Related Manuals for Fronius TXi TWIN
Summary of Contents for Fronius TXi TWIN
- Page 1 Operating Instructions Upright console TXi TWIN Wall-mounted console TXi TWIN EN-US Operating instructions 42,0426,0284,EA 008-15012024...
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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 Mounting the wall-mounted console TXi TWIN Supply the torch body change station with compressed air Installing the Torch Body Coupling... - Page 4 Installing the coding ring Troubleshooting Safety Troubleshooting Service, maintenance and disposal Safety Maintenance activities Changing the O-rings in the torch body coupling Adjusting the pneumatic cover 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 accordance with the intended purpose. The manufacturer accepts no liab- ility for any damage resulting from improper use. Intended use also means: Reading and adhering to all instructions in the Operating Instructions Reading and adhering to all safety instructions and danger notices... -
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
Before starting up the device, ensure that no one can be put in danger. The device must be examined at least once a week for externally detectable dam- age and functionality of the safety devices. Maintenance and It is impossible to guarantee that bought-in parts are designed and manufac- repair tured to meet the demands made of them, or that they satisfy safety require- ments. -
Page 10: Copyright
Copyright Copyright of these Operating Instructions remains with the manufacturer. 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... -
Page 11: General
General Device concept The TXi TWIN is a torch body change station for twin welding systems. Two ver- sions are available: Upright console TXi TWIN Wall-mounted console TXi TWIN Upright console Wall-mounted console The torch body change station is used:... -
Page 12: Required System Components
Required system The OPT/i WF Twin Torch Change (4,101,171,IK) option must be installed in the components twin wirefeeder. 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: Application Example
Application ex- ample (5) (6) (7) (8) (10) (11) 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... -
Page 14: Scope Of Supply
Scope of Supply Upright console Torch body change station scope of supply incl. 3x torch-body racks 2x wire cutter holders Base plate for add-on devices Compressed air maintenance unit (on the rear of the device) 4x adjusting shim 1 mm (0.04 inch) 4x adjusting shim 1.5 mm (0.06 inch) -
Page 15: Tools Scope Of Supply
Tools Scope of Supply BY2,0201,4862 44,0350,4076 BY2,0201,4863... -
Page 16: Warning Notices Affixed To The Device
The symbols warn against (upright console) operating the equipment incorrectly, as this may result in serious injury and dam- age to property. Model No. Art.No. www.fronius.com Ser.No. 24 VDC 6 bar 1,5 A IP23 WARNING! Danger of serious injuries due to mechanically moving parts. -
Page 17: Warning Notices On The Device (Wall-Mounted Console)
(wall-mounted operating the equipment incorrectly, as this may result in serious injury and dam- console) age to property. Model No. Art.No. www.fronius.com Ser.No. 24 VDC 6 bar 1,5 A IP23 WARNING! Danger of serious injuries due to mechanically moving parts. During maintenance and servicing, keep the device de-energized and depressurized. -
Page 18: 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! Danger from falling or toppling devices. This can result in severe personal injury and damage to property. ▶... -
Page 19: Operating Controls, Connections And Mechanical Components
Operating controls, connections and mechanical components Safety WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in serious personal injury and damage to property. ▶ All the work and functions described in this document must only be carried out by technically trained and qualified personnel. -
Page 20: Operating Controls, Connections, And Mechanical Components Of The Wall-Mounted Con
Connection used for supplying the Fronius add-on devices with com- pressed air (wire cutter, welding torch cleaning devices) (14) 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 mech-... - Page 21 I/O connection for add-on devices To connect the Fronius add-on devices to the torch body change station Compressed air maintenance unit In preparation for the installation of an optional interface to connect to the robot controller Compressed air connection for wire cutter Compressed air connection "A"...
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Page 22: Tactile Sensor (Option)
Tactile sensor (option) General The optional tactile sensor is a teach- ing tool for robot integrators for meas- uring 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... -
Page 23: Connector Pin Assignments And Signal Descriptions
Connector pin assignments and signal descrip- tions Safety WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in serious personal injury and damage to property. ▶ All the work and functions described in this document must only be carried out by technically trained and qualified personnel. -
Page 24: Pin Assignment Of Standard I/O Connection For Robot Controller
Pin assignment CAUTION! of standard I/O connection for Danger from overcurrent. robot controller Damage to the connection power supply may result. ▶ 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 sta- tion and the robot controller as short as possible. - Page 25 Signal Description Connection to X11.1.1 Optional signal. "Start cleaning" signal (when using On Robacta Reamer Twin: starts Robacta Reamer Twin) the cleaning process. „Reinigung starten“ signal (when using Robacta TC) On Robacta TC: starts the cleaning process. Connection to X11.1.4 Optional signal.
- Page 26 Signal Description Connection to X11.1.6 Optional signal. "Gas nozzle free" signal (when us- On Robacta Reamer Twin: indicates ing Robacta Reamer Twin) that the gas nozzle clamping device is not holding a gas nozzle. TC Ready (when using Robacta TC) On Robacta TC: indicates that Robacta TC is ready for a cleaning operation.
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Page 27: Assignment Of I/O Connection For Add-On Devices
Assignment of CAUTION! I/O connection for add-on Danger due to overcurrent. devices Damage to the connection power supply can be the result. ▶ 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 sta- tion and the robot controller as short as possible. -
Page 28: 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 "Installation and Commissioning" chapter. WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in serious personal injury and damage to property. ▶... -
Page 29: Operating Personnel, Maintenance Personnel
WARNING! Danger from compressed air escaping from the torch body coupling, flying debris, and sharp components. This can result in serious personal injury and damage to property. ▶ Always wear the following protective equipment when carrying out the work described below: Safety glasses with side guards, Gloves - electrically insu- lating and heat protective, Protective helmet. -
Page 30: Installing The Torch Body Change Station
In the case of gantry or linear travel, the torch body change station should travel with the robot. If assembly is not possible, observe the necessary tolerances. * 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 31: Mounting The Wall-Mounted Console Txi Twin
Mounting the WARNING! wall-mounted console TXi Danger due to mechanical moving parts moving unexpectedly. TWIN This can result in serious personal injury and damage to property. ▶ Before starting work, disconnect all devices and system components in- volved from all pneumatic and/or hydraulic supply lines and ensure that the supply lines remain disconnected until the work is completed. -
Page 32: Supply The Torch Body Change Station With Compressed Air
20 Nm / 14.75 lb ft per screw Fit the wall-mounted console with mounting bracket to the wall Ground the wall-mounted console TXi TWIN The ground connection is located on the rear of the device. Supply the torch WARNING! -
Page 33: Installing The Torch Body Coupling
Installing the Torch Body Coupling Safety WARNING! Danger due to mechanical moving parts moving unexpectedly. This can result in serious personal injury and damage to property. ▶ Before starting work, disconnect all devices and system components in- volved from all pneumatic and/or hydraulic supply lines and ensure that the supply lines remain disconnected until the work is completed. -
Page 34: Checking The Function Of The Torch Body Coupling
Checking the NOTE! function of the Flawless operation of the interchangeable coupling can only be guaranteed with torch body coup- ling a vertical alignment facing down. Actuate the torch body coupling five times using a robot signal and check whether the torch body coupling opens and closes If the torch body coupling opens and closes correctly, check the manual locking of a torch body in the torch body coupling. - Page 35 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 36: Setting Up The Robot
Setting up the robot General Before starting automatic mode, set up the robot using the robot program- ming aid included in the scope of sup- ply. The notch on the programming aid in- dicates the direction in which the gas nozzle of a torch body locked in the torch body coupling points. - Page 37 Supporting tools: Feeler gauge Flashlight Notch pointing forward Position the programming aid accord- ing to the following illustrations. Position programming aid 0° - ±0.5° 0° - ±0.5° 0.0 - 0.5 mm 0.0 - 0.5 mm 0.0 - 0.5 mm 0° - ±0.5° NOTE! The following positions are not permissible.
- Page 38 If additional robots are present, set up the robots for all remaining torch-body racks.
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Page 39: 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 Danger from electrical current. During the TouchSensing process, the tactile sensor sensor has an open-circuit voltage of up to 70 V (max. 3 A). This can result in serious personal injury and damage to property. - Page 40 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 touches 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...
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Page 41: Commissioning
Danger from impermissible force! This can result in damage to property. ▶ 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... - Page 42 max. 100 N max. 100 N Max. permissible force exerted by the robot on Max. permissible force exerted by the robot on the upright console the wall-mounted console - regardless of wheth- er the wall-mounted console is mounted on the rear of the device or on the right-hand side of the device...
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Page 43: Program Sequence
Program sequence Safety CAUTION! Danger from incomplete installations. This can result in serious damage to property. ▶ Only start automatic mode once the torch body change system has been in- stalled 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 44: Program Sequence
Program Se- quence Start Move to pos. A - approx. 25 mm (0.98 in.) adjacent to the wire cutter - Speed: High speed mode Query Power source ready - Unwind wire electrodes 1 and 2 signal until the wire electrode protrudes 50 mm (1.97 inch) out of the gas nozzle Move to pos. - Page 45 - Wind wire electrodes 1 and 2 for approx. 500 mm (19.69 inch) signal - Wire retraction speed: 600 cm/min (236.22 ipm) Query Power source ready Query torch body sensor Stop program 'True' (torch-body rack free) - Torch body changeover error 'False' Move to pos.
- Page 46 Move to pos. F - Move up 30 mm (1.18 in.) above the center of the torch-body rack - Speed: max. 30 cm/min (11.81 ipm) Move to pos. G - Move up 60 mm (2.36 in.) above the center of the torch-body rack - Speed: High speed mode Query...
- Page 47 Query ‘True‘ Torch body sensor (new torch body present) ‘False‘ Reset - Change torch body signal Wait 1 second Query Torch body sensor ‘False‘ (torch body is picked up successfully) Error: Torch neck not recognized ‘True‘ Move to pos. J (+0,5mm / +0.019 in.
- Page 48 Query Stop program ‘False‘ Wire electrode 1 - Wire electrode error present ‘True‘ Move to pos. N - approx. 50 mm (1.97 in.) adjacent to the wire sensor - Speed: 100 cm/min (39.37 ipm) Move to pos. O - Wire electrode 2 directly in front of the wire sensor - Speed: 50 cm/min (19.69 ipm) Query Stop program...
- Page 49 Query Stop program Sensor first Robacta TX ‘True‘ - Robacta TX cover error cover ‘False‘ Move to pos. C - 10 mm (0.39 inch) above the wire cutter - Speed: High speed mode Reset - Cut wire electrode signal...
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Page 50: Installing Optional Equipment
Installing Optional Equipment Safety Follow the safety rules below when carrying out all tasks described in the "Op- tions" chapter. WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in serious personal injury and damage to property. ▶... -
Page 51: Installing The Torch-Body Rack
WARNING! Danger due to hot system components and/or equipment. This can result in serious burns or scalding. ▶ Before starting work, allow all hot system components and/or equipment to cool to +25°C/+77°F (e.g., coolant, water-cooled system components, wirefeeder drive motor, etc.). ▶... - Page 52 30 Nm 22.12 lb·ft 4 Nm 2.95 lb·ft NOTE! Connect the torch-body rack to the torch body change station as per the Circuit Diagram.
- Page 53 30 Nm 22.12 lb·ft 10 Nm 7.37 lb·ft 4 Nm 2.95 lb·ft...
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Page 54: Installing The Wire Cutter
Installing the The installation procedure for the wire cutter is described using the upright con- Wire Cutter sole as an example. The installation procedure on the wall-mounted console is the same. Installing the Robacta Reamer V Twin... -
Page 55: Installing The Coding Ring
Installing the With the aid of the coding ring (optionally available), up to 7 different torch bod- coding ring ies can be defined mechanically. 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... - Page 56 The torch bodies are defined by screw- ing in the cylinder head screws A, B, and C differently (Hexagon socket size 2.5 mm). Symbols: Cylinder head screw is screwed in (Cylinder head screw present) IMPORTANT! Combination without screwed-in cylinder head screws is not permit- ted.
- 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 –...
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Page 58: Troubleshooting
Troubleshooting Safety Follow the safety rules below when carrying out all the tasks described in the "Troubleshooting" chapter. WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in serious personal injury and damage to property. ▶... -
Page 59: Troubleshooting
WARNING! Danger due to hot system components and/or equipment. This can result in serious burns or scalding. ▶ Before starting work, allow all hot system components and/or equipment to cool to +25°C/+77°F (e.g., coolant, water-cooled system components, wirefeeder drive motor, etc.). ▶... - Page 60 Torch body coupling does not open Cause: Compressed air supply of the torch body coupling is too low Remedy: Ensure compressed air supply according to the specifications in the Operating Instructions Cause: Solenoid valve defective Remedy: Replace solenoid valve Cause: Pneumatic or electrical control lines faulty Remedy: Replace faulty control lines...
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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! Danger from incorrect operation and work that is not carried out properly. This can result in serious personal injury and damage to property. ▶... -
Page 62: Maintenance Activities
WARNING! Danger due to hot system components and/or equipment. This can result in serious burns or scalding. ▶ Before starting work, allow all hot system components and/or equipment to cool to +25°C/+77°F (e.g., coolant, water-cooled system components, wirefeeder drive motor, etc.). ▶... -
Page 63: Changing The O-Rings In The Torch Body Coupling
Changing the O- Remove the torch body from the torch body coupling rings in the torch Unscrew the torch body coupling from the drive unit/the hosepack body coupling NOTE! When inserting new O-rings, make sure that they are properly greased. Fit the torch body coupling to the hosepack/drive unit correctly Adjusting the The pneumatic cover is set as follows on delivery:... -
Page 64: Disposal
Set closing speed: Turning the adjusting screw to the left causes the cover to close more quickly. Disposal Disposal must only be carried out in accordance with the section of the same name in the "Safety rules" chapter. -
Page 65: Technical Data
Technical data Upright console Supply voltage + 24 V DC TXi TWIN Nominal pressure 6 bar/87.02 psi Standard I/O Input: + 24 V DC/ max. 1.5 A Degree of protection IP 23 EMC device class Dimensions l x w x h 662.5 x 348.2 x 835.5 mm... -
Page 66: 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.
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