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Troubleshooting
Related Manuals for Fronius Robacta TX W
Summary of Contents for Fronius Robacta TX W
- Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating Instructions Robacta TX W Torch body changeover system 42,0426,0091,EN 020-15032017 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
Contents Safety rules ..............................General ..............................Proper use ............................Environmental conditions........................Obligations of the operator........................Obligations of personnel ........................Specific hazards............................ Protecting yourself and others ......................EMC Device Classifications ........................EMC measures ............................. EMF measures............................Safety measures at the installation location and during transport ............Safety measures in normal operation .................... - Page 6 Compressed air supply specifications....................Application example........................... Application example..........................Bolt torch body changeover station to the underlying surface (foundation) ..........Safety..............................Bolting the torch body changeover station to the underlying surface (foundation) ....... Installing the torch body changeover station - in conjunction with VR 7000 / VR 7000 CMT ....Safety..............................
- Page 7 Start-up ..............................Prerequisites for start-up........................Start-up ..............................Program sequence............................. Safety..............................Speed data for the program sequence ....................Subprograms in the program sequence....................Program sequence..........................Troubleshooting Safety................................. Safety..............................Troubleshooting ............................Troubleshooting ............................ Care, maintenance and disposal Safety................................. Safety..............................Maintenance for each torch body service, at least weekly................. Preparation ............................
- Page 8 Preparation ............................122 Safety..............................122 Removing the old torch body sensor ....................122 Fitting the new torch body sensor ......................123 And finally............................. 124 Disposal ..............................125 Disposal ..............................125 Technical data Technical data............................129 Torch body changeover station......................129 Torch body coupling..........................
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Page 9: 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 operat- ing company, inefficient operation of the device. -
Page 10: Environmental Conditions
Environmental Operation or storage of the device outside the stipulated area will be deemed conditions as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage. 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:... -
Page 11: Protecting Yourself And Others
Protecting your- When welding, you expose yourself to numerous dangers. In addition to these self and others operating instructions, the safety instructions of the manufacturer of the entire welding system must also be observed. Keep all persons, especially children, out of the working area while any devic- es are in operation or welding is in progress. -
Page 12: Emf Measures
EMF measures Electromagnetic fields may pose as yet unknown risks to health: effects on the health of others in the vicinity, e.g. wearers of pacemakers and hearing aids wearers of pacemakers must seek advice from their doctor before ap- proaching the device or any welding that is in progress for safety reasons, keep distances between the welding cables and the welder's head/torso as large as possible do not carry welding cables and hosepacks over the shoulders or wind... -
Page 13: Commissioning, Maintenance And Repair
Commissioning, It is impossible to guarantee that bought-in parts are designed and manufac- maintenance and tured to meet the demands made of them, or that they satisfy safety require- repair ments. Use only original spare and wearing parts (also applies to standard parts). Do not carry out any modifications, alterations, etc. -
Page 14: Data Protection
Data protection The user is responsible for the safekeeping of any changes made to the fac- tory settings. The manufacturer accepts no liability for any deleted personal settings. 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. -
Page 15: General Information
General information... -
Page 17: General
General Device concept Robacta TX is an automatic torch body ch- angeover system, comprising: Torch body changeover station Torch body coupling Robacta TX torch body With Robacta TX, robots are used to auto- matically place worn torch bodies onto the torch body changeover station and replace them with new torch bodies. -
Page 18: System Components
To operate the torch body changeover station, the following system components are also tem components needed in addition to the welding system: Robacta TX W torch body changeover station TX W tool kit Torch body coupling Robacta TX W torch body... -
Page 19: Contact Tip Recommendation
NOTE! The locking balls (1) are intended for dry operation. Do not lubricate the locking balls. Torch body coupling Robacta TX W torch body Wire cutter Contact tip rec- NOTE! In conjunction with the torch body changeover system, we recommend ommendation that you use the 'CB' contact tip. -
Page 20: Tcp Measurement System
The device is intended solely for changing Fronius torch bodies. The device is intended solely for use in conjunction with Fronius system components. This applies to the cooling units and coolant in particular - only use the device in conjunction with Fronius cooling units and Fronius coolant. -
Page 21: Warning Notices On The Device
The device is fitted with safety symbols and a rating plate. The safety symbols and rating on the device plate must not be removed or painted over. The symbols warn against operating the equip- ment incorrectly, as this may result in serious injury and damage. Model No. Robacta TX W Art.No. 4,044,008 Ser.No. www.fronius.com... - Page 22 For indoor use only WARNING! Risk of severe injury from torch body falling. Pressing the Un- lock/Lock button will release the torch body from the torch body coupling, causing it to fall to the ground. When pressing the Unlock/Lock button, make sure that the torch body is held in one hand or has been put down in a safe place there are no other persons in the working area of the robot...
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Page 23: Transport
Transport Transport devic- The device is to be transported by the following devices: on pallets using a forklift truck on pallets using a lift truck WARNING! Equipment that falls or topples over can cause serious or even fatal injury. Secure the device to prevent it from falling over when transporting on a forklift truck or lift truck Do not suddenly change direction, brake or accelerate Transport notices... -
Page 25: Controls, Connections And Mechanical Components
Controls, connections and mechani- cal components... -
Page 27: Control Elements And Connections
Wire sensor checks whether the wire electrode is protruding from the welding torch I/O connection for accessory equipment to connect Fronius accessory equipment to the torch body changeover station Compressed air connection "C" Unlock/Lock button for manual operation of the torch body coupling WARNING! Risk of severe injury from torch body falling. - Page 28 Robot control connection compartment for optionally connecting the torch body changeover station to the robot control via standard I/O connection for robot control field bus coupler Compressed air connection "B" connection to supply the torch body changeover station with 5.50 - 6.00 bar (79.77 - 87.02 psi) of dry and oil-free compressed air Size: 3/8"...
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Page 29: Mechanical Components
Mechanical components Safety WARNING! Operating the equipment incorrectly can cause serious injury and damage. All the functions described may only be used by trained and qualified personnel. Do not use the functions described until you have thoroughly read and understood the following documents: these operating instructions all the operating instructions for the system components, especially the safe- ty instructions... -
Page 30: Pin Assignments And Signal Descriptions
Pin assignments and signal descriptions Safety WARNING! Operating the equipment incorrectly can cause serious injury and damage. All the functions described may only be used by trained and qualified personnel. Do not use the functions described until you have thoroughly read and understood the following documents: these operating instructions all the operating instructions for the system components, especially the safe-... - Page 31 Input (from the Output (from the Signal torch body robot to the changeover sta- torch body tion to the ro- changeover sta- bot) tion) Torch body sensor 9 Torch body sensor 10 Robacta TX sensor 1 cover Robacta TX sensor 2 cover Robacta TX valve 1 cover Robacta TX valve 2 cover 'C-Act.
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Page 32: Signal Descriptions
Signal descrip- Signal Signal description tions Torch body sensor 1 The respective torch body is deposited in the corresponding torch body rack Torch body sensor 2 Torch body sensor 3 Torch body sensor 4 Torch body sensor 5 Torch body sensor 6 Torch body sensor 7 Torch body sensor 8 Torch body sensor 9... - Page 33 Signal Signal description Gas nozzle free / 'TC Signal only available as an option. Ready' "Gas nozzle free" signal for Robacta Reamer V only: gas nozzle clamping device on welding torch cleaning device is not holding a gas nozzle 'TC Ready' signal for Robacta TC devices on- welding torch cleaning device is ready Gas nozzle free / Cleaning Signal only available as an option.
- Page 34 Signal Signal description Cleaning motor raised Signal only available as an option. "Cleaning motor raised" signal for Robacta Reamer V only: cleaning motor is raised Cut wire Signal only available as an option. activates the wire cutter Wire cutter closed Signal only available as an option.
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Page 35: Installation And Commissioning
Installation and commissioning... -
Page 37: Safety
Safety Safety Observe the following safety instructions for all work described in the "Installation and start- up" section. WARNING! Incorrect operation or shoddy workmanship can cause serious injury or damage. All activities described in these operating instructions may only be carried out by trained and qualified personnel. -
Page 38: Before Installation And Commissioning
Before installation and commissioning Operators, main- NOTE! The device must only be used by one person at a time. It is also necessary tenance person- to ensure that no one else is within the working area of the device when the device is being used. -
Page 39: Compressed Air Supply Requirements
Compressed air supply requirements Compressed air To ensure that the torch body changeover system functions correctly, the following com- supply specifica- pressed air supply specifications must be met: tions Compressed air is free of oil Compressed air is free of dust - no dirt particles larger than 5 μm Compressed air is free of water Compressed air supply at 5.50 - 6.00 bar (79.77 - 87.02 psi) Minimum inner diameter of compressed air lines 5.5 mm (0.22 in.) -
Page 40: Application Example
Application example Application ex- ample (17) (16) (15) (14) (13) (12) (11) (10) NOTE! Irrespective of the overall welding system setup adhere to the compressed air specifications provide the compressed air supply to the wire-feed unit and the torch body changeover station as shown Compressed air supply line 5.50 - (10) -
Page 41: Bolt Torch Body Changeover Station To The Underlying Surface (Foundation)
Bolt torch body changeover station to the underly- ing surface (foundation) Safety CAUTION! Risk of injury from compressed air escaping unintentionally. The torch body changeover station must remain depressurised and de-energised until in- stallation has been completed. Bolting the torch NOTE! Different fixings may be required to set up the device depending on the body changeover type of underlying surface (foundation). -
Page 42: Installing The Torch Body Changeover Station - In Conjunction With Vr 7000 / Vr 7000 Cmt
Installing the torch body changeover station - in con- junction with VR 7000 / VR 7000 CMT Safety CAUTION! Risk of injury from compressed air escaping unintentionally. The torch body changeover station must remain depressurised and de-energised until in- stallation has been completed. General NOTE! For wire-feed units with the "Welding torch gas purging"... - Page 43 Undo screw (3) Disconnect compressed air line from the gas purging option connection (4) Fit mounting plate and junction valve onto wire-feed unit and secure using the TX 25 screw (5) provided Insert the supplied compressed air line with an outer diameter of 6 mm into connection (6) on the junction valve and into the gas purging option connection (7)
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Page 44: Installing The Torch Body Changeover Station
Installing the Insert compressed air line into com- torch body pressed air connection "A" on the torch changeover sta- body changeover station and into tion connection (1) on the junction valve Insert gas purging line from the hose- pack (2) into connection (3) on the jun- ction valve... -
Page 45: Installing The Torch Body Changeover Station - In Conjunction With Vr 1500 / Vr 1530 / Vr 1550
Installing the torch body changeover station - in con- junction with VR 1500 / VR 1530 / VR 1550 Safety CAUTION! Risk of injury from compressed air escaping unintentionally. The torch body changeover station must remain depressurised and de-energised until in- stallation has been completed. -
Page 46: Installing The Torch Body Changeover Station
Fit mounting plate and junction valve onto wire-feed unit and secure using 2 TX 25 screws (5) provided Insert the supplied compressed air line with an outer diameter of 6 mm into connection (6) on the junction valve and into the welding torch gas purging connection (7) Installing the Insert compressed air line into com-... -
Page 47: Installing The Torch Body Changeover Station - In Conjunction With Vr 1500-Pap
Installing the torch body changeover station - in con- junction with VR 1500-PAP Safety CAUTION! Risk of injury from compressed air escaping unintentionally. The torch body changeover station must remain depressurised and de-energised until in- stallation has been completed. General NOTE! For wire-feed units with the "Welding torch gas purging"... - Page 48 Undo screws (4) on the wire-feed unit Disconnect compressed air line from (6) (6) welding torch gas purging connection Fit mounting plate and junction valve onto wire-feed unit and secure using the two TX 25 screws (6) provided Insert the compressed air line with an (10) outer diameter of 8 mm into the wel- ding torch gas purging connection (7)
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Page 49: Installing The Torch Body Changeover Station
Installing the Insert compressed air line into com- torch body pressed air connection "A" on the torch changeover sta- body changeover station and into tion connection (1) on the junction valve... -
Page 50: Checking The Torch Body Sensor, Setting The Wire Sensor
Checking the torch body sensor, setting the wire sensor Safety CAUTION! Risk of injury from compressed air escaping unintentionally. The torch body changeover station must remain depressurised until all work is completed. Checking the Establish a connection with the robot torch body sen- control. -
Page 51: Setting The Wire Sensor
Setting the wire Rotate the wire electrode in the sensor opening (2) of the wire sensor (1) du- ring the entire setting process LED (4) comes on if the wire sen- sor (1) detects the wire electrode Turn the adjusting screw (3) in the re- verse direction until the LED (4) goes Wire sensor is deactivated Only turn the adjusting screw (3) until... -
Page 52: Preparing Torch Body With Steel Inner Liner
Preparing torch body with steel inner liner Preparing the Insert the inner liner from the original torch body equipment kit of the hosepack being used (1) as far as it will go into the torch body Push the cutting aid (2) as far as it will go onto the inner liner Tighten the locking screw (3) of the cutting aid... - Page 53 Insert the inner liner into the torch body Insert the TX inlet/outlet nozzle (4) fully into the torch body Press down the TX inlet/outlet nozzle until you hear a click...
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Page 54: Preparing The Torch Body With Plastic Inner Liner
Preparing the torch body with plastic inner liner Preparing the Insert the inner liner from the original torch body equipment kit of the hosepack being used (1) as far as it will go into the torch body Push the cutting aid (2) as far as it will go onto the inner liner Tighten the locking screw (3) of the cutting aid... - Page 55 Insert the inner liner into the torch body Insert the TX inlet/outlet nozzle (4) fully into the torch body Press down the TX inlet/outlet nozzle until you hear a click...
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Page 56: Preparing System Components For Robacta Hosepacks
Preparing system components for Robacta hose- packs Safety CAUTION! Risk of injury from compressed air escaping unintentionally. The torch body changeover station must remain depressurised until all work is completed. Preparing the Press centre bolt (1) out of the torch torch body cou- body coupling (2) pling for Robacta... -
Page 57: Preparing The Inner Liner For Robacta Hosepacks
Remove grub screw (4) from centre bolt using 1.5mm Allen key (5) Screw run-off plate (3) into centre bolt Push centre bolt (1) into torch body coupling (2) Preparing the in- NOTE! More detailed information about fitting the inner liner can be found in the ner liner for Ro- Robacta hosepack operating instructions. - Page 58 Fit the inner liner as described in the Robacta hosepack operating instruc- tions, but do not cut it yet Cut the inner liner as shown follow the instructions for cutting the inner liner as described in the Robacta hosepack operating inst- ructions Deburr inner liner follow the instructions for debur-...
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Page 59: Preparing The Torch Body Coupling For Robacta Drive And Robacta Drive Cmt Hosepacks With Steel Inner Liners
Preparing the torch body coupling for Robacta Drive and Robacta Drive CMT hosepacks with steel inner liners Preparing the Insert the inner liner from the original torch body cou- equipment kit of the hosepack being pling for Robacta used (1) as far as it will go into the torch Drive and Robac- body coupling (2) as shown ta Drive CMT... -
Page 60: Preparing The Torch Body Coupling For Robacta Drive And Robacta Drive Cmt Hosepacks With Plastic Inner Liners
Preparing the torch body coupling for Robacta Drive and Robacta Drive CMT hosepacks with plastic inner liners Preparing the Insert the inner liner from the original torch body cou- equipment kit of the hosepack being pling for Robacta used (1) as far as it will go into the torch Drive and Robac- body coupling (2) as shown ta Drive CMT... -
Page 61: Preparing The Power Source
Preparing the power source Preparing the On the power source being used, create a new job for advancing and winding back power source the wire electrode Wire threading speed: 600 cm/min (236.22 ipm) Set filter time for flow watchdog to 25 seconds using RCU 5000i... -
Page 62: Fitting The Torch Body Coupling
Fitting the torch body coupling Safety CAUTION! Risk of injury from compressed air escaping unintentionally. The torch body changeover station must remain depressurised until all work is completed. Fitting the torch NOTE! When fitting the torch body coupling, the TCP moves by 50 mm (1.97 in.). body coupling For Robacta Drive and Robacta Drive CMT drive units: Push centre bolt (1) approx. -
Page 63: Aligning Torch Body For Special Rack Positions
Aligning torch body for special rack positions General The Robacta TX torch body is configured at the factory in such a way that the end of the torch body points away from the torch body changeover station when the torch body is deposited in the torch body rack The direction in which the end of the torch body is pointing depends on the position in which the torch body is bolted to the torch body insulation... -
Page 64: Aligning The Robot Programming Aid
Turn the torch body (3) as required Push the torch body insulation (2) as far as it will go onto the torch body The pin (4) on the torch body insu- lation must fit into one of the three holes (5) NOTE! Always tighten the oppo- site screw. -
Page 66: Connecting And Adjusting The Compressed Air Amplifier
Connecting and adjusting the compressed air ampli- fier General NOTE! When using the compressed air maintenance unit option, connect and ad- just the compressed air amplifier as per the "Compressed air maintenance unit" section in the "Robacta TX options" operating instructions. Connecting the Screw a compressed air connection compressed-air... -
Page 67: Adjusting The Compressed-Air Booster Unit
Adjusting the Pull control dial (1) to unlock it compressed-air Turn the control dial (1) until the pres- booster unit sure gauge (2) shows 1.3 MPa = 13 bar = 188.55 psi if necessary in the case of long hosepacks, set the pres- sure to max. -
Page 68: Changing The Torch Body Manually
Changing the torch body manually Safety CAUTION! Risk of injury from escaping compressed air and flying parts from the torch body coupling. When manually changing the torch body, always wear the following protective equipment: ear protection protective goggles with side protection gloves - electrically insulated and providing protection against heat Changing the When carrying out the following work, position the robot arm and the torch body cou-... - Page 69 Check that the gap between the torch body (3) and the torch body coupling (4) is the same around the entire peri- meter Shake and pull the torch body with your hand if the torch body does not come off the torch body coupling, then the connection between the torch body and the torch body coupling...
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Page 70: Setting Up The Robot
Setting up the robot Dimensions of the rack holder in- 350 mm (13.78 in.) cluding torch body racks 300 mm (11.81 in.) 150 mm (5.91 in.) 75 mm (2.95 in.) 150 mm (5.91 in.) 175 mm (6.69 in.) Preparing the ro- NOTE! Whenever installing the bot programming robot programming aid always:... -
Page 71: Safety
Safety CAUTION! Risk of injury from escaping compressed air and flying parts from the torch body coupling. During the activities described below, always wear the fol- lowing protective equipment: ear protection protective goggles with side protection gloves - electrically insulated and providing protection against heat Determining the CAUTION! Risk of injury from razor-sharp TCP tips. - Page 72 Press and hold the Unlock/Lock button (1) on the torch body changeover stati- torch body coupling lock opens Remove torch body from torch body coupling Place both parts of the robot program- ming aid (2) onto the torch body cou- pling on the robot (3) and hold in place Release the Unlock/Lock button on the torch body changeover station...
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Page 73: Setting Up The Robot
CAUTION! Risk of severe injury from razor-sharp tip of the robot programming aid: only touch robot program- ming aid wearing protective gloves only touch exterior surfaces (7) of robot programming aid do not touch the tip of the ro- bot programming aid Shake and pull the robot programming aid with your hand if the robot programming aid does not come off the torch body coupling, then the connection between the robot programming aid and the torch body coupling is OK... - Page 74 Move the robot into the second part of the robot programming aid, leaving a gap of approx. 1.5 mm (0.06 in.) Check the following: both parts of the robot program- ming aid must be the same distan- ce to each other around the entire perimeter the edges of both parts of the ro- bot programming aid must lie flush...
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Page 75: Start-Up
Start-up Prerequisites for The following prerequisites must be fulfilled for the start-up: start-up Torch body changeover station bolted to the underlying surface Torch body changeover station installed All torch body sensors checked, wire sensor set All torch bodies have been prepared When using a Robacta hosepack: system components for Robacta hosepack pre- pared When using a Robacta Drive or Robacta Drive CMT hosepack: torch body coupling... -
Page 76: Program Sequence
Program sequence Safety CAUTION! Risk of damage. Do not start in automated mode until the torch body change system has been properly installed and started up. Speed data for A list of all speeds and corresponding units in the program sequence: the program se- quence cm/min... -
Page 77: Program Sequence
Program se- quence... -
Page 85: Troubleshooting
Troubleshooting... -
Page 87: Safety
Safety Safety Observe the following safety instructions for all work described in the "Troubleshooting" section. WARNING! Incorrect operation or shoddy workmanship can cause serious injury or damage. All activities described in these operating instructions may only be carried out by trained and qualified personnel. All functions described in these op- erating instructions may only be used by trained and qualified personnel. -
Page 88: Troubleshooting
Troubleshooting Troubleshooting Torch body unexpectedly loses contact with the torch body coupling during gas purging Cause: Gas purging pressure too high Remedy: Adjust gas purging pressure Torch body unexpectedly loses contact with the torch body coupling during gas purging Cause: Gas hole in centre bolt dirty Remedy: Clean gas hole in centre bolt - see "Cleaning the gas hole"... - Page 89 Torch body coupling does not open Cause: Compressed air supply of torch body changeover station too low Remedy: Ensure compressed air supply is as per the specifications in the operating in- structions Torch body coupling does not open Cause: Incorrect output pressure set on the compressed air amplifier Remedy: Adjust compressed air amplifier as per the specifications in the operating in- structions...
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Page 91: Care, Maintenance And Disposal
Care, maintenance and disposal... -
Page 93: Safety
Safety Safety Observe the following safety instructions for all work described in the "Care, maintenance and disposal" section. WARNING! Incorrect operation or shoddy workmanship can cause serious injury or damage. All activities described in these operating instructions may only be carried out by trained and qualified personnel. -
Page 94: Maintenance For Each Torch Body Service, At Least Weekly
Maintenance for each torch body service, at least weekly Preparation When carrying out the following work, position the robot arm so that the Unlock/Lock button on the torch body changeover station can be pressed with one hand the torch body can be removed from or placed onto the torch body coupling with the other hand Feed out the wire electrode from the hosepack Hold torch body with one hand... -
Page 95: Checking The Torch Body For Damage And Wear
Checking the Check wire guide pin (1) for damage torch body for Check coolant pin (2) for damage damage and wear Check gas pin (3) for damage If a component is damaged, send the torch body and the entire torch body coupling to the manufactu- rer's service department. -
Page 96: Checking The Torch Body Coupling
Checking the Check the surface within the marked torch body cou- area (1) for dirt pling If dirty, clean the marked area and eliminate the cause of the dirt Check the surface within the marked area (1) for damage If damaged, send the entire torch body coupling to the manufactu- rer's service department Check whether there is coolant residue on the surface within the marked area (1) - Page 97 Unscrew the nozzle fitting (3) from the torch body Remove the inner liner and TX inlet/ outlet nozzle (4) from the torch body Keep TX inlet/outlet nozzle for re- fitting at a later stage Put the nozzle fitting, spatter guard, contact tip and gas nozzle back on again Insert inner liner (5) as far as it will go...
- Page 98 Cut off the inner liner at the end of the cutting aid (8) using cutting pliers Deburr the inner liner at both ends Insert the inner liner into the torch body NOTE! Replace the TX inlet/outlet nozzle if: no click is heard when fitting the TX inlet/outlet nozzle is worn Insert the TX inlet/outlet nozzle (4) fully...
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Page 99: Changing The Plastic Inner Liner In The Torch Body
Changing the Remove the gas nozzle from the torch plastic inner liner body in the torch body Unscrew the contact tip (1) from the torch body Unscrew the spatter guard (2) from the torch body Unscrew the nozzle fitting (3) from the torch body... - Page 100 Remove the inner liner and TX inlet/ outlet nozzle (4) from the torch body Keep TX inlet/outlet nozzle for re- fitting at a later stage Put the nozzle fitting, spatter guard, contact tip and gas nozzle back on again Insert inner liner (5) as far as it will go into the torch body Push the cutting aid (6) as far as it will go onto the inner liner...
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Page 101: And Finally
Deburr the inner liner at both ends Insert the inner liner into the torch body NOTE! Replace the TX inlet/outlet nozzle if: no click is heard when fitting the TX inlet/outlet nozzle is worn Insert the TX inlet/outlet nozzle (4) fully into the torch body Press down the TX inlet/outlet nozzle until you hear a click... -
Page 102: Monthly Maintenance - Changing The Inner Liner In The Centre Bolt
Monthly maintenance - changing the inner liner in the centre bolt Preparation When carrying out the following work, position the robot arm so that the Unlock/Lock button on the torch body changeover station can be pressed with one hand the torch body can be removed from or placed onto the torch body coupling with the other hand Feed out the wire electrode from the hosepack Hold torch body with one hand... -
Page 103: Changing The Steel Inner Liners For Robacta Drive And Robacta Drive Cmt Hosepacks
Changing the Unscrew run-off plate (1) from centre steel inner liners bolt (2) for Robacta Drive using a 6 mm socket wrench insert and Robacta Remove run-off plate (1) and worn in- Drive CMT hose- ner liner from centre bolt (2) packs Cut new inner liner using cutting pliers Robacta Drive... -
Page 104: Changing The Plastic Inner Liners For Robacta Drive And Robacta Drive Cmt Hosepacks
Insert inner liner (3) into run-off plate Screw run-off plate and inner liner into centre bolt Changing the Unscrew run-off plate (1) from centre plastic inner lin- bolt (2) ers for Robacta using a 6 mm socket wrench insert Drive and Robac- Remove run-off plate (1) and worn in- ta Drive CMT ner liner from centre bolt (2) -
Page 105: And Finally
Deburr the inner liner at both ends Insert inner liner (3) into run-off plate Screw run-off plate and inner liner into centre bolt And finally... Thread the wire electrode into the hosepack Connect the compressed air line to compressed air connection "A" on the torch body changeover station Establish the compressed air and power supply to the torch body changeover station Place the torch body correctly onto the torch body coupling... -
Page 106: Maintenance When Required
Maintenance when required Maintenance The following work should only be carried out when required. when required Servicing the core bolt to service the core bolt, refer to the "Servicing the core bolt" section Replacing coolant stops to change the coolant stops, refer to the "Replacing coolant stops" section Cleaning the gas hole to clean the gas hole, refer to the "Cleaning the gas hole"... -
Page 107: Servicing The Centre Bolt
Servicing the centre bolt Preparation When carrying out the following work, position the robot arm so that the Unlock/Lock button on the torch body changeover station can be pressed with one hand the torch body can be removed from or placed onto the torch body coupling with the other hand Feed out the wire electrode from the hosepack Hold torch body with one hand... -
Page 108: Safety
Safety CAUTION! Risk of injury from compressed air escaping unintentionally. The torch body changeover station must remain depressurised and de-energised until all work is completed. Servicing the Check gas pin (1) for damage core bolt Check coolant pin (2) for damage Check wire guide pin (3) for damage If a component is damaged, send the entire torch body coupling to... -
Page 109: And Finally
Check the O-rings (7) on the gas pin for damage and replace if necessary And finally... Insert the core bolt and inner liner into the torch body coupling Screw torch body coupling onto drive unit - use the correct tightening torque for the torch body coupling Thread the wire electrode into the hosepack Connect the compressed air line to compressed air connection "A"... -
Page 110: Changing Coolant Stops
Changing coolant stops Preparation When carrying out the following work, position the robot arm so that the Unlock/Lock button on the torch body changeover station can be pressed with one hand the torch body can be removed from or placed onto the torch body coupling with the other hand Feed out the wire electrode from the hosepack Hold torch body with one hand... -
Page 111: Removing Coolant Stops
Removing cool- Place the bit insert for coolant stops (1) ant stops onto the manual torque wrench (2) NOTE! Push the bit insert on the manual torque wrench as far as it will go into the coolant stops. Unscrew coolant stops (3) from the torch body coupling using the manual torque wrench Preparing new... - Page 112 Insert the 7 x 1 mm O-ring into the groove (2) on the outside of the cou- pling crown Insert the 2 x 1 mm O-ring into the groove (3) on the coupling plunger Insert the coupling valve (4) into the coupling crown (5) Insert the spring (6) into the coupling crown (5)
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Page 113: Fitting New Coolant Stops
completed coolant stop Carry out the steps listed above on the second coolant stop Fitting new cool- NOTE! Fit the coolant stops as far ant stops as they will go onto the bit insert on the manual torque wrench. Lightly lubricate the O-ring on the coo- lant stop Fit the ready-made coolant stop onto the bit insert for the coolant stop (1) on... -
Page 114: Cleaning The Gas Hole
Cleaning the gas hole Preparation When carrying out the following work, position the robot arm so that the Unlock/Lock button on the torch body changeover station can be pressed with one hand the torch body can be removed from or placed onto the torch body coupling with the other hand Feed out the wire electrode from the hosepack Hold torch body with one hand... -
Page 115: Safety
Safety CAUTION! Risk of injury from compressed air escaping unintentionally. The torch body changeover station must remain depressurised and de-energised until all work is completed. Cleaning the gas Unscrew the gas pin (1) from the core hole bolt using the 5.5 mm socket wrench Take the control slide (2) and spring under the control slide off the core bolt Clean the control slide (2) and spring... -
Page 116: And Finally
Clean the hole (4) Re-fit the spring and control slide in the hole (4) NOTE! The spring and control slide must drop into the hole (4) without any resistance. Screw the gas pin (1) into the core bolt using a 5.5 mm socket wrench And finally... -
Page 117: Changing The Welding Torch Flange
Changing the welding torch flange Preparation When carrying out the following work, position the robot arm so that the Unlock/Lock button on the torch body changeover station can be pressed with one hand the torch body can be removed from or placed onto the torch body coupling with the other hand Feed out the wire electrode from the hosepack Hold torch body with one hand... -
Page 118: Changing The Welding Torch Flange
Changing the Undo the screws (1) welding torch Remove the torch body insulation (2) flange Undo all six grub screws (3) on the wel- ding torch flange (4) Remove old welding torch flange (4) Fit assembly aid (5) onto torch body Push new welding torch flange (4) as far as it will go onto the torch body NOTE! The pin (6) with a diameter... -
Page 119: And Finally
Push the torch body insulation (2) as far as it will go onto the torch body ensure that the torch body insula- tion is in the same position on the torch body as it was before dis- mantling the pin (8) in the torch body insula- tion must fit into one of the three holes (9) NOTE! Always tighten the oppo-... -
Page 120: Pressing The Emergency Release Button
Pressing the emergency release button General NOTE! Only press the emergency release button: if the torch body does not come off the torch body coupling after the appro- priate robot control command has been issued if the torch body cannot be changed manually to remove the torch body manually from the torch body coupling, refer to "Changing the torch body manually"... -
Page 121: Pressing The Emergency Release Button
Pressing the Remove the plastic placeholder (1) emergency re- from the plastic sleeve on the torch lease button body coupling (2) Unscrew the grub screw (3) from the torch body coupling using a 1.5 mm Al- len key NOTE! The opening in the plastic sleeve of the torch body coupling must be directly above the ex- posed hole in the torch body cou-... -
Page 122: Replacing The Torch Body Sensor
Replacing the torch body sensor Preparation Depressurise the compressed air line of the torch body changeover station and make sure that this compressed air line remains depressurised for the duration of the work on the device Disconnect the compressed air line from compressed air connection "A" on the torch body changeover station CAUTION! Risk of injury from escaping compressed air from compressed air connection "A". -
Page 123: Fitting The New Torch Body Sensor
Undo cable tie (3) Unplug the plug from the PC board ac- cording to the position of the rack hol- der. In this case (4) Example: Torch body rack mounted at posi- tion 2 on the rack holder - unplug the torch body sensor at connecti- on 'X3 sensor 2' on the PC board in the torch body changeover sta-... -
Page 124: And Finally
Plug in the sensor plug into the PC board according to the position of the rack holder. In this case (4) Example: Torch body rack mounted at posi- tion 2 on the holder retainer - connect the plug of the torch body sensor to connection 'X3 sensor 2' on the PC board in the torch body changeover station... -
Page 125: Disposal
Disposal Disposal Dispose of in accordance with the applicable national and local regulations. -
Page 127: Technical Data
Technical data... -
Page 129: Technical Data
Technical data Torch body Supply voltage + 24 V DC changeover sta- Nominal pressure 6 bar tion 87.02 psi Standard I/O Input: + 24 V DC/ max. 1.5 A Total cycle time 25 - 30 s Degree of protection IP 20 EMC emission class Dimensions l x w x h 477 x 759 x 785 mm... -
Page 131: Appendix
Appendix... -
Page 132: Pneumatic Diagram
Pneumatic diagram V23072012... -
Page 133: Declaration Of Installation
(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 136 FRONIUS INTERNATIONAL GMBH Froniusplatz 1, A-4600 Wels, Austria Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940 E-Mail: sales@fronius.com www.fronius.com www.fronius.com/addresses Under http://www.fronius.com/addresses you will find all addresses of our Sales & service partners and Locations...