Trumpf TruArc Weld 1000 Operator's Manual
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Trumpf TruArc Weld 1000 Operator's Manual

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B1154en
Chapter 1
Safety
1
2
3
4
4.1
4.2
4.3
5
5.1
2020-09-01
1-3
1-5
1-6
1-7
1-7
1-8
1-8
1-9
1-9
1-9
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1-1

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Summary of Contents for Trumpf TruArc Weld 1000

  • Page 1: Table Of Contents

    Chapter 1 Safety Safety concept 1‐3 Regulations and guidelines 1‐5 Terms 1‐6 Operational safety 1‐7 Intended use 1‐7 Significant change to the machine 1‐8 Authorized personnel 1‐8 Hazards 1‐9 Mechanical dangers 1‐9 Dangers of slipping, tripping or falling 1‐9 Moving robot axes 1‐9 Tilting and falling workpieces 1‐10...
  • Page 2 Sharp-edged workpieces 1‐10 Wire feed from the welding torch 1‐10 Dangers from electricity 1‐10 Dangers due to the open electrical cabinet 1‐11 Electrical voltage on the welding wire 1‐11 Thermal dangers 1‐11 Fire hazard 1‐11 Dangers due to fire 1‐12 Danger due to flying sparks 1‐12 Hot surfaces and workpieces...

  • Page 3: Safety Concept

    Safety concept Chapter Safety The "Safety" chapter describes the safety concept of the machine. It specifies the guards and the manufacturer's design measures for safe operation of the machine. It points out dangers when handling the machine and specifies measures taken by the user to avoid possible dangers. The "Hazards"...
  • Page 4 Signaling word Description CAUTION If the dangerous situation is not prevented, light inju- ries could result. NOTICE If the situation is not prevented, damage to property could result. Signaling words Tab. 1-1 1‐4 Safety concept 2020-09-01 B1154en...

  • Page 5: Regulations And Guidelines

    EC Machinery Directive 2006/42/EC. The automated welding cell is a complete machine. The standards applied by TRUMPF are stated in the EU declara- tion of conformity supplied. With the CE marking, TRUMPF confirms compliance with the fol- lowing EU directives: ■...

  • Page 6: Terms

    Terms Term Description User The user is the person who is responsible for the operation of the machine or system and has the authority to issue orders to employees. Machine A machine (complete machine) according to the definition in the EC Machinery Direc- tive is the entirety of interconnected assemblies and components, of which at least one component is movable.

  • Page 7: Operational Safety

    The user may use the machine in the industrial and commercial sector. Installation, operating and transport conditions defined by TRUMPF must be adhered to and maintenance work must be carried out in accordance with the Operator's manual. The user must observe the specifications of the country in which the machine is being operated as well as national and regional safety and accident prevention regulations.

  • Page 8: Significant Change To The Machine

    Significant change to the machine Delivery condition The machine is delivered as a complete machine, as defined by the EC Machinery Directive, with a EU declaration of conformity. The machine is operationally safe at the time of commissioning. The user can produce goods with the machine as intended. After commissioning, the responsibility for the safety of the machine is transferred from the manufacturer to the customer.

  • Page 9: Hazards

    Hazards The "Hazards" section is based on the manufacturer's risk assessment and describes the residual risk. The user must take measures to prevent the hazards. Mechanical dangers Dangers of slipping, tripping or falling Slipping, tripping or falling! CAUTION Risk of injury. Ø...

  • Page 10: Tilting And Falling Workpieces

    Tilting and falling workpieces Tilting or falling workpieces! CAUTION Head and hand injuries. Ø Only process workpieces up to a max. size of 2000 x 600 x 600 mm (78.7 x 23.6 x 23.6 in). Ø Place workpieces statically with clamping fixtures (e.g. col- lets, etc.) and bring them into a position with a secure center of gravity.

  • Page 11: Dangers Due To The Open Electrical Cabinet

    Dangers due to the open electrical cabinet The electrical cabinet may be opened only by an electrician. Electrical voltage! DANGER Electric shock! Ø Keep the electrical cabinet closed. Ø Before opening the electrical cabinet: turn off the MAIN SWITCH and secure it against being switched back on again.

  • Page 12: Dangers Due To Fire

    Dangers due to fire Fire! WARNING Serious injuries. Ø In the event of fire, leave the danger zone and take fire pro- tection measures. Danger due to flying sparks Severe injuries due to fires and explosions. WARNING Ø Do not place any flammable materials on the welding table. Place flammable materials at least 11m (36ft) away from the Ø...
  • Page 13 In the case of hazardous substances, TRUMPF only indicates the sources of danger. The user must estimate the dangers caused by a raw material. The user must check and estimate the required measures. When the machine is switched off the valve for the main gas supply must be closed.

  • Page 14: Noise Hazards

    Noise hazards Increased sound pressure level through pneumatics For certain processes, the A-weighted sound pressure level of the system may exceed 71 dB. In this case, persons in the area surrounding the machine will be exposed to increased noise pol- lution.

  • Page 15: Dangers In The Event Of A Network Con

    Dangers in the event of a network connection The electrical cabinet may be opened only by an authorized spe- cialist. Note It is possible to connect to the customer network using the FAB interface option. 1‐15 B1154en 2020-09-01 Hazards...

  • Page 16: Measures To Be Taken By The Manufacturer

    Measures to be taken by the manufacturer Noise protection The A-weighted emission sound pressure level at the worksta- tion of the personnel is between 70 dB(A) and 80 dB(A). The operating conditions of the machine during the measurement, the measuring method and the exact measurement results of the A-weighted emission sound pressure level can be taken from the noise measurement report.
  • Page 17 Rear safety doors (hinged Operating unit with foot switches Power source doors) Operating-mode key switch 10 Exhaust system Lateral safety doors (sliding Upper cover with exhaust hood Extendible partition wall doors) Operating elements on the Anti-glare protection robot welding arm EMERGENCY STOP push-but- Danger zones and safeguarding device Fig.
  • Page 18 Manual mode Automatic mode Program test Key switch positions Fig. 105430 Main switch The main switch is used to switch the machine on and off. The main switch can be secured with a padlock against being switched back on again. The main switch has two switch settings: Switch setting 0 The machine is switched off and the voltage...
  • Page 19 EMERGENCY STOP push-button, mobile operating EMERGENCY STOP push-button, central operating unit unit EMERGENCY STOP push-button Fig. 105429 EMERGENCY STOP has the following effect: ■ All axis motions stop. ■ All drives are switched off electrically. ■ The power supply of the power source is interrupted. ■...
  • Page 20 Safety contacts for door monitoring Safety contacts Fig. 105427 If one or several of the safety doors are opened during opera- tion, the robot is stopped and transferred into a safe state. A restart of the machine has to be acknowledged again. Anti-glare protection A two-part anti-glare protection at the front of the machine pro- tects the operator from optical radiation and prevents access to...
  • Page 21 Note After closing the anti-glare protection the START / RESET but- ton must be pressed. Afterwards, the welding process can be resumed. Partition wall for two-station Note operation The two-station operation is only active if the anti-glare protec- tion was closed before the program was ended at the 1st station. The work area is separated by a partition wall for two-station operation.
  • Page 22 Position Description Foot switch is not pressed. Foot switch is ■ Robot is responding. pressed down ■ Robot moves at a reduced speed in the manual to the 1st pres- operating mode. sure point (neu- ■ Freedrive is activated (robot can be moved man- tral position).

  • Page 23: Safety-Relevant Signs On The Machine

    Safety-relevant signs on the machine Safety-relevant signs Fig. 105431 Safety-relevant signs on the Meaning machine Entering the area prohibited. This also applies for: ■ Framework elements. ■ Z axis. ■ Control cabinet inner cover. ■ Consoles on the power source. Warning of electrical voltage.
  • Page 24 Safety-relevant signs on the Meaning machine No access for persons with a pacemaker or with an implanted defibrillator. Persons with a pacemaker or with an implanted defibrillator must maintain the largest possible safety distance! General warning notice. Warning of respiratory irritation. Safety-relevant signs Tab.

  • Page 25: Organizational Measures To Be Taken By

    Organizational measures to be taken by the user The user must take the following measures before starting work- ing on the machine: ■ Perform a risk assessment in accordance with national regu- lations. The "Dangers" section can be used as the basis for creating the risk assessment.

  • Page 26: Water Protection

    Checking danger zone and Guards must not be acknowledged when persons are in the dan- guards ger zone. The personnel must always make sure that nobody is in the danger zone before acknowledging. Personnel are only allowed to operate the machine with func- tional guards.

  • Page 27: Spare Parts, Accessories, Software, Operating Materials

    Spare parts, accessories, software, operating materials Liability disclaimer TRUMPF is not liable for damage if external parts and accesso- ries are used or if spare parts and accessories approved by TRUMPF are not installed or replaced properly. TRUMPF is not liable for damages resulting from the installation or operation of software which is not approved by TRUMPF.

  • Page 28: Disassembly And Disposal

    Disassembly and disposal TRUMPF recommends commissioning Technical Service or a specialist disposal company with the dismantling and disposal of a machine, component or system. The information below must be passed on to the specialist company performing the disposal work. Preparing disassembly...
  • Page 29 Area of application: Europe accordance with Article 33 of the REACH agreement. TRUMPF products contain components whose lead content is above the limit value of 0.1 percent by weight. Lead is bound in alloys and does not constitute a danger.
  • Page 30 1‐30 Disassembly and disposal 2020-09-01 B1154en...
  • Page 31 Floor requirements 2‐5 User interface 2‐5 Floor quality 2‐6 Weight load 2‐6 Ambient conditions 2‐7 Lighting 2‐8 Compressed air supply 2‐9 Compressed air connection 2‐9 Establishing compressed air 2‐10 2‐1 B1154en Installation conditions TruArc Weld 1000 (RW01) - Version 2...
  • Page 32 2‐16 Transport 2‐17 Preparing transport 2‐17 Permitted auxiliary tools 2‐17 Checking, unloading and transporting the 2‐21 machine On delivery: check the machine 2‐21 Unloading and transporting the machine 2‐22 2‐2 Installation conditions TruArc Weld 1000 (RW01) - B1154en Version 2...

  • Page 33: Who Does What

    An instruction video can be called up via a QR code on the front of the machine. QR code for information on commissioning Fig. 109244 Link: https://trumpf.clickandlearn.at/manuals/TruArcWeld_Com/ story.html 2‐3 B1154en Installation conditions TruArc Weld 1000 (RW01) - Version 2...

  • Page 34: Planning Aid

    Technical Service, the required means of trans- portation and auxiliary transport equipment is provided by them. 2-3 weeks Feedback ■ Provide TRUMPF with feedback to confirm that the requirements of the installation conditions have been implemented. During installation and Electrical installation ■...

  • Page 35: Installation Site

    Installation site Space requirements The following is documented in the TRUMPF installation: ■ Arrangement of the machine ■ Space requirements for standard installation ■ Space requirements of the moving elements − Doors on the electrical cabinet − Lateral sliding doors Note The installation plan delivered with the machine is always valid.

  • Page 36: Floor Quality

    Floor quality Floor quality ■ The carrying capacity and deformation of the foundation are defined by the bedding module. The bedding module k must be at least 15,000 kN/m ■ The strength at the surface of the foundation upon which the concrete slab rests is defined by the deformation modules from the load plate pressure test according to DIN 18134 or ÖNORM B4417.

  • Page 37: Ambient Conditions

    Support points of the Mobile welding cell Weight mobile welding cell Weight of the complete system 2980 kg (6569.8 lbs) Static load of all support points of 7.5 kN the machine, front Static load of all support points of 15 kN the machine, rear Weight load Tab.

  • Page 38: Lighting

    Ambient conditions for the Control status Temperature Humidity power source Operation -10 °C ... +45 °C 30 to 95% relative (+14 °F ... +113 °F) humidity ≤ 50% at 45°C ≤ 90% at 20°C Ambient conditions for the power source Tab.

  • Page 39: Compressed Air Supply

    Compressed air supply Note The connection point is indicated on the installation plan using this symbol. The machine is supplied with compressed air for: ■ Anti-glare protection ■ Linear axis Compressed air supply Properties Requirement connected loads Required network pressure 6 bar to 7 bar (87 to 101.5 psi) Air consumption (required volume about 0.1m...

  • Page 40: Establishing Compressed Air

    Hose clip Stop valve Pneumatic connection Fig. 109247 Establishing compressed air Note When the machine is delivered, the stop valve is closed. 1. Connect pneumatic line with a hose clamp. 2. Open the compressed air supply. 3. Open the stop valve. 4.

  • Page 41: Electrics

    Electrics Target group The specifications in the "Electrical" section must be imple- mented by a company which specializes in electrical installations. IEC/NEC conditions The IEC conditions apply worldwide, the NEC conditions apply only to Canada and the USA. Power supply Note The central connection point is on the electrical cabinet and is shown on the installation plan with the illustrated symbol.

  • Page 42: Connecting Cables

    Mobile welding cell Connected load (IEC) 21 kVA Connected load (NEC) 21 kVA Fuse protection at 400V (IEC) 32 A type C Fuse protection at 460V (NEC) 40 A class J Average electrical power consump- 15 kW tion Connected loads Tab.

  • Page 43: Power Supply

    The customer must, if necessary, provide a residual current ■ circuit breaker. ■ TRUMPF recommends a fault current circuit breaker with a fault current of 1 A and a reaction time of 1 second. 2‐13 B1154en Electrics - Version 2...

  • Page 44: Power Supply Configurations

    IT system A surge diverter is required if the machine is connected to an IT system. TRUMPF recommends surge diverters from the following manu- facturers: ■ Phoenix Contact GmbH & Co. KG, Flachsmarktstrasse 8, 32825 Blomberg, Germany e-mail: info@phoenixcontact.com.

  • Page 45: Operating Materials

    Fig. 106730 Material combinations for The choice of shielding gas and welding wire depends on the welding jobs material to be welded. TRUMPF recommends the following mate- rial combinations for the supplied welding jobs: 2‐15 B1154en Operating materials - Version 2...

  • Page 46: Establishing Shielding Gas Connection

    Material Shielding Wire Wire thick- ness Unalloyed mild steels Corgon 18 1 mm Aluminum Argon AlMg 5 1 mm CrNi (Nirosta steels) Cronigon 2 1.4301 1 mm Specifications for shielding gases and welding wires for sup- Tab. 2-15 plied welding jobs Notes ■...

  • Page 47: Transport

    Transport Transport of the system from the truck to its final installation site needs to be prepared and carried out. TRUMPF delivers the machine free to the purchaser's address. The customer is responsible to transport the machine to the installation site.
  • Page 48 Authorized additional equipment Carrying capacity Transporting the Indoor crane. Slinging equipment: According to the machine weight machine to the installa- ■ Adjustable crane chain tion site ■ 2 shackles, form A (DIN 82101) Armored rollers: 1 steerable, 2 fixed According to the machine weight Forklift truck Permitted auxiliary tools Tab.
  • Page 49 Indoor crane Transport with indoor crane Fig. 102474 Forklift truck Transport with forklift truck Fig. 102477 2‐19 B1154en Transport - Version 2...
  • Page 50 Armored rollers The machine can be transported to the installation site on arm- ored rollers in the following ways: ■ Position the machine directly on armored rollers when unloading it from the truck. ■ Due to a danger of tilting, only raise the machine using hydraulic hoisting jacks at the points marked and insert arm- ored rollers underneath.

  • Page 51: Checking, Unloading And Transporting The

    2. Record visible damage caused during transport on the cargo note and have the record countersigned by the truck driver. 3. Report any hidden transport damage to the insurance com- pany and TRUMPF within six days. 2‐21 B1154en Transport - Version 2...

  • Page 52: Unloading And Transporting The Machine

    Unloading and transporting the machine Suspended load! DANGER Falling loads could lead to severe bodily injury or even death. Ø Observe safety regulations for the handling of heavy loads. Ø Never walk under a suspended load. Use tested and appropriately sized tackle and means of Ø...

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