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Fronius Robacta TX 10i/G/W Operating Instructions Manual
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Fronius Robacta TX 10i/G/W Operating Instructions Manual

Fronius Robacta TX 10i/G/W Operating Instructions Manual

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Operating
Instructions
Robacta TX 10i/G/W console
EN
Operating Instructions
42,0426,0170,EN
010-12022024

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Summary of Contents for Fronius Robacta TX 10i/G/W

  • Page 1 Operating Instructions Robacta TX 10i/G/W console Operating Instructions 42,0426,0170,EN 010-12022024...
  • Page 3 Contents Safety rules Explanation of safety notices 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 Commissioning, maintenance and repair Safety inspection...
  • Page 4 Preparing the torch body Preparing torch bodies with steel inner liners Preparing torch bodies with plastic inner liners Configuring the torch-body racks Safety General Configuring the torch-body rack Checking the torch body sensor and setting the wire sensor Safety Connecting the torch body change station to the robot control Checking the torch body sensor Setting the wire sensor Fitting the torch body coupling to the MHP R hosepack...
  • Page 5 Troubleshooting Safety Safety Troubleshooting Troubleshooting Care, maintenance and disposal Safety Safety Replacing the inner liner in the torch body Replacing a steel inner liner in the torch body Replacing a plastic inner liner in the torch body Replacing the inner liner in the core bolt Replacing a steel inner liner in the core bolt Replacing a plastic inner liner in the core bolt Replacing the inner liner in the MHP R hosepack...
  • Page 6 Safety rules Explanation of DANGER! safety notices Indicates immediate danger. ▶ If not avoided, death or serious injury will result. WARNING! Indicates a potentially hazardous situation. ▶ If not avoided, death or serious injury may result. CAUTION! Indicates a situation where damage or injury could occur. ▶...
  • Page 7 Proper use The device is to be used exclusively for its intended purpose. Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage. Proper use includes: carefully reading and following all the instructions given in the operating in- structions studying and obeying all safety and danger notices carefully...
  • Page 8 Specific hazards Stay out of the working area of the robot. The device must be incorporated into a higher-level safety system within a se- cured area. If this area has to be accessed when setup and maintenance work is carried out, make sure that the entire system is switched off for the duration of the work in this area and that it is prevented from starting up accidentally, e.g.
  • Page 9 Check for possible problems, and check and evaluate neighbouring devices' res- istance to interference according to national and international requirements: Safety devices Power, signal and data transfer lines IT and telecommunications devices Measuring and calibrating devices Supporting measures for avoidance of EMC problems: Mains supply If electromagnetic interference arises despite correct mains connection, additional measures are necessary (e.g.
  • Page 10 Any safety devices that are not functioning properly must be repaired before switching on the device. Never bypass or disable safety components. Before switching on the device, ensure that no one is likely to be endangered. Check the device at least once a week for obvious damage and proper function- ing of safety devices.
  • Page 11 Data protection The user is responsible for the safekeeping of any changes made to the factory 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 13 General information...
  • Page 15 To operate the torch body change station, the following system components are tem components needed in addition to the welding system: Torch body change station Robacta TX 10i/G/W console Tool kit TX/i Torch body coupling TX/i Core bolt TX/i G or core bolt TX/i W - depending on the system...
  • Page 16 The torch body change station is used hold up to 10 torch bodies hold a welding-torch cleaning device hold a wire cutter hold a TCP measurement system Torch body change station Tool kit TX/i comprising: Robot programming aid (2 parts) Installation tool for torch body coupling TX/i 3 TCP tips...
  • Page 17 Any power source from the TPS/i series welding system Any Fronius robot wirefeeder from the WF R and WF R PAP series Any Fronius unreeling wirefeeder from the WF REEL R series that is syn- chronised by the power source...
  • Page 18 Proper use The device is intended solely for changing Fronius torch bodies. The device is intended solely for use in conjunction with Fronius system compon- ents. This applies to the cooling units and coolant in particular - only use the device in conjunction with Fronius cooling units and Fronius coolant.
  • Page 19 The symbols warn against operating the equipment incorrectly, as this may result in serious injury and dam- age. Model No. Art.No. www.fronius.com Ser.No. 24 VDC 6 bar 1,5 A IP23 WARNING! Risk of serious injury from mechanically powered parts.
  • Page 20 Transport Transport The device is to be transported by the following devices: devices on pallets using a forklift truck on pallets using a lift truck WARNING! Danger from equipement toppling over or falling. This can result in serious personal injury and damage to property. ▶...
  • Page 21 Controls, connections and mechan- ical components...
  • Page 23 Controls, connections and mechanical compon- ents 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 Fronius accessory equipment with compressed air (wire cut- ters, welding-torch cleaning devices) I/O connection for accessory equipment To connect Fronius accessory equipment to the torch body change station Mechanical com- Rack holder ponents for holding up to 10 torch-body racks...
  • Page 25 Pin assignments and signal descriptions 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 26 Input* Output** Signal 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 Torch body sensor 10 Sensor 1st Robacta TX cover Sensor 2nd Robacta TX cover Valve 1st Robacta TX cover Valve 2nd Robacta TX cover...
  • Page 27 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 28 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 only: Welding-torch cleaning device is ready Gas nozzle free / clean- Signal only available as an option.
  • Page 29 Assignment of CAUTION! connection to external options Danger due to overcurrent. Damage to connection supply can be the result. ▶ Secure supply against overcurrent with a 1.5 A slow-blow fuse. NOTE! To avoid faults, keep the cable between the torch body change station and the robot control as short as possible.
  • Page 31 Installation and commissioning...
  • Page 33 Safety Safety Observe the following safety rules for all work described in the "Installation and start-up" section. 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 34 WARNING! Danger from compressed air escaping from the torch body coupling, flying parts, and sharp components. This can result in serious personal injury and damage to property. ▶ During the work described below, always wear the following protective equip- ment: Protective goggles with side protection, Gloves - electrically insulated and providing protection against heat, Safety helmet.
  • Page 35 Before installation and commissioning Operators, main- WARNING! tenance person- Risk of machines starting automatically. This can result in serious injury and damage to property. ▶ The device must only be operated/serviced by 1 person at a time. ▶ Ensure that there is only 1 person within the working area of the device when the device is being worked on.
  • Page 36 Application example Application ex- ample (2) (3) (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 torch body change station as shown Interconnecting hosepack Robot Wirefeeding hose...
  • Page 37 Installing the torch body change station Bolting the torch WARNING! body change sta- tion to the un- Danger from mechanically powered parts and escaping compressed air. derlying surface This can result in serious personal injury and damage to property. ▶ (foundation) Before starting any work, take the measures listed below and make sure that these measures remain in effect until all work is completed:...
  • Page 39 Preparing the torch body Preparing torch NOTE! bodies with steel Make sure when fitting that the inner inner liners liner (1) is pushed in as far as it will go against the contact tip (2). NOTE! The coupling surface of the torch body must always be free of oil, grease, dust and moisture.
  • Page 40 Preparing torch NOTE! bodies with Make sure when fitting that the inner plastic inner liners liner (1) is pushed in as far as it will go against the contact tip (2). NOTE! The coupling surface of the torch body must always be free of oil, grease, dust and moisture.
  • Page 41 Configuring the torch-body racks 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 42 Configuring the torch-body rack...
  • Page 43 Checking the torch body sensor and setting the wire sensor 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 44 Checking the torch body sensor Check that the LED lights up on the torch body sensor. If the LED does not light up, check the connection between the robot control and the torch body change station Check all the other torch body sensors Setting the wire Rotate the wire electrode in the sensor...
  • Page 45 Fitting the torch body coupling to the MHP R hosepack 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 46 Steel inner liner Plastic inner liner Screw the cap onto the inner liner as far as it will go. The inner liner must be visible through the hole in the cap.
  • Page 47 Fitting the torch body coupling to the WF 25i Robacta Drive / WF 60i Robacta Drive CMT drive unit Safety WARNING! Danger due to mechanical moving parts moving unexpectedly. This can result in serious personal injury and damage to property. ▶...
  • Page 48 Preparing the torch body coup- ling for steel in- ner liners use the cutting pipe from the original equipment kit for the drive unit used Fitting the torch NOTE! body coupling The coupling surfaces between the torch body coupling and torch body must always be free of oil, grease, dust and moisture.
  • Page 49 Manually unlocking / locking the torch body coup- ling Manually unlock- NOTE! ing / locking the torch body coup- When the torch body coupling is un- ling locked, the locking balls (1) do not protrude out of the inside of the torch body coupling.
  • Page 50 Checking the torch body coupling function Checking the Actuate the torch body coupling 5 times with a robot signal and check that torch body coup- the torch body coupling opens and closes ling function If the torch body coupling opens and closes correctly, then check that a torch body can be locked in the torch body coupling manually Torch body coupling closed Torch body coupling open...
  • Page 51 Converting the torch body coupling from TX/i low to TX/i high General Robacta TX/i can be operated with a system pressure of 5-16 bar. There are two versions here: Robacta TX/i low For system pressures of 5-7.5 bar With vent valve in the torch body coupling Robacta TX/i high For system pressures of 8-16 bar Without vent valve in the torch body coupling...
  • Page 52 Insert fitting tool 44,0450,1443 in- to the torch body coupling Unscrew the brass washer from the torch body coupling 44,0450,1443 Remove the vent valve (e.g. with a scriber or needle-nosed pliers or with a 1.5 mm drill) Insert the brass washer into the torch body coupling Insert fitting tool Secure brass washer with the fit-...
  • Page 53 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 54 Determining the CAUTION! TCP of the weld- ing torch, de- Risk of injury from razor-sharp TCP tips. termining the X- Do not touch the pointed end of the TCP tips. axis and Y-axis of the torch body Screw 3 TCP tips into the holes (1) change station of the rack holder Measure TCP of the welding torch...
  • Page 55 Permissible deviations: max. 0,5 mm / 0,02 inch, max. ± 0,5° NOTE! The following positions are not permissible. Setting up the robot...
  • Page 56 If present, set up the robot for all further torch-body racks...
  • Page 57 Start-up Prerequisites for The following prerequisites must be fulfilled for start-up: start-up Torch body change station installed All torch body sensors checked and wire sensor set All torch bodies prepared Torch body coupling fitted Torch bodies oriented for special rack positions (only if necessary) Torch body coupling function checked Robot set up using robot programming aid Start-up...
  • Page 58 Program sequence Safety CAUTION! Danger from incomplete installations. This can result in serious damage to property. ▶ 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 59 Program se- quence Start Move to pos. A - above torch-body rack Query power Stop program 'False' source ready - Power source error 'True' - Select job to advance wire electrode - Feeder inching speed: 600 cm/min (236.22 ipm) Move to pos. B - approx.
  • Page 60 Stop program Query wire - Wire cutter error 'False' cutter closed 'True' Move to pos. D - 5 mm (0.2 in.) above wire cutter Reset "Cut wire electrode" signal - "Wind back wire electrode" signal - Wind back wire electrode until behind coupling point - Feeder inching speed: 600 cm/min (236.22 ipm)
  • Page 61 Move to pos. G - Insert 75 mm (2.95 in.) above centre of torch-body rack - Speed: max. 100 cm/min (39.37 ipm) Move to pos. H - Move down into torch-body rack Speed: max. 50 cm/min (19.69 ipm) Wait 0.5 seconds Query torch body sensor (torch body Wait 0.5...
  • Page 62 Wait 0.5 seconds Query Stop program torch body - Torch body change error 'False' sensor (new torch body present) 'True' Move to pos. K - 75 mm (2.95 in.) above centre of torch body to be picked up Query torch 'False' Stop program body sensor...
  • Page 63 Move to pos. L - 25 mm (0.98 in.) above centre of torch body to be picked up Move to pos. M - Pick up torch body flush - Speed: max. 100 cm/min (39.37 ipm) Reset - "Change torch body" signal Wait 2 - 3 seconds Move to pos.
  • Page 64 Move to pos. O - 75 mm (2.95 in.) above top of torch- body rack - 50 mm (1.97 in.) next to centre of torch-body rack - Speed: max. 1000 cm/min (393.70 ipm) Reset Only with Robacta TX cover option - "Valve 2nd Robacta TX cover"...
  • Page 65 - "Advance wire electrode" signal - Signal duration: 1 second Reset Query wire 'False' cutter open - "Cut wire" signal Query wire 'True' 'True' cutter open Move to pos. C - Enter wire cutter 'False' - "Cut wire electrode" signal Stop program - Wire cutter error Wait 0.5 seconds...
  • Page 67 Options...
  • Page 69 Safety Safety Observe the following safety rules for all work described in the "Options" section. 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 70 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 71 Fitting the torch-body rack Fitting the torch-body rack NOTE! Connect the torch-body rack to the torch body change station as shown in the circuit diagram.
  • Page 73 Fitting the compressed air maintenance unit Fitting the com- pressed air maintenance unit...
  • Page 74 Fitting the wire cutter Fitting the wire cutter Use the screws supplied with the torch body change station...
  • Page 75 Fitting the Robacta Reamer V Easy, Robacta Reamer brush head Alu edition Fitting the Robacta Reamer V Easy, Robacta Reamer brush head Alu edition...
  • Page 76 Fitting the Robacta Reamer V Fitting the Robacta Reamer...
  • Page 77 Connecting the torch body change station to the Robacta TC 1000 / Robacta TC 2000 Connecting the torch body change station to the Robacta TC 1000 / Robacta TC 2000 Use the screws supplied with the torch body change station...
  • Page 78 Installing the pneumatic Robacta TX cover Installing the pneumatic Robacta TX cov- NOTE! Reuse the two screws shown to screw down the pneumatic cover - just the screws, not the washers.
  • Page 79 NOTE! Connect the cover connectors to the PC board in the torch body change station as shown in the circuit dia- gram.
  • Page 80 If present, install the second cover in the same way...
  • Page 81 Troubleshooting...
  • Page 83 Safety Safety Observe the following safety rules for all work described in the "Troubleshooting" section. 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 84 WARNING! Danger due to hot system components and/or equipment. 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 85 Troubleshooting Troubleshooting Only for a water-cooled welding torch: After a torch body has been changed, there is some residual coolant on the torch body Cause: Torch body coupling is worn Remedy: Send the torch body coupling to the manufacturer's service depart- ment Cause: Compressed air escaping from the torch body coupling is causing...
  • Page 87 Care, maintenance and disposal...
  • Page 89 Safety Safety Observe the following safety rules for all work described in the "Care, mainten- ance and disposal" section. 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 90 WARNING! Danger due to hot system components and/or equipment. 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 91 Replacing the inner liner in the torch body Replacing a steel Removing the torch body from the torch body coupling inner liner in the torch body NOTE! When refitting, make sure that the in- ner liner (1) is pushed in as far as it will go against the contact tip (2).
  • Page 92 NOTE! The coupling surface of the torch body must always be free of oil, grease, dust and moisture. Replacing a Removing the torch body from the torch body coupling plastic inner liner in the torch body...
  • Page 93 NOTE! When refitting, make sure that the in- ner liner (1) is pushed in as far as it will go against the contact tip (2). NOTE! The coupling surface of the torch body must always be free of oil, grease, dust and moisture.
  • Page 94 Replacing the inner liner in the core bolt Replacing a steel Removing the torch body from the torch body coupling inner liner in the Unscrew the torch body coupling from the drive unit core bolt use the cutting pipe from the original equipment kit for the drive unit used Fit the torch body coupling correctly on the drive unit...
  • Page 95 use the cutting pipe from the original equipment kit for the drive unit used Fit the torch body coupling correctly on the drive unit (see section "Fitting the torch body coupling to the WF 25i Robacta Drive / WF 60i Robacta Drive CMT drive unit", depending on which hosepack is used)
  • Page 96 Replacing the inner liner in the MHP R hosepack Replacing the in- Removing the torch body from the torch body coupling ner liner Disconnect the hosepack from all system components For water-cooled hosepacks: Close the coolant connections on the hosepack with the cover provided...
  • Page 97 Steel inner liner Plastic inner liner Screw the cap onto the inner liner as far as it will go. The inner liner must be visible through the hole in the cap. Connect the hosepack to the system components once more...
  • Page 98 Replacing the O-rings in the torch body coupling Replacing the O- Removing the torch body from the torch body coupling rings in the torch Unscrew the torch body coupling from the drive unit / hosepack body coupling Fit the torch body coupling correctly on the hosepack / drive unit (see section "Fitting the torch body coupling to the MHP R hosepack"...
  • Page 99 Changing coolant stops Replacing Removing the torch body from the torch body coupling coolant stops Unscrew the torch body coupling from the drive unit / hosepack Remove the core bolt from the torch body coupling Fit the torch body coupling correctly on the hosepack / drive unit (see section "Fitting the torch body coupling to the MHP R hosepack"...
  • Page 100 Disposal Disposal Dispose of in accordance with the applicable national and local regulations.
  • Page 101 Technical data...
  • Page 103 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 Protection class IP 23 EMC device class Dimensions l x w x h 662.5 x 348.2 x 835.5 mm 26.08 x 13.71 x 32.89 in.