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Summary of Contents for Fronius TXi TWIN
- Page 1 Perfect Welding / Perfect Charging / / Solar Energy Operating Instructions Upright console TXi TWIN Wall-mounted console TXi TWIN Torch body changeover system 42,0426,0284,EA 004-30062020 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
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Page 3: Table Of Contents
Setup Regulations..........................Specifications for the Compressed Air Supply..................Installing the Torch Body Change Station....................Fastening the upright console TXi TWIN to the surface (foundation) ........... Mounting the wall-mounted console TXi TWIN..................Supply the torch body change station with compressed air.............. - Page 4 Troubleshooting ............................Safety..............................Troubleshooting ............................ Service, maintenance and disposal ......................Safety..............................Maintenance activities........................... Changing the O-rings in the Torch Body Coupling ................Disposal ..............................Technical data............................Upright console TXi TWIN ........................Wall-mounted console TXi TWIN......................Torch body coupling..........................Declaration of Incorporation........................
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Page 5: Safety Instructions
Safety Instructions Explanation of DANGER! Safety Instruc- tions Indicates an immediate danger. ► Death or serious injury may result if appropriate precautions are not taken. WARNING! Indicates a possibly dangerous situation. ► Death or serious injury may result if appropriate precautions are not taken. CAUTION! Indicates a situation where damage or injury could occur. -
Page 6: Intended Use
Intended Use The device must only be used for its intended purpose. Utilization for any other purpose, or in any other manner, shall be deemed to be not in ac- cordance with the intended purpose. The manufacturer accepts no liability for any damage resulting from improper use. -
Page 7: Personal Protection And Protection Of Others
If this area has to be accessed for preparatory or maintenance work, ensure that the entire system is shut down for the duration of access to this area and remains shut down to prevent unintended operation, e.g., as a result of a control error In addition to these Operating Instructions, the operating instructions and safety rules of the robot manufacturer must be followed. -
Page 8: Emf Measures
Supporting measures to avoid EMC problems: Grid power supply If electromagnetic interference occurs despite a grid connection that complies with regulations, take additional measures (e.g., use a suitable grid filter). Control lines Keep them as short as possible Route them close together (also to avoid EMF problems) Route them far from other lines Equipotential bonding Shield, if necessary... -
Page 9: Maintenance And Repair
The device must be examined at least once a week for externally detectable damage and functionality of the safety devices. Maintenance and It is impossible to guarantee that bought-in parts are designed and manufactured to meet repair the demands made of them, or that they satisfy safety requirements. Use only original spare and wearing parts (also applies to standard parts). - Page 10 Text and illustrations were accurate at the time of printing. Fronius reserves the right to make changes. The contents of the Operating Instructions shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for im- provement, or can point out any mistakes that you have found in the Operating Instruc- tions, we will be most grateful for your comments.
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Page 11: General
General Device concept The TXi TWIN is a torch body change station for twin welding systems. Two versions are available: Upright console TXi TWIN Wall-mounted console TXi TWIN Upright console Wall-mounted console The torch body change station is used: to store up to 8 torch bodies... -
Page 12: Required System Components
The OPT/i WF Twin Torch Change (4,101,171,IK) option must be installed in the twin wire- components feeder. Twin welding system with conventional robot TXi TWIN torch body change station Upright console 4,044,030 Wall-mounted console 4,044,038 Fieldbus connection (optional) ProfiNet 4,100,707... - Page 13 NOTE! Regardless of the setup of the entire welding system ► Adhere to the compressed air specifications ► Implement the compressed air supply of the torch body change station as shown Wirefeeding hose Wirefeeder WF 30i Twin Torch hosepack with torch body coupling and torch body MTB 2x500i W Wire drum Robot controller Data cable...
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Page 14: Scope Of Supply
Scope of Supply Upright Console Torch body change station Scope of Supply incl. 3 torch-body racks 2 wire cutter holders Base plate for add-on devices Compressed air maintenance unit (on the rear of the device) 4 adjusting shims, 1 mm (0.04 inch) 4 adjusting shims, 1.5 mm (0.06 inches) Not shown:... -
Page 15: Warning Notices Affixed To The Device
The symbols warn against operating the right console) equipment incorrectly, as this may result in serious injury and damage to property. Model No. Art.No. Ser.No. www.fronius.com 24 VDC 6 bar 1,5 A IP23 WARNING! Danger of serious injuries due to mechanically moving parts. During mainte- nance and servicing, keep the device de-energized and depressurized. -
Page 16: Warning Notices On The Device (Wall-Mounted Console)
The symbols warn against operating the (wall-mounted equipment incorrectly, as this may result in serious injury and damage to property. console) Model No. Art.No. www.fronius.com Ser.No. 24 VDC 6 bar IP23 1,5 A WARNING! Danger of serious injuries due to mechanically moving parts. -
Page 17: Transport
Transport Transport Equip- Transport the device using the following transport equipment: ment On a pallet using a counterbalanced lift truck On a pallet using a lift truck WARNING! Falling or toppling devices can be deadly. ► When transporting the device by counterbalanced lift truck or lift truck, secure the de- vice to prevent it from falling ►... -
Page 18: Operating Controls, Connections And Mechanical Components
Operating controls, connections and mechanical components Safety WARNING! Operating the device incorrectly can cause serious injury and damage to property. ► All functions described may only be used by trained personnel. ► Do not use the functions described here until you have fully read and understood the Operating Instructions. -
Page 19: Operating Controls, Connections And Mechanical Components Of The Wall-Mounted Console
Connection used for supplying the Fronius add-on devices with compressed air (wire cutter, welding torch cleaning devices) (13) I/O connection for add-on devices To connect the Fronius add-on devices to the torch body change station Operating con- trols, connec- tions and... - Page 20 Fixing bracket For mounting add-on devices Locking pin To manually open the pneumatic cover: Pull out the pin - the pneumatic cover can be opened To lock the cover in place, rotate the pin 90° When closing the cover, make sure the pin is back in its original position.
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Page 21: Tactile Sensor (Option)
Tactile sensor (option) General The optional tactile sensor is a teaching tool for robot integrators for measuring the torch-body racks. Applications: Before robot programming For commissioning For periodic checks For maintenance After a crash For new torch bodies IMPORTANT! The tactile sensor is intended exclusively for automated operation! The robot cell may only be entered for teaching by the user after conscious approval (access only for specialist personnel). -
Page 22: Connector Pin Assignments And Signal Descriptions
Connector pin assignments and signal descriptions Safety WARNING! Danger due to incorrect operation. This can result in severe personal injury and damage to property. ► All functions described may only be used by trained personnel. ► Do not use the functions described here until you have fully read and understood the Operating Instructions. - Page 23 Pin I/O Signal 01 O + 24 V 02 O GND 03 I Torch body sensor 1 Torch body sensor 2 04 I 05 I Torch body sensor 3 06 I Torch body sensor 4 07 I Torch body sensor 5 08 I Torch body sensor 6 Torch body sensor 7...
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Page 24: Assignment Of Fieldbus Connection For Robot Control
35 O Cut the wire electrode Reserve Reserve Assignment of CAUTION! fieldbus connec- tion for robot con- Danger of damage to the connection power supply due to overcurrent. trol ► Provide the power supply with 1.5 A fuse protection against overcurrent. NOTE! To avoid interference, keep the line length between the torch body change station and the robot controller as short as possible. - Page 25 Signal Inputs on bus | terminal Cleaning motor bottom/"Cleaning error" E17 | terminal 2.4 - 1408 Cleaning motor top E18 | terminal 2.4 - 1408 Reserve E19 | terminal 2.4 - 1408 Reserve E20 | terminal 2.4 - 1408 Reserve E21 | terminal 2.4 - 1408 Move swiveling device to the right E22 | terminal 2.4 - 1408...
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Page 26: Signal Descriptions
Signal descrip- The signals are described using the example of the standard I/O connection. The signals tions from the Profinet fieldbus are the same, but sorted differently. Signal Signal description Torch body sensor 1 Each torch body is stored in the corresponding torch-body rack Torch body sensor 2 Torch body sensor 3 Torch body sensor 4... - Page 27 Swiveling device left Signal is only available in conjunction with the Robacta Reamer V Twin: Swiveling device is positioned on the left Swiveling device right Signal is only available in conjunction with the Robacta Reamer V Twin: Swiveling device is positioned to the right Reserve for relay OUT Reserve signal for actuator (relay contact) Parting agent in the dipping bowl...
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Page 28: Assignment Of I/O Connection For Add-On Devices
Cleaning motor bottom/"Cleaning error" Signal is only available in conjunction with the Robacta Reamer V Twin and Ro- bacta TC devices. "Cleaning motor bottom" signal only on Robacta Reamer V Twin: Cleaning motor at the bottom "Cleaning error" signal only for Robacta TC devices: Error during cleaning Cleaning motor top Signal is only available on the Robacta Reamer V Twin:... -
Page 29: Before Installation And Initial Operation
Before installation and initial operation Safety Please follow the safety rules below when carrying out all the tasks described in the "In- stallation and Commissioning" chapter. WARNING! Incorrect operation and incorrectly performed work can cause serious injury and damage to property. ►... -
Page 30: Operating Personnel, Maintenance Personnel
CAUTION! Risk of injury from compressed air escaping from the torch body coupling, flying de- bris, and sharp components. ► Always wear the following protective equipment when carrying out the work described below: Safety glasses with side guards Gloves - electrically insulating and heat protective Protective helmet Operating Per- NOTE! -
Page 31: Installing The Torch Body Change Station
These mounting materials are not part of the scope of supply for the device. The installer is responsible for selecting the proper mounting materials. * Only use the adjusting shims when necessary Ground the upright console TXi TWIN The ground connection is located on the rear of the device. -
Page 32: Mounting The Wall-Mounted Console Txi Twin
Mounting the WARNING! wall-mounted console TXi TWIN Risk of serious injuries due to mechanically moving parts and escaping com- pressed air. ► Before beginning any work, disconnect the compressed air supply line for the torch body change station from the compressed air supply. -
Page 33: Supply The Torch Body Change Station With Compressed Air
Ground the wall-mounted console TXi TWIN The ground connection is located on the rear of the device. Supply the torch WARNING! body change sta- tion with com- Risk of serious injuries due to mechanically moving parts and escaping com- pressed air pressed air. -
Page 34: Installing The Torch Body Coupling
Installing the Torch Body Coupling Safety WARNING! Risk of serious injuries due to mechanically moving parts and escaping com- pressed air. Before beginning any work: ► Disconnect the compressed air supply line for the torch body change station from the compressed air supply. - Page 35 Torch body coupling closed Torch body coupling open NOTE! Always insert the torch body into the torch body coupling so that it is straight and until it reaches the stop. BY2,0201,4862 NOTE! If the torch body can be correctly locked in the torch body coupling by hand, then the torch body coupling is ready for use.
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Page 37: Setting Up The Robot
Setting up the robot General NOTE! Before starting automatic mode, set up the robot using the robot programming aid included in the scope of supply. Functions of the The notch (1) on the robot programm- robot program- ing aid represents the gas nozzle of the ming aid torch body –... - Page 38 Measure the TCP of the robot pro- gramming aid Position the robot programming aid as pictured below (= provisional position) A maximum distance of 7 mm (max. 0.26 inch) between the rear of the robot pro- gramming aid and the torch-body rack is permissible, however it must always lie directly on the torch-body rack 0°...
- Page 39 NOTE! The following positions are not permissible. 0,5° 0,5° 0° < 0,5 mm (< 0,02 inch) Position the robot programming aid as pictured below (= end position) There must no longer be a gap between the rear of the robot programming aid and the torch-body rack and it must lie directly on the torch-body rack 0°...
- Page 40 NOTE! The following positions are not permissible. 0° 0° 0,5° NOTE! If additional robots are present, set up the robots for all remaining torch-body racks...
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Page 41: Measuring The Torch-Body Racks Using The Tactile Sensor
Measuring the torch-body racks using the tactile sensor Measuring the WARNING! torch-body racks using the tactile An electric shock can be fatal. sensor During the TouchSensing process, the tactile sensor has an open-circuit voltage of up to 70 V (max. 3 A). ►... - Page 42 With min. 3 vertical movements, determine the horizontal plane of the torch-body rack until the large measuring probe touches the surface Perform straight horizontal movement to the left until the large measuring probe touch- es the left inside of the torch-body rack Perform straight horizontal movement backwards until the large measuring probe touches the rear surface Perform straight horizontal movement to the right until the large measuring probe...
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Page 43: Commissioning
CAUTION! Risk of damage due to impermissible force! ► Except for the Fronius components, there must be no other parts on or mounted on the torch body change station! ► During operation, observe the max. permissible forces in accordance with the figures below! max. -
Page 44: Program Sequence
Program sequence Safety CAUTION! Danger of damage to property. ► Only start automatic mode once the torch body change system has been installed and commissioned correctly. Speed Specifica- List of all speeds specified in the programming sequence, in the respective units: tions for the Pro- gram Sequence cm/min... -
Page 45: Program Sequence
Program Se- quence... -
Page 51: Installing Optional Equipment
Installing Optional Equipment Safety Follow the safety rules below when carrying out all tasks described in the "Options" chap- ter. WARNING! Incorrect operation and incorrectly performed work can cause serious injury and damage to property. ► All work listed in these Operating Instructions may only be performed by trained spe- cialist personnel. -
Page 52: Installing The Torch-Body Rack
CAUTION! Risk of injury from hot system components. ► Before starting work, allow all hot system components to cool to room temperature, such as: Torch body Torch body coupling CAUTION! Risk of injury from compressed air escaping from the torch body coupling, flying de- bris, and sharp components! ►... - Page 53 30 Nm NOTE! Connect the torch-body rack to the torch body change station as per the Circuit Di- agram. 30 Nm...
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Page 54: Installing The Wire Cutter
10 Nm Installing the Wire The installation procedure for the wire cutter is described using the upright console as an Cutter example. The installation procedure on the wall-mounted console is the same. Installing the Ro- bacta Reamer V Twin... -
Page 55: Installing The Coding Ring
Installing the cod- With the aid of the coding ring, up to 7 different torch bodies can be defined mechanically. ing ring Position the coding ring on the torch body using the 3 position markers Using the lower threaded pin, secure the coding ring tangentially Hexagon socket size 1.5 mm Screw in the second threaded pin until the coding ring is fixed as shown... - Page 56 The torch bodies are defined by screwing in the cylinder head screws A, B, and C diffe- rently (Hexagon socket size 2.5 mm). Symbols: Cylinder head screw is screwed in (Cylinder head screw present) IMPORTANT! Combination without screwed-in cylin- der head screws is not permitted. During operation, data must always be retrieved from all 3 sensors.
- Page 57 Insert the torch body into the torch-body rack. Position the sensor in relation to the cylinder head screw so that the sensor detects the screw, but not the coding ring (without screw). IMPORTANT! The sensor must not touch the cylinder head screw! Tighten the front jam nut size 19 mm, tightening torque = 5 Nm Tighten the rear jam nut...
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Page 58: Troubleshooting
Troubleshooting Safety Follow the safety rules below when carrying out all the tasks described in the "Trouble- shooting" chapter. WARNING! Incorrect operation and incorrectly performed work can cause serious injury and damage to property. ► All work listed in these Operating Instructions may only be performed by trained spe- cialist personnel. -
Page 59: Troubleshooting
CAUTION! Risk of injury from hot system components. ► Before starting work, allow all hot system components to cool to room temperature, such as: Torch body Torch body coupling CAUTION! Risk of injury from compressed air escaping from the torch body coupling, flying de- bris, and sharp components. - Page 60 Torch body coupling not locked correctly Cause: The coupling areas of the torch body coupling and torch neck are covered with grease/dirty/damaged Remedy: Ensure that the coupling areas are free of grease, clean, and undamaged Cause: Incorrect torch body change station/torch-body rack installation position Remedy: Torch body change station/torch-body rack must only be installed horizontally (the gas nozzle of stored torch bodies must point downwards)
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Page 61: Service, Maintenance And Disposal
Service, maintenance and disposal Safety Follow the safety rules below when carrying out all the tasks described in the "Service, Maintenance, and Disposal" chapter. WARNING! Incorrect operation and incorrectly performed work can cause serious injury and damage to property. ► All work listed in these Operating Instructions may only be performed by trained spe- cialist personnel. -
Page 62: Maintenance Activities
CAUTION! Risk of injury from hot system components. ► Before starting work, allow all hot system components to cool to room temperature, such as: Torch body Torch body coupling CAUTION! Risk of injury from compressed air escaping from the torch body coupling, flying de- bris, and sharp components. -
Page 63: Disposal
Disposal Materials should be disposed of according to valid local and national regulations. -
Page 64: Technical Data
26.08 x 13.71 x 32.89 in. Weight 43.5 kg / 95.90 lbs. Wall-mounted Supply voltage + 24 V DC console TXi TWIN Nominal pressure 6 bar/87.02 psi Standard I/O Input: + 24 V DC/ max. 1.5 A Degree of protection... -
Page 65: Declaration Of Incorporation
(technische Dokumentation) (technical documents) (technique documentation) Ing. Josef Feichtinger Ing. Josef Feichtinger Ing. Josef Feichtinger Günter Fronius Straße 1 Günter Fronius Straße 1 Günter Fronius Straße 1 A - 4600 Wels-Thalheim A - 4600 Wels-Thalheim A - 4600 Wels-Thalheim 2016 ppa. - Page 68 FRONIUS INTERNATIONAL GMBH Froniusstraße 1 A-4643 Pettenbach AUSTRIA contact@fronius.com www.fronius.com Under www.fronius.com/contact you will find the addresses of all Fronius Sales & Service Partners and locations.
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