ESAB Xcellerator User manual

Brand: ESAB

Model: Xcellerator

Type: User manual

Instruction manual

Original instructions

0463 623 001 US 20190219

Valid for: serial no. 815-xxx-xxxx

XCellerator

XC1300, XC2000

TABLE OF CONTENTS

0463 623 001 © ESAB AB 2019

SAFETY ....................................................................................................... 5

1.1 Meaning of symbols............................................................................... 5

1.2 Safety precautions ................................................................................. 5

1.3 General safety......................................................................................... 7

1.3.1 Standard compliance............................................................................ 8

1.3.2 Requirements of operating personnel .................................................. 8

1.3.3 Personal Protective Equipment ............................................................ 9

1.4 Installation safety ................................................................................... 9

1.4.1 Installation of safeguarding .................................................................. 9

1.5 Wiring safety ........................................................................................... 10

1.5.1 Protective ground ................................................................................. 10

1.5.2 Equipotential bonding........................................................................... 10

1.6 Releasing a person trapped in or by the machine .............................. 10

1.7 Decommissioning, storage, and disposal ........................................... 10

1.8 Safety layout ........................................................................................... 11

1.9 Safety....................................................................................................... 11

1.9.1 Manufacturer ........................................................................................ 11

1.9.2 Health and safety regulations............................................................... 12

1.9.3 Arc safety ............................................................................................. 13

1.9.4 Maintenance......................................................................................... 14

1.9.5 Guarantee ............................................................................................ 14

1.9.6 Installation ............................................................................................ 14

1.9.7 Manual operation.................................................................................. 15

INTRODUCTION.......................................................................................... 16

2.1 Intended use ........................................................................................... 16

2.2 Equipment............................................................................................... 16

TECHNICAL DATA ...................................................................................... 17

3.1 Functional specifications ...................................................................... 17

3.1.1 Parameter setting ................................................................................. 17

3.1.2 Position................................................................................................. 17

3.2 Technical data......................................................................................... 17

3.3 Calculating offset ................................................................................... 18

INSTALLATION............................................................................................ 20

4.1 Lifting instructions ................................................................................. 20

4.1.1 Using a forklift....................................................................................... 20

4.2 Mounting ................................................................................................. 21

4.2.1 Rough setting ....................................................................................... 22

4.2.2 Anchoring ............................................................................................. 25

4.2.3 Connecting the exhaust system ........................................................... 26

4.2.4 Connecting ........................................................................................... 26

4.2.5 Mounting optional equipment ............................................................... 27

TABLE OF CONTENTS

0463 623 001 © ESAB AB 2019

4.3 Wiring ...................................................................................................... 27

4.3.1 Connection to robot controller .............................................................. 27

4.4 Safety components ................................................................................ 29

4.5 Before first start ..................................................................................... 30

4.5.1 Parameter setting ................................................................................. 30

4.5.2 Initial test .............................................................................................. 30

4.6 Ambient conditions ................................................................................ 30

4.7 External supply....................................................................................... 31

4.7.1 Voltage ................................................................................................. 31

4.7.2 Pneumatic (Option) .............................................................................. 31

OPERATION ................................................................................................ 32

5.1 Measures before start ............................................................................ 32

5.2 Starting the robot on the programming pendant ................................ 33

5.3 Release of persons trapped in the XCellerator ................................... 33

5.4 Positioning safety components ............................................................ 36

5.5 Function safety system ......................................................................... 36

5.6 Stops........................................................................................................ 36

5.7 Emergency stop ..................................................................................... 37

5.8 Safety stop .............................................................................................. 37

5.9 Control panel .......................................................................................... 38

5.10 Programming pendant ........................................................................... 38

MAINTENANCE........................................................................................... 41

6.1 General .................................................................................................... 41

6.2 Maintenance............................................................................................ 41

6.2.1 Maintenance schedule for the XCellerator Base .................................. 41

6.2.2 Maintenance positions 0459990668 and 0459990670......................... 42

6.2.3 Maintenance positioner V2TR-500D5 .................................................. 44

6.2.3.1 Check current transfer unit and ground disc ..................................... 45

6.2.3.2 Check tension of timing belt .............................................................. 45

6.3 Servo units.............................................................................................. 46

6.3.1 General................................................................................................. 46

6.3.2 Reduction gear ..................................................................................... 46

6.3.3 AC Servo .............................................................................................. 46

TROUBLESHOOTING................................................................................. 47

7.1 Error messages ...................................................................................... 47

7.2 Outline of alarm ...................................................................................... 47

7.3 Service contact information .................................................................. 48

7.3.1 Contact information .............................................................................. 48

ORDERING SPARE PARTS ........................................................................ 50

DIMENSIONS....................................................................................................... 51

WORKING AREAS .............................................................................................. 52

TABLE OF CONTENTS

0463 623 001 © ESAB AB 2019

FIXTURES............................................................................................................ 53

ACCESSORIES ................................................................................................... 54

WEAR PARTS...................................................................................................... 56

Rights reserved to alter specifications without notice.

1 SAFETY

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1 SAFETY

1.1 Meaning of symbols

As used throughout this manual: Means Attention! Be Alert!

DANGER!

Means immediate hazards which, if not avoided, will result in immediate,

serious personal injury or loss of life.

WARNING!

Means potential hazards which could result in personal injury or loss of life.

CAUTION!

Means hazards which could result in minor personal injury.

WARNING!

Before use, read and understand the instruction manual

and follow all labels, employer's safety practices and

Safety Data Sheets (SDSs).

1.2 Safety precautions

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who

works on or near the equipment observes all the relevant safety precautions. Safety

precautions must meet the requirements that apply to this type of equipment. The following

recommendations should be observed, in addition to the standard regulations that apply to

the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the

equipment. Incorrect operation of the equipment may lead to hazardous situations, which

could result in injury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

○ its operation

○ the location of emergency stops

○ its function

○ the relevant safety precautions

○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:

○ no unauthorized person is within the working area of the equipment when it is

started up

○ no-one is unprotected when the arc is struck or work is started with the

equipment

3. The workplace must:

○ be suitable for the purpose

○ be free from drafts

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4. Personal safety equipment:

○ Always wear recommended personal safety equipment, such as safety glasses,

flame-proof clothing, safety gloves

○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which

could become trapped or cause burns

5. General precautions:

○ Make sure the return cable is connected securely

○ Work on high voltage equipment may only be carried out by a qualified

electrician

○ Appropriate fire extinguishing equipment must be clearly marked and close at

hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

WARNING!

Arc welding and cutting may cause injury to yourself and others. Take precautions

when welding and cutting.

ELECTRIC SHOCK - Can kill

• Install and ground the unit in accordance with instruction manual.

• Do not touch live electrical parts or electrodes with bare skin, wet gloves,

or wet clothing.

• Insulate yourself from work and ground.

• Ensure your working position is safe

ELECTRIC AND MAGNETIC FIELDS - Pose health risks

• Welders with pacemakers fitted should consult their doctor before welding.

EMF may interfere with some pacemakers.

• Exposure to EMF may have other health effects which are unknown.

• Welders should use the following procedures to minimize exposure to

EMF:

○ Route the electrode and work cables together on the same side of

your body. Secure them with tape when possible. Do not place your

body between the torch and work cables. Never coil the torch or work

cable around your body. Keep the welding power source and cables

as far away from your body as possible.

○ Connect the work cable to the workpiece as close as possible to the

area being welded.

FUMES AND GASES - Can be dangerous to your health

• Keep your head out of the fumes.

• Use ventilation, extraction at the arc, or both, to take fumes and gases

away from your breathing zone and the general area.

ARC RAYS - Can injure eyes and burn skin

• Protect your eyes and body. Use the correct welding screen and filter lens

and wear protective clothing.

• Protect bystanders with suitable screens or curtains.

NOISE - Excessive noise can damage hearing

Protect your ears. Use ear defenders or other hearing protection.

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MOVING PARTS - Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have only

qualified people remove covers for maintenance and troubleshooting as

necessary. Reinstall panels or covers and close doors when service is

finished and before starting engine.

• Stop engine before installing or connecting unit.

• Keep hands, hair, loose clothing and tools away from moving parts.

FIRE HAZARD

• Sparks (spatter) can cause a fire. Make sure there are no inflammable

materials nearby.

• Do not use on closed containers.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding and allied processes.

CAUTION!

Class A equipment is not intended for use in residential

locations where the electrical power is provided by the

public low-voltage supply system. There may be

potential difficulties in ensuring electromagnetic

compatibility of class A equipment in such locations,

due to conducted as well as radiated disturbances.

NOTE!

Dispose of electronic equipment at a recycling

facility!

To conform with the European Directive 2012/19/EC on

Waste Electrical and Electronic Equipment and its

implementation in accordance with national law,

electrical and/or electronic equipment that has reached

the end of its life must be disposed of at a recycling

facility.

As the person responsible for the equipment, it is your

responsibility to obtain information on approved

collection stations.

For further information contact the nearest ESAB dealer.

ESAB has an assortment of welding accessories and personal protection equipment

for purchase. For ordering information, contact your local ESAB dealer or visit us on

our website.

1.3 General safety

This machinery fulfills all relevant provisions of Directive 2006/42/EC on machinery.

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This machinery also fulfills all relevant provisions of Directive 2004/108/EC on

electromagnetic compatibility (EMC).

The "EC-Declaration of conformity" with the subsequent CE-marking attached to this

machinery is only valid if this machinery is installed according to the installation instructions

in this manual.

YASKAWANordicAB's is not responsible for errors or safety risks that may occur with

equipment connected to and/or installed on the machine, nor errors or safety risks that may

occur on the machine caused by equipment connected to and/or installed on the machine.

1.3.1 Standard compliance

This machine is developed and manufactured according to all relevant provisions of the

following harmonized standards:

• EN349:1993+A1:2008 Safety of machinery — Minimum gaps to avoid crushing of parts

of the human body

• EN574:1996+A1:2008 Safety of machinery — Two-hand control devices — Functional

aspects — Principles for design

• EN953:1997+A1:2009 Safety of machinery — Guards — General requirements for the

design and construction of fixed and movable guards

• ENISO13849-1:2008 Safety of machinery — Safety-related parts of control systems

— Part1: General principles for design

• ENISO13849-2:2012 Safety of machinery — Safety-related parts of control systems

— Part2: Validation

• ENISO13855:2010 Safety of machinery — Positioning of safeguards with respect to

the approach speeds of parts of the human body

• EN 1037:1995+A1:2008 Safety of machinery — Prevention of unexpected start-up

• ENISO10218-1:2011 Robot and robotic devices — Safety requirements for industrial

robots — Part1: Robots

• ENISO10218-2:2011 Robot and robotic devices — Safety requirements for industrial

robots — Part2: Robot system and integration

• ENISO12100:2010 Safety of machinery — General principles for design — Risk

assessment and risk reduction

• ENISO13850:2008 Safety of machinery — Emergency stop — Principles for design

• ENISO13857:2008 Safety of machinery — Safety distances to prevent hazard zones

being reached by upper and lower limbs

• EN 60204-1:2006+A1:2009 Safety of machinery — Electrical equipment of machines —

Part1: General requirements

• EN 61000-6-2:2005+AC:2005 Electromagnetic compatibility (EMC) –Part6-2: Generic

standards – Immunity for industrial environments

• EN 61000-6-4:2007+A1:2011 Electromagnetic compatibility (EMC) – Part6-4: Generic

standards – Emission standard for industrial environments

1.3.2 Requirements of operating personnel

The machine must only be operated by specially trained persons.

General

Operating personnel must not be under the influence of alcohol, drugs, or similar substances.

Operating personnel must not have a restricted field of vision or be restricted in any other

way that could lead to risks. Operating personnel must be in a suitable state of health to

operate the system/component (attention must be paid in particular to medical aids, such as

pacemakers, etc.

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Qualified personnel

Persons involved in commissioning, operation, maintenance, and repair of the

system/component must be familiar with the system/component and trained accordingly.

They must have read and understood the operating manuals. Furthermore, they must be

instructed and must be able to avoid possible residual risks to themselves and others while

working on the system/ component or to reduce such risks as much as possible. To maintain

the qualification, the safety instruction must be repeated at least every year.

1.3.3 Personal Protective Equipment

WARNING!

Use Personal Protective Equipment (PPE), such as safety shoes, helmet, goggles,

hearing protection, and gloves, appropriate for the type of operation being carried

out, in order to reduce risk of personal injury.

WARNING!

Use hearing protection to reduce the level of noise exposure when the machine is

running.

1.4 Installation safety

WARNING!

• Install the safeguarding

Failure to observe this warning may result in injury or damage.

• Do not start the machine or turn ON the power before it is firmly anchored.

The machine may overturn and cause injury or damage.

• Do not install or operate a machine that is damaged or lacks parts.

Failure to observe this warning may cause injury or damage.

• Do not start the machine or turn ON the power before the exhaust system is

connected.

Exhaust gases in workshops are a health hazard.

NOTE!

Important

Install the machine in a location so that the installation into which it is incorporated

complies with the regulations of Machinery Directive 2006/42/EC.

Failure to observe this warning may result in injury or damage.

Read

When installing, it is necessary to observe environmental conditions

requirements. See chapter 4.2Mounting.

1.4.1 Installation of safeguarding

Installing the safeguarding ensures safety and prevents unforeseen accidents for personnel

and damage to equipment. The following excerpt is for your information and guidance:

Responsibility for safeguarding (ENISO10218-2:2011)

The user of a machine or complete system shall ensure that safeguarding is provided and

used in accordance with sections 5, 6, and 7 of ENISO10218-2:2011 Robots and robotic

devices - Safety requirements for industrial robots — Part2: Robot systems and integration.

The means and degree of safeguarding, including any redundancies, shall correspond

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directly to the type and level of hazard presented by the machine system consistent with the

application. Safeguarding may include, but not be limited to safeguarding devices, barriers,

interlock barriers, perimeter guarding, awareness barriers, and awareness signals.

1.5 Wiring safety

WARNING!

Before wiring, turn OFF the primary power supply and put up a warning sign. (e.g.

"DO NOT TURN THE POWER ON".) Failure to observe this warning may result in fire

or electric shock.

WARNING!

Wiring must be performed by authorized or certified personnel. Failure to observe this

warning may result in fire or electric shock.

Important

Keep equipotential bonding and protective grounding separated. Equipotential bonding and

protective grounding are two separate circuits.

1.5.1 Protective ground

WARNING!

Protective grounding must be performed following standard EN 60204-1. Failure to do

so may result in severe incidents.

1.5.2 Equipotential bonding

The wire must be chosen according to standard EN60204-1. For equipotential bonding,

connect the wire directly to the frame of the machine.

NOTE!

Never share this line with other ground lines or grounding electrodes for other

electric power, motor power, welding devices, etc.

1.6 Releasing a person trapped in or by the machine

Read

For instructions on "Releasing a person trapped in or by the machine," see section 5.3

Release of persons trapped in the XCellerator.

1.7 Decommissioning, storage, and disposal

Decommissioning must comply with all applicable local and national standards at the time of

decommissioning. The unit must be decommissioned, stored, and disposed of in accordance

with applicable national laws, regulations, and standards.

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1.8 Safety layout

1. Reset emergency stop "MACHINE ON"

Air and safe power supply on

5. Door

2. Control cabinet main switch 6. Safety reset

3. Emergency stop 7. OP-panel

4. Valve air shut-off

1.9 Safety

The machine is designed for arc welding and must work together with a fixture.

YASKAWANordicAB's is not responsible for errors or safety risks that may occur with

equipment connected to and/or installed on the machine, nor errors or safety risks

that may occur on the machine caused by equipment connected to and/or installed on

the machine.

The machine must only be operated by personnel with sufficient knowledge and skills.

It is prohibited for any person to stay inside the safety guarding when the machine is

in operation.

1.9.1 Manufacturer

Address: YASKAWANordicAB

POBox504

SE-38525Torsås

Verkstadsgatan2

Phone: +46 480 417 800

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Fax: +46 486 414 10

Machine type: See machinery sign

Machine no.: See machinery sign

Year of manufacture: See machinery sign

1.9.2 Health and safety regulations

All machines can be dangerous if they are operated incorrectly. Therefore, it is of utmost

importance that all users of the machine fully read, understand, and observe the following

safety precautions and warnings. Read these instructions periodically.

All safety precautions have been observed in the manufacture of this equipment. However,

all risks cannot be compensated for; otherwise the working capabilities of the machine would

be limited.

All equipment has been assembled and tested by YASKAWANordicAB's personnel. If the

equipment is properly installed and connected, it will work properly. In the unlikely event of a

malfunction, contact our service organization before making any attempt to modify the

machinery.

Basic safety precautions should always be followed to reduce the risk of fire, electric shock,

and personal injury.

WARNING!

Observe and follow local safety regulations.

Unauthorized persons must not operate the machine.

Do not leave the machine unattended during operation. Ensure that all users of the

machine have read and understood the information in this document.

Safe use of the machine involves:

• The operator

• The machine

• The use of the machine

The operator

The operator must be in good physical condition and not under the influence of any

substance that might impair their vision, dexterity, or judgment. Do not use the machine if you

are fatigued, as you may lose control of the machine. Be alert at all times.

Working with any machine can be strenuous if the operator suffers from an illness that might

be aggravated by strenuous work. Check with your doctor before operating your system.

Work clothing

Clothing must be sturdy and well fitting, yet allow complete freedom of movement. Do not

wear loose clothing, loose sleeves or cuffs, scarves, necklaces, rings, or other items that may

become caught in the machine. Long hair should be tied back.

Good footwear is important as a safety precaution. Wear sturdy boots with non-slip soles.

Steel-toe safety boots are recommended.

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1.9.3 Arc safety

Noise

WARNING!

Noise generated by the welding process may exceed limits.

The noise generated by the arc can reach high levels. Prolonged exposure may

damage your hearing. Always wear hearing protection.

YASKAWANordicAB has measured the emission of airborne noise according to the

Machinery directive.

Operation <85dB(A)

Stand by <70dB(A)

Glare

WARNING!

The light created by the arc contains IR and UV radiation. Exposure to IR and UV

radiation damages eyes and skin. The effect of the radiation increases at closer

proximity to the arc.

Use protective shields and curtains to block this radiation. When examining the arc,

always use a welding shield of sufficient strength and protect any exposed skin with

sturdy clothing.

Heat and fire

CAUTION!

Working with an arc will scintillate hot particles. Always wear protective gloves when

handling the workpiece.

Check fire extinguisher regularly.

Use fire extinguisher suitable for textile, inflammable liquids, electricity

Do not store inflammable material or liquids near the machine.

Emission of gases

The machine does not emit gases. Emitted gases are the result of the welding process and

are generated by the protective gas, wire, and material used.

It is the customer's obligation to evacuate any possible gases.

Air pollution

The arc will generate smoke and fumes. Avoid exposure to fumes generated by heating the

material. Sufficient ventilation is required to evacuate any fumes, and a protective mask must

be used when working near the arc.

Material containing any of the following elements may produce unhealthy amounts of

dangerous fumes: lead, cadmium, zinc, chrome, nickel, mercury, or beryllium.

Machine safety

The machine is tested as a separate unit by YASKAWANordicAB's personnel in accordance

with the Essential Health and Safety Requirements.

Warning signs

The following sign is applied to the machine and must be respected. Location, see figure in

chapter 5.1Measures before start.

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WARNING!

There are high-voltage parts in the equipment that present a risk of electric shock,

which may result in death or severe injury.

1.9.4 Maintenance

Do not modify a YASKAWANordicAB machine in any way. Use spare parts from

YASKAWANordicAB or from a supplier expressly approved by YASKAWANordicAB for your

machine. Using parts from other suppliers may affect the safety or functionality of the

machine.

Recommended service is stated in the documentation.

WARNING!

Do not clean, lubricate, or adjust the machine while it is in operation. Turn off the

main power first.

NOTE!

Keep your eyes open — that's your best protection to avoid accidents.

1.9.5 Guarantee

Do not store these operating instructions without having first read them carefully, and insist

that the operators of this machine also read them thoroughly. They are for your own safety!

This information contains operating and safety instructions for this YASKAWANordicAB

machine.

This machine is intended for high-production capacity. Therefore, strict safety regulations

must be observed in order to reduce the risk of accidents and physical damage.

Carelessness or inappropriate use of the machine may result in severe or even fatal

accidents. Avoid unnecessary disturbances by following the guidelines and safety

precautions provided in this manual.

The machine will only operate correctly if the operator follows the information and

instructions provided in the operating manuals.

YASKAWANordicAB provides a guarantee for this machine. The guarantee is valid

according to the signed contract, beginning on the day of installation. The guarantee is only

valid if genuine spare parts from YASKAWANordicAB are used exclusively.

In order to correctly and promptly order spare parts, please provide the following information:

• Machine type

• Machine no.

• Part no.

• Number of parts

• Voltage information, when applicable

See 8Ordering spare parts and optional equipment.

Changes to robot jobs might cause damage to the machine and may only be done by

specially trained personnel.

1.9.6 Installation

Refer to the installation and service manuals for each machine and unit included in this

documentation. Also see 4Installation.

Following installation, a complete check of all safety functions must be performed.

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Pneumatic system

Be careful when connecting the pneumatic system to the main supply, as valves, cylinders,

and tools may move unexpectedly.

1.9.7 Manual operation

When resetting a robot, it is of utmost importance that it be performed accurately. If in doubt,

ask a service engineer or trained personnel.

WARNING!

The highest precautions must be taken when running the machine in TEACH mode.

Passing program steps or setting IN/OUT signals in the robot job may cause loss of

interlocking function, i.e. the fixtures and positioner may lose balance, the fixture

may be released, or the setting may be lost. This may cause severe damage to

machinery as well as personal injuries.

If the robot is set to a physical position other than the position for the actual step in the job,

the robot will move at high speed to the next position when PLAY - START mode is selected.

2 INTRODUCTION

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2 INTRODUCTION

2.1 Intended use

XCellerator is designed to be equipped with fixtures and to be incorporated into machinery

controlled by a robot controller system. The machine is intended to assist welding robots by

shifting workpieces.

2.2 Equipment

XCellerator is supplied with:

• XCellerator Base

• Positioner with two stations

• Wheel kit

• MOTOMAN-MA1440 (XC1300) MA2010 (XC2000) industrial robot

• Assembly kit for robot controller

• Cable set between positioner and robot controller

• Instruction manual

• Declaration of Conformity

Main parts

• Housing

• Rotating table

• MA1440 Robot (only for XC1300)

• MA2010 Robot (only for XC2000)

The positioners can be equipped at different distances between fixture discs.

Optional equipment

• Welding equipment for MIG/MAG welding

• Media transfer (signal, air, current) for the positioner

• Fixed table or 3-axis positioner (depending on the selected type and design)

• Interior door and cabinet located on the opposite side (left or right)

• MotoWeb for remote supervision and administration

• MotoSim with kinematic simulation

• Beacon light

• Machine foot kit

• Signal and air transmission unit for HM/TM modules

• Additional power supply for HM/TM modules

• Retro fit bracket for HM/TM modules

3 TECHNICAL DATA

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3 TECHNICAL DATA

3.1 Functional specifications

Version Note

XC1300 L=1300

XC2000 L=2000

3.1.1 Parameter setting

NOTE!

The positioner's parameter setting is not included in manuals because it is subject to

change. See the positioner's part number for the correct MMS document.

3.1.2 Position

Repetitive position accuracy: ±0.004in (±0.1mm)

3.2 Technical data

Maximum load and capacity

XC1300/XC2000

Centerrotatingaxis

XC1300/XC2000 Tiltingaxis

Dynamic torque 1307lb-ft (1772Nm) 868.1lb-ft (1177Nm)

Static torque 1045.1lb-ft (1417Nm) 694lb-ft (941Nm)

Max. capacity load 1102.3lb (500kg)

Max. offset 0.50ft (0.15m)

Motor power 3.0kW 1.3kW

Gear ratio reducer 119:1 165:1

Gear ratio total 119:1 165:1

Efficiency 0.82 0.81

Nominal speed 12.6rpm 9.0rpm

Max. speed 16.8rpm 23.5rpm

Temperature 32to104°F(0to+40°C)*

Humidity 20to80%RH at constant temperature**

Vibration acceleration

4.9m/s

(0.5g) or less

Main supply See the requirements for the robot controller system in its

installation/instruction manual.

Pneumatic compressed air specification (option)

Working pressure 87psi (0.6MPa)

Minimum pressure 72.5psi (0.5MPa)

Quality According to ISO8573-1, Class 5,4,3

Welding capacity (standard single carbon brush)

Continuous duty 100% 350A

Continuous duty 60% 460A

3 TECHNICAL DATA

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*This option is only available for the XC2000.

**The ambient conditions are general requirements if no specific equipment, such as an IP

kit or similar, allows for certain extreme environments or conditions.

• Free from corrosive gas, liquid, or explosive gas

• Free from exposure to water or oil

• Free from abnormal exposure to dust

• Free from excessive electrical noise (plasma)

• Located indoors

2×rotate, 2×tilt with central turntable axis Rotating axis Tilting axis

Dynamic torque 669lb-ft (907Nm) 1189lb-ft (1612Nm)

Static torque 535.5lb-ft (726Nm) 981lb-ft (1330Nm)

Max. capacity load 1102.3lb (500kg) 1102.3lb (500kg)

Max. offset 0.5ft (0.145m) 0.89ft (0.270m)

Motor power 1.3kW 2.0kW

Gear ratio spur 90/40

Gear ratio reducer 59:1 171:1

Gear ratio total 132.75:1 171:1

Efficiency 0.7 0.82

Nominal speed 11.3rpm 10.6rpm

Max. speed 30rpm 23.4rpm

The machine should not be overloaded to ensure long and safe operation with high

positioner accuracy. Follow the restrictions.

3.3 Calculating offset

Calculating offset

(Max. static torque of axis in Nm)

--------------------------------------------- =X Max. offset of axis in m

(M Max. payload in kg × 9.81)



Maximum x-offset rotating axis HM-500D

Maximum static torque of rotating axis = 941Nm.

M Maximum payload 500kg (incl. fixtures).

X Maximum offset from rotation center at 500kg = 191mm.

3 TECHNICAL DATA

0463 623 001

- 19 -



Maximum x-offset rotating axis V2TR-500D5

Maximum static torque of rotating axis = 726Nm.

M Maximum payload 500kg (incl. fixtures).

X Maximum offset from rotation center at 500kg = 145mm.

4 INSTALLATION

0463 623 001

- 20 -

4 INSTALLATION

4.1 Lifting instructions

Read

Read and understand the contents of chapter1. Safety before handling the

machine.

WARNING!

Crane operation and forklift truck operation must be only performed by authorized

personnel. When handling the positioner:

• Do not place any part of your body under a suspended machine.

• Do not move the machine over another person's body.

Careless handling can result in severe personnel injury.

4.1.1 Using a forklift

CAUTION!

Transport the machine carefully, as the side walls are easily damaged.

NOTE!

The XCellerator cannot be lifted by a crane.

To lift the machine, use a fork lift with its forks in their outer position. Insert the forks in the

beams and lift the machine as shown in the Lifting instructions illustration. Anchor the

machine and transport it slowly with due caution in order to avoid overturning or slippage.

Using the included wheel kit, the machine can be transported using a hand pallet truck with a

lifting capacity of at least 8818.5lb (4metrictons).

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ESAB Xcellerator User manual

ESAB Xcellerator User manual

ESAB Xcellerator User manual

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