Fronius ROBACTA CTC Operating Instructions Manual
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Fronius ROBACTA CTC Operating Instructions Manual

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/Perfect Welding
ROBACTA CTC
-
4,050,001 Robacta CTC ø25 M6
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4,050,002 Robacta CTC ø25 M8x1,5
4,050,003 Robacta CTC ø27 M6
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4,050,004 Robacta CTC ø27 M8x1,5
Version:
2021/05
Revision:
1.2
42,0426,0373,EN
Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Solar Energy
Operating Instructions
Spare parts list
Contact Tip Changer

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  • Page 1 Contact Tip Changer 4,050,001 Robacta CTC ø25 M6 4,050,002 Robacta CTC ø25 M8x1,5 4,050,003 Robacta CTC ø27 M6 4,050,004 Robacta CTC ø27 M8x1,5 Version: 2021/05 Revision: 42,0426,0373,EN Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
  • Page 2 KYOKUTOH Europe GmbH © Radlkoferstraße 2 81373 München/Germany Phone: +49-89-741185-313 Fax: +49-89-741185-315 Office Unna Max-Planck-Straße 4 59423 Unna/Germany Phone: +49-2303-93615-00 Fax: +49-2303-93615-29 info@kyokutoh.de www.kyokutoh.de...
  • Page 3 Foreword Foreword This operating manual contains all information pursuant to § 3 Equipment Safety Act "Conditions for putting into circulation" (in conjunction with Machinery Directive 2006/42/EC as amended). The operating manual is intended for persons who will be/are tasked with working on/with the machine described here.

  • Page 4: Table Of Contents

    Table of Content Table of content Declaration of Conformity ....................... 1 Technical Specifications ........................2 Type ............................3 Dimension ..........................4 Sensor Technology ........................5 Basic Saftey Instructions ........................7 Explanation of symbols and instructions ................. 7 Proper use ..........................8 Improper use ...........................
  • Page 5 Table of Content 5.4.1 Preparation process....................... 20 5.4.2 Confirmation of engine running ..................21 5.4.3 Cut off welding wire ...................... 22 5.4.4 Turn off and remove the nozzle ..................24 5.4.5 Cleaning the contact tip ....................26 5.4.6 Actuation of the magazine (revolver) ................27 5.4.7 Remove contact tip .......................
  • Page 6 05.10.2020 M. Swientek Technology e filter added, additional information added Change chap. 2.1 Contact & Gas Nozzle 21.05.2021 G.Heimann Technology Change chap. 5.3.4 Fronius item number addedt. 21.05.2021 G.Heimann Technology Change chap. 9.1 List of spare parts 21.05.2021 G.Heimann Technology Amendment Appendix E-Plan updated 21.05.2021 G.Heimann...

  • Page 7: Declaration Of Conformity

    1. Declaration of Conformity 1 Declaration of Conformity EG-Konformitätserklärung nach der EG-Maschinenrichtlinie 2006/42/EG EC-Declaration of Conformity Hiermit erklärt die KYOKUTOH Europe GmbH Herewith we Radlkoferstraße 2 D –81373 München dass die nachfolgend bezeichneten Maschinen, aufgrund ihrer Konzeption und Bauart, soweit in der von uns in Verkehr gebrachten Ausführung, den einschlägigen grundlegenden Sicherheits–...

  • Page 8: Technical Specifications

    2. Technical Specifications 2 Technical Specifications CTC-001 Contact Tip Changer Motor designation BLM460SHP-GFV Supply voltage 0-240V/AC Control voltage 24V/DC Power supply connection Without plug (cable) Rotation sensor Inductive Power line 24V Without plug (cable) Motor Power 60 W Torque about 34Nm Type of drive electrical Splash guard...

  • Page 9: Type

    2. Technical Specifications 2.1 Type Robacta CTC ø27 M6 Robacta CTC Robacta CTC Robacta CTC ø27 M8x1,5 ø25 M6 ø25 M8x1,5 Nozzle Nozzle Nozzle Nozzle Contact tip Contact tip Contact tip Contact tip...

  • Page 10: Dimension

    2. Technical Specifications 2.2 Dimension...

  • Page 11: Sensor Technology

    2. Technical Specifications 2.3 Sensor Technology Note! Please pay attention to the correct cable connection. E3T Photoelectric sensor / E3Z photoelectric sensor / E2E proximity sensor / magazine query control request cutter query 1- E2E: Determining the position of the cutter before cutting the welding wire in the cutting unit. (Output signal: SS1) Lower blade does Lower blade does...
  • Page 12 2. Technical Specifications 2- E3Z: To check the presence of nozzle and contact tip. To check the complete removal of nozzle and contact tip. For checking incomplete fastening of the contact tip up to 0.5 mm with the mounting thread. (Output signal: LS) *For example, if the length of the thread of the contact tip is 7.0mm, the sensor determines the contact tip from 6.5 to 7.0mm to the tip body.

  • Page 13: Basic Saftey Instructions

    3. Basic Saftey Instructions 3 Basic Saftey Instructions The health and safety of employees can only be guaranteed provided the described safety measures are adhered to during all phases of life (construction, transport, installation etc.). Generally speaking, the usual accident prevention regulations (Accident prevention regulations, UUV) apply, in particular the UUV regarding safety at machines.

  • Page 14: Proper Use

    3. Basic Saftey Instructions 3.2 Proper use Note! The operational safety of the supplied machine is only guaranteed in case of proper use. This product is only for use to change specified contact tips. Proper use also includes adherence to the operating and/or user instructions (including those provided by the supplier) and adherence to all maintenance and service intervals.

  • Page 15: Obligation To Instruct

    3. Basic Saftey Instructions 3.4 Obligation to instruct The operator must instruct his employees regarding the possible risks, residual risks and the measures to be taken in order to avoid these risks prior to the initial commissioning. This instruction must be issued to every employee who operates the system or is in immediate proximity of these hazards.

  • Page 16: Conduct In Case Of Hazards And Faults

    3.8 Conduct in case of hazards and faults Warning! Shut down system using EMERGENCY STOP. Additional measures must be specified by the operator. In the event of hazards or faults (irregularities) stop working; shut down the system and wait until it is stationary.

  • Page 17: Special Safety Instructions

    3. Basic Saftey Instructions 3.12 Special safety instructions Note! Adhere to any user manuals for individual components that may be included in the appendix. Caution! Never place your hand or finger into the terminal opening while the machine is in operation.

  • Page 18: Hazards During Maintenance, Repair And Similar Work

    3. Basic Saftey Instructions 3.13 Hazards during maintenance, repair and similar work Caution! Immediately after the completion of repair work, the safety devices must be reinstalled and checked regarding their effectiveness. All repairs and maintenance work may only be carried out if the main switch of the machine is set to the “0”...

  • Page 19: Setup And Assembly

    4. Setup and Assembly 4 SETUP AND ASSEMBLY Note! The machine must be set up in accordance with the planner’s installation plan. 4.1 Place of installation, place of use Explosion areas are not permitted for this machine. Observe the maximum load-bearing capacity of the installation area (statics). A special foundation is not necessary.

  • Page 20: Commissioning / Setup

    5. Commissioning / Setup 5 COMMISSIONING / SETUP Caution! The commissioning of the machine may only be performed when wearing suitable safety clothing. Note! As a rule, this machine may only be operated by authorized operating personnel, who fulfill the requirements regarding training, briefing and qualifications. 5.1 Safety requirements Warning! Correct faults immediately.

  • Page 21: Preparation For Operation

    5. Commissioning / Setup 5.3 Preparation for operation Warning! The disconnection of the electrical connection between the mains supply and the control cabinet must be ensured. The following steps are necessary to successfully remove and attach the nozzle and contact tip: Before teaching: 1- Ensure that the unit is securely attached to the stand.

  • Page 22: Process Preparation For Teaching

    5. Commissioning / Setup 5.3.2 Process preparation for teaching 1- Use the cleaning unit as a reference point / level for parallel alignment of the torch (see picture below). 2- If the torch is parallel to the cleaning unit, move the torch horizontally to each unit. 3- Make sure that nozzle and contact tip are centered in the removal and attaching units so that tolerances are the lowest.

  • Page 23: Signals

    4000 1000 must be switched off (OFF signal). 5.3.4 Spacer Each CTC Fronius SET is delivered with a selection of spacers as standard. The spacer provides the right distance to optimally remove the gas nozzle. Name: Item number: Verwendung: FS-17,8L 42,0411,0350 Nozzle Outer - Ø...
  • Page 24 5. Commissioning / Setup 42,0001,4048 FS-32,8L 42,0001,4051 FS-32,8L 42,0001,4474 FS-32,8L 42,0001,4496 FS-32,8L 42,0001,4080 FS-32,8L 42,0001,4086 FS-32,8L 42,0001,4497 FS-32,8L 42,0001,4639 FS-32,8L 42,0001,4045 FS-32,8L 42,0001,4047 FS-32,8L 42,0001,4475 FS-32,8L 42,0001,4495 FS-32,8L 42,0001,4788 FS-32,8L 44,0350,2028 FS-32,8L 42,0001,4085 FS-32,8L 42,0001,4087 FS-32,8L 42,0001,4088 FS-32,8L 42,0001,4049 FS-35L 42,0001,4050 FS-35L 42,0001,4476...

  • Page 25: Change Spacer

    5. Commissioning / Setup 5.3.5 Change Spacer Remove the 4 fastening screws. Put the cover aside. Remove the entire nozzle removal unit. Remove the jaws from the nozzle removal unit. Remove the jaw guide ring. The spacer can now be removed. The unit is reassembled in reverse order.

  • Page 26: Teaching Process

    5. Commissioning / Setup 5.4 Teaching process 5.4.1 Preparation process Process Details -> Start (Unless otherwise specified, turn all signals OFF) -> Reset the robot signal -> MC (Output): ON / (Motor drive: Power ON) -> after a second (The magazine can be filled with a total of 10 contact tips. To refill, the magazine must be turned back to its original position after changing the contact tip ten times) The following monitoring is carried out using the SS2 photoelectric sensor: 1- The magazine is turned back to its original position...

  • Page 27: Confirmation Of Engine Running

    5. Commissioning / Setup 5.4.2 Confirmation of engine running (Before preforming the change process, it must be checked that the permissible engine load is not exceeded when idling, e.g. if foreign objects have penetrated the interior and become noticeable, or that resistance has increased due to the wear of parts) (Speed setting 4 = 1000rpm, Torque limit= lower than 25% Do not perform the change process if the engine load exceeds 25%) ->...

  • Page 28: Cut Off Welding Wire

    Move the welding torch and guide the electrode wire into position (2). Query of the signals  welding system ready / power source ready / wire feed unit ready (see Fronius Interface operating instructions) -> Hold the electrode wire in place and guide it out of the nozzle (Note: The electrode wire tip must not hit the housing surface of the cutting unit.
  • Page 29 5. Commissioning / Setup -> Guide the electrode wire to position (3) Note - If a Fronius Wire Brake Device is installed in the welding system, it can be used to hold the wire in place during the cutting process.

  • Page 30: Turn Off And Remove The Nozzle

    5. Commissioning / Setup 5.4.4 Turn off and remove the nozzle Requirements for turning off and removing the gas nozzle: 1- In principle, when the nozzle is inserted into the removal unit and the unit is pressed down, the clamping jaws extend mechanically. In this case, however, the jaws are not in the actual clamping position.
  • Page 31 5. Commissioning / Setup -> Move the torch to the stop of the spacer. Push the nozzle 8mm further down. During this movement, the clamping jaws are extended, and the nozzle is clamped more and more. Spacer stop Push 8 mm down 300cm/min or slower (48mm/s) ->...

  • Page 32: Cleaning The Contact Tip

    5. Commissioning / Setup 5.4.5 Cleaning the contact tip Requirements for cleaning the contact tip: 1- Cleanability of the contact tip 2- Rotation speed “Speed setting 2“: (High Speed) 4000rpm 3- Direction of rotation of the cleaning unit when cleaning: (Reverse Rotation) 4- Engine torque: Max.

  • Page 33: Actuation Of The Magazine (Revolver)

    5. Commissioning / Setup 5.4.6 Actuation of the magazine (revolver) The magazine (revolver-shaped rotating unit) (To avoid bending the welding torch, the mechanical switch should not be pressed down more than 8mm.) -> Press the switch down about 7 mm (Push down speed: 300cm/min or 48mm/s) ->...
  • Page 34 5. Commissioning / Setup -> After about a second “Forward rotation” IN0 (FWD) / (Input): OFF -> Stop engine -> Insert the contact nozzle into the contact tip removal unit (Insertion speed: 300cm/min or. slower 48mm/s) -> Insert the contact tip so far that the clamping jaws can grip over the entire circumference. The retaining head must not come into contact with the clamping jaws.
  • Page 35 5. Commissioning / Setup -> The direction of rotation (REV) and simultaneous lifting of the welding torch. (After visual inspection that the contact nozzle has been removed.) -> “Reverse rotation“ IN1 (REV) / (Input): OFF (The height at which the contact nozzle is completely removed corresponds to thread length + an excess length approx.

  • Page 36: Contact Tip Attachement

    5. Commissioning / Setup 5.4.8 Contact tip attachement Requirements for attaching contact tip: 1- Basically, if the contact tip holder is pressed 5 - 7 mm downwards, a connection with the rotating unit is created. 2- Rotating speed: Speed setting 1 (Medium speed: 2000rpm) 3- Engine torque: restriction (IN2 (TL) / (Input): OFF 4- Direction of rotation of the motor when attaching contact tip: REV ->...

  • Page 37: Attachment Nozzle

    5. Commissioning / Setup (The distance of pushing down should correspond to the condition of the fully tightened contact nozzle: 9-10mm) -> TLC signal (Output): ON (With active torque detection signal) -> Wait 0.5s -> “Reverse rotation” IN1 (REV) / (Input): OFF ->...
  • Page 38 5. Commissioning / Setup -> Drive the torch down until the insulating part comes into light contact with the gas nozzle. Caution: Do not push the unit down (Insertion speed: 300cm / min or slower 48mm / s) -> Drive the welding torch into the unit at a lower speed of 100 cm / min (16 mm / s)  Distance so that the nozzle is not yet pressed down by the welding torch.
  • Page 39 5. Commissioning / Setup -> ”Torque limit“ IN2 (TL) / (Input): OFF (Torque limit available) -> “Speed setting 1” IN3 (M0) / (Input): OFF IN3 (M0) / (Input): OFF (Medium speed) -> ”Forward rotation“ IN0 (FWD) / (Intput): ON -> VA signal (Output): ON (when the speed detection signal is activated) ->...
  • Page 40 5. Commissioning / Setup -> TLC signal (Output): ON (when the torque detection signal is activated) -> ”Forward rotation“ IN0 (FWD) / (Input): OFF -> Speed setting 3” IN4 (M1) (Input): OFF -> Extend the torch at a speed of 200 cm/min or. (33 mm/s) ->...

  • Page 41: Storage And Transport

    6. Storage and Transport 6 STORAGE AND TRANSPORT During all transportation, lifting or moving work, all safety regulations must be adhered to. This also includes that only tested and suitable lifting tools may be used! Caution! Failure to heed the following instructions in the event of damage may void your insurance cover.

  • Page 42: Handover And Inspection

    Document identified damage immediately (sketch, digital / instant camera, description of the damage). – Forward the corresponding documents immediately to Fronius International GmbH! In case of interim storage, ensure the following: – Suitable storage area e.g. dry, clean, heated, measures taken to prevent corrosion –...

  • Page 43: Maintenance And Repair

    8. Decommissioning / Dismantling 7 Maintenance and Repair Note! Maintenance, repair and cleaning must be carried out by appropriately qualified personnel (in keeping with the respective task). 7.1 Maintenance 1- Check the attachment, removal unit and nozzle holder for correct functionality 2- Check the unlocking of the contact tip removal unit for correct functionality 3- Check the plain bearings for correct functionality 4- Remove dust and dirt from the guide pins...
  • Page 44 7. Maintenance and Repair...

  • Page 45: Cleaning

    7. Maintenance and Repair 7.2 Cleaning Note! Only clean the machine using suitable auxiliary materials. Caution! Switch the machine off before cleaning and secure against unauthorized restart. It goes without saying that you should clean and care for your machine regularly. How often you must clean it depends primarily on your work and environment.
  • Page 46 7. Maintenance and Repair – Do not clean the machine using high-pressure cleaning equipment. – Supply parts must be maintained in accordance with manufacturer specifications. – Maintain a clean and tidy environment during all servicing work. – Keep traffic routes clear. –...

  • Page 47: Decommissioning/Dismantling

    8. Decommissioning / Dismantling 8 Decommissioning/Dismantling Caution! Be sure to adhere to accident prevention regulations! Warning! Be sure to allow residual energy to safely dissipate. 8.1 Safety regulations Note! Decommissioning may only be performed by commissioned specialist personnel. Warning! Switch the machine off prior to decommissioning and secure against unauthorized restart.

  • Page 48: Spareparts

    9. Spareparts 9 SPAREPARTS Note! Non-original or faulty replacement parts can cause damage or machine malfunctions. Caution! Replacement parts may only be replaced, or repairs performed by specialist personnel, as there is a risk of injury on account of stored residual energy. In order that valuable production time is not lost in the event of the failure of components that are subject to wear and to minimize downtime, we recommend that you keep a stock of replacement parts.

  • Page 49: Patrlist

    9. Spareparts 9.1 Partlist Sparepart list Robacta Model: 4,050,001 4,050,002 Clamping jaws 4,050,003 4,050,004 for contact tip Item no.: 42,0411,0357 42,0411,0358 Quantity: Treibwerk für 4,050,001 Kontaktdüsen- 4,050,002 Driving finger magazin: 4,050,003 for contact tip 4,050,004 holder Item no.: 42,0411,0359 Quantity: Robacta Model: 4,050,001 4,050,003...

  • Page 50: Service

    10. Service 10 SERVICE Note! The penetration of cooling water from the welding grippers into the transmission housing can result in the damage of the intake gearwheel incl. the bearings in the transmission area, depending on operating conditions. Be sure to regularly lubricate the transmission! (See Maintenance) Warning! There is a risk of becoming trapped or injured as a result of the movement of the components.
  • Page 51 – The brush is worn out – Exchange for new ones Contact tip is not cleaned In the event of faults, questions or spare parts deliveries, please contact your Fronius contact person.

  • Page 52: Appendix

    11. Appendix 11 APPENDIX 11.1 Data on the different contact tips Contact tips with wrench size Outer diameter ØA: Ø7 – Ø10 Wrench size B: 6 - 9 Length C: Thread length D: Distance between the tip of the thread length „0“...

  • Page 53: Data On Different Nozzles

    11. Appendix 11.2 Data on different nozzles Threaded nozzle Shape: Straight (S) / Conical (T) / Stepped (D) Outer diameter ØF: Ø34mm or smaller Length H: Knurling length l: 60mm or smaler...

  • Page 54: Elektronic

    11. Appendix 11.3 Elektronic Motor Specification – Speed Control Motor CTC Speed Control Motor spec Frame Size 80 mm Rated Output Power 60 W Gearhead Ratio 20:1 Power Supply AGE11513 Single Phase 200~240 VAC (Frequency converter type BLE2D60-C) Three Phase 200~240 VAC Frequency (Hz) 50/60 Rated Torque (Gearhead Shaft)
  • Page 55 11. Appendix...
  • Page 56 FRONIUS INTERNATIONAL GMBH Froniusstraße 1, A-4643 Pettenbach, Austria E- Mail: sales@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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