Table of Contents
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Summary of Contents for Fronius Drive EasyTwin
- Page 1 Perfect Welding / Perfect Charging / / Solar Energy Operating Instructions Drive EasyTwin System extension 42,0426,0194,EN 005-25052020 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
- Page 3 Thank you for the trust you have placed in our company and congratulations on buying this high-quality Fronius product. These instructions will help you familiarise yourself with the product. Reading the instructions carefully will enable you to learn about the many different features it has to offer.
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Page 5: Table Of Contents
Installing the CrashBox Drive EasyTwin on the robot................Attaching the torch neck ........................Securing the hosepack to the spring balancer suspension devices ............. Connecting the hosepack ........................Installing the wirefeeding hose in the Robacta Drive EasyTwin ............Threading the welding wire ........................Safety rules ..............................General .............................. - Page 6 Alignment of welding torch relative to the workpiece for fillet welds ............. Alignment of welding torch relative to the workpiece for lap joints............Area of application for Drive EasyTwin - steel, diameter 1.2 mm - 1.0 mm .......... Welding technology options ........................
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Page 7: Installation And Commissioning
Installation and commissioning Standard and The welding wire can be fed in two different ways with the Drive EasyTwin process. PowerLiner vari- ants With the Standard variant, the welding wire is fed from the drum in the direction of the Ro- bacta Drive EasyTwin by means of a wirefeeder. -
Page 8: Installing The Crashbox Drive Easytwin On The Robot
Installing the CrashBox Drive EasyTwin on the robot... -
Page 9: Attaching The Torch Neck
Attaching the Possible tilt angles: torch neck x = 5° / 25° / 45° / 65° Securing the Secure the hosepack to the spring ba- hosepack to the lancer suspension devices using Vel- spring balancer cro® fasteners suspension de- In the case of a 6 m hosepack > vices use at least 3 suitably positioned spring balancer suspension devi-... -
Page 10: Connecting The Hosepack
Connect the compressed air line to the control box Connect the gas feed to the control box (min. 30 l/min) Installing the The wirefeeding hose must only be fitted when using the device for the first time. wirefeeding hose in the Robacta Drive EasyTwin... -
Page 11: Threading The Welding Wire
Now the welding wire must be threaded (see "Threading the welding wire" from Figure 3 on page 12) Threading the NOTE! welding wire For technical reasons, only the inner liners provided in the original equipment kit must be used. - Page 12 * Fully open...
- Page 13 *** Set the contact pressure (3 rings must be visible)
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Page 15: Safety Rules
Safety rules General The device is manufactured using state-of-the-art technology and according to recognised safety standards. If used incorrectly or misused, however, it can cause: injury or death to the operator or a third party, damage to the device and other material assets belonging to the operating company, inefficient operation of the device. -
Page 16: Obligations Of The Operator
Ambient temperature range: during operation: -10 °C to + 40 °C (14 °F to 104 °F) during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F) Relative humidity: up to 50% at 40 °C (104 °F) up to 90% at 20 °C (68 °F) The surrounding air must be free from dust, acids, corrosive gases or substances, etc. -
Page 17: Noise Emission Values
Suitable protective clothing must be worn when working with the device. The protective clothing must have the following properties: Flame-resistant Insulating and dry Covers the whole body, is undamaged and in good condition Safety helmet Trousers with no turn-ups Protective clothing refers to a variety of different items. Operators should: Protect eyes and face from UV rays, heat and sparks using a protective visor and reg- ulation filter Wear regulation protective goggles with side protection behind the protective visor... -
Page 18: Danger From Flying Sparks
The following components are responsible, amongst other things, for the degree of toxicity of welding fumes: Metals used for the workpiece Electrodes Coatings Cleaners, degreasers, etc. Welding process used The relevant material safety data sheets and manufacturer's specifications for the listed components should therefore be studied carefully. -
Page 19: Meandering Welding Currents
The electrode (rod electrode, tungsten electrode, welding wire, etc.) must never be immersed in liquid for cooling Never touch the electrode when the power source is switched on. Double the open circuit voltage of a power source can occur between the welding elec- trodes of two power sources. -
Page 20: Emc Device Classifications
EMC Device Clas- Devices in emission class A: sifications Are only designed for use in industrial settings Can cause line-bound and radiated interference in other areas Devices in emission class B: Satisfy the emissions criteria for residential and industrial areas. This is also true for residential areas in which the energy is supplied from the public low-voltage mains. -
Page 21: Specific Hazards
Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example: Fans Cogs Rollers Shafts Wirespools and welding wires Do not reach into the rotating cogs of the wire drive or into rotating drive components. Covers and side panels may only be opened/removed while maintenance or repair work is being carried out. -
Page 22: Requirement For The Shielding Gas
Odourless and colourless shielding gas may escape unnoticed if an adapter is used for the shielding gas connection. Prior to assembly, seal the device-side thread of the adapter for the shielding gas connection using suitable Teflon tape. Requirement for Especially with ring lines, contaminated shielding gas can cause damage to equipment and the shielding gas reduce welding quality. -
Page 23: Safety Measures In Normal Operation
When transporting the device, observe the relevant national and local guidelines and ac- cident prevention regulations. This applies especially to guidelines regarding the risks aris- ing during transport. Do not lift or transport operational devices. Switch off devices before transport or lifting. Before transporting the device, allow coolant to drain completely and detach the following components: Wirefeeder... -
Page 24: Commissioning, Maintenance And Repair
(e.g. relevant product standards of the EN 60 974 se- ries). Fronius International GmbH hereby declares that the device is compliant with Directive 2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following address: http://www.fronius.com... -
Page 25: Copyright
Copyright Copyright of these operating instructions remains with the manufacturer. The text and illustrations are all technically correct at the time of printing. We reserve the right to make changes. The contents of the operating instructions shall not provide the ba- sis for any claims whatsoever on the part of the purchaser. -
Page 26: General
The frontpull drive is controlled via a control unit. Both wire electrodes are brought together in the welding torch in such a way that two independent welding potentials are available. The Drive EasyTwin process only works when used with filler metal from drums. -
Page 27: Lead Power Source And Trail Power Source
Please note the following when dimensioning the robot: the robot The torch holder on the robot must be stable. The Drive EasyTwin welding torch with CrashBox weighs ??? kg. The robot hose pack and wirefeeding hoses must be routed via a balancer in the robot... -
Page 28: Welding Torch Cleaning Station
Welding torch A welding torch cleaning station is recommended to ensure optimum performance of the cleaning station automated Drive EasyTwin welding process, for example: Robacta Reamer Twin Mechanical torch cleaning device, suitable for all base materials, such as steel, aluminium, CrNi steels, copper, etc. -
Page 29: System Requirements
Cooling unit: 1 x FK 4000-R FC LEADING TRAILING Drive EasyTwin For a stable and reproducible "Drive EasyTwin" process, the following mechanical require- mechanical re- ments must be met: quirements Precise torch guidance for robots or single-purpose machines (e.g. straight-line car-... -
Page 30: Control Elements And Connections
Control elements and connections Drive EasyTwin drive unit con- trols Function Gas-test button for setting the required gas flow rate on the pressure regulator Wire threading button to thread the wire electrode into the torch hosepack with no accompanying flow... -
Page 31: Welding Technology Aspects
Grounding (earthing) cable laid in a loop Grounding (earthing) cable coiled Welding circuit The welding circuit inductivity L and the welding circuit resistance r must be calibrated sep- inductivity L, arately for each power source for the "Drive EasyTwin" process. welding circuit re- sistance r... -
Page 32: Stick Out
90 - 100° Welding torch tilt angle neutral to slightly forward Arc combination Different arc types can be combined in the "Drive EasyTwin" process. options The welding direction is defined by the wire pairing (Ø 1.2 mm lead power source/Ø 1.0 trail power source) and the construction of the welding torch. -
Page 33: Pcs/Pulsed
PCS/pulsed Symbols Trail wire electrode Lead wire electrode Active pulsed arc with droplet transfer Inactive pulsed arc (no droplet transfer) Welding current of lead power source Welding current of trail power source Welding direction Material transfer I (A) t (s) PCS/pulsed: Welding current/time curve and schematic representation of the material transfer Special features Greater penetration by the PCS arc of the lead wire electrode... -
Page 34: Welding Parameter Standard Values
Welding parameter standard values Alignment of Align welding torch (1) relative to the welding torch rel- workpiece (2) as shown on the left- ative to the work- hand figure piece for fillet Welding torch (1) at a 5° angle to the welds welding direction 35 - 40°... -
Page 35: Area Of Application For Drive Easytwin - Steel, Diameter 1.2 Mm - 1.0 Mm
68,5° Area of applica- The Drive EasyTwin characteristic range covers Vd. = 5 m/min (one power source) to Vd. tion for Drive Ea- = 15 m/min. syTwin - steel, diameter 1.2 mm - This range is determined by the following 1.0 mm... - Page 36 Sheet thickness: from 3 mm a-dimension single a3 - a4.5 layer: Vs-2 m/min a4.5: Vs-1.2 m/min If an a-dimension greater than 4.5 mm is required, then multi- layer technology is recommended. Multiple layer fillet welds/PB position: Sheet thickness: from 3 mm a-dimension multi- a3 - a4.5 ple layer:...
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Page 37: Care, Maintenance And Disposal
Gas purge the inner liners arc time After 50 hours of Gas purge the Robacta Drive EasyTwin drive unit arc time Check the feed rollers If the feed rollers are worn, the axle block of the pressure rollers and the counter bearing of the double roller must be replaced (see "Replacing wearing parts"). -
Page 38: Replacing Wearing Parts
Replacing wearing parts Preparation replacing the feed rollers and nozzle * Fully open... -
Page 40: Replacing The Inlet Nozzle
Replacing the in- let nozzle Now the welding wire must be threaded (see "Threading the welding wire" from Figure 5 on page 12) Replacing the feed rollers... - Page 41 Now the welding wire must be threaded (see "Threading the welding wire" from Figure 5 on page 12)
- Page 44 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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