PE 2 GND 3 24 V DC 200 mA Input 4 Clamp cl...

Page 15: ...it 2 Rubber gasket for welding torch s gas nozzle 3 Thrust ring 4 Injection unit complete 5 Adjusting screw for the dosing of anti spatter fluid Proceed as follows 1 Before you operate the device mount the rubber gasket fitting the gas nozzle of the welding torch Figure 11 Rubber gasket 1 Mark the gas nozzle diameter of the welding torch 2 Loosen the cover 1 3 Attach the rubber gasket 2 to the cov...

Page 16: ...jection unit Figure 13 Stroke movement of the injection unit Pay attention to the max stroke movement for injection The max stroke travel traversing movement of the welding torch should not exceed 6 mm We recommend a maximum injection impulse of 3 s The injection pulse is reset upon moving out of the injection unit Use the adjusting screw 8 to adjust the amount of anti adhesives per injection impu...

Page 17: ...ws 1 For better access loosen the protection plate and move it backwards 2 Move the welding torch to the cutting position Pay attention to the desired stick out length 3 Move the free wire end to the fixed cutter at the lower cutting edge 4 As soon as you have programmed the desired cutting length the protection plate must be moved forward again The gap between the fixed cutter and the protection ...

Page 18: ... 20 Nm 10 6 Mounting the milling cutter This section describes how to mount the milling cutter The parts of the system are depicted in the figure below Figure 16 Mounting the milling cutter 1 Milling cutter 2 Wrench SW17 3 Wrench SW21 4 Compressed air motor 5 Bellows 6 Motor protection cap 7 Motor output shaft Use only tools with a suitable width across flats when replacing the milling cutter Moto...

Page 19: ...re that the cylindrical part of the gas nozzle 2 rests evenly against the clamping prism 1 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 u...

Page 20: ...o be depressurized during set up Proceed as follows 1 Loosen the clamping screws M8 45 6 using an Allen key 8 Meanwhile hold the compressed air motor 8 2 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 3 Move the compressed air motor 8 upwards in the fastener 9 until the front side of...

Page 21: ...21 Robot Gun Cleaning Station Kemppi Oy 2016 1616 OPERATING MANUAL 10 10 Establishing the electrical connection Figure 21 Circuit diagram ...

Page 22: ...Y1 5 2 directional valve stroke UP DOWN Y2 5 2 directional valve for clamping cylinder CLAMP RELEASE Y2 5 2 directional valve for wire cutter ON OFF Y3 5 2 directional valve for injector ON OFF Air blast option Air blast through cable assembly ON OFF Ready Home position of the cleaning station stroke cylinder down S1 activated S1 Lift down S2 Clamping cylinder open If the operating pressure is too...

Page 23: ... 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 Figure 22 Connecting the pneumatic system ...

Page 24: ... 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 Electric shock Dangerous voltage can be produced because of defective cables Check all live cables and connections for proper installation Replace any parts that have suffered damage deformation or wear The maintenance int...

Page 25: ...witch Add more anti spatter fluid Check all supply lines leading to the cylinder and the fittings Replace directional valve Y4 Too much or too little spray mist Metering quantity incorrectly adjusted Change setting of throttle screw Too little spray mist Injection time too short Operating pressure too low Injection time greater than waiting time Check operating pressure No spray mist Operating pre...

Page 26: ...tions must be adhered to Switch off the power supply Cut off the compressed air supply Pull the power plug Observe the information given in Chapter 11 16 DISPOSAL For disposal the locally applicable regulations laws provisions standards and guidelines must be observed For the welding torch system to be properly disposed of it must be unmounted first 17 MATERIALS This product consists for the most ...

Page 27: ...And you know ...

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