Fronius 4,044,008 Operating Instructions Manual Download Page 56

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Preparing system components for Robacta hose-

packs

Safety

Preparing the
torch body cou-
pling for Robacta
hosepacks

Press centre bolt (1) out of the torch
body coupling (2)

Unscrew run-off plate (3) from centre
bolt

using a 6 mm socket wrench insert

CAUTION!

Risk of injury from compressed air escaping unintentionally. The torch

body changeover station must remain depressurised until all work is completed.

(2)

(1)

(3)

Summary of Contents for 4,044,008

Page 1: ...mental chlorine free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy 42 0426 0091 EN 020 15032017 Robacta TX W Operating Instructions Torch body...

Page 2: ...2...

Page 3: ...essential prerequisites for excellent results Explanation of safety symbols If you see any of the symbols depicted in the Safety rules chapter special care is re quired DANGER Indicates immediate and...

Page 4: ...4...

Page 5: ...ion 19 Note on wirefeeding 19 Compatible system components for the overall welding system 19 TCP measurement system 20 Proper use 20 Warning notices on the device 21 Warning notices on the device 21 T...

Page 6: ...e torch body coupling for Robacta hosepacks 56 Preparing the inner liner for Robacta hosepacks 57 Preparing the torch body coupling for Robacta Drive and Robacta Drive CMT hosepacks with steel inner l...

Page 7: ...fety 102 Changing the steel inner liners for Robacta Drive and Robacta Drive CMT hosepacks 103 Changing the plastic inner liners for Robacta Drive and Robacta Drive CMT hosepacks 104 And finally 105 M...

Page 8: ...y sensor 122 Fitting the new torch body sensor 123 And finally 124 Disposal 125 Disposal 125 Technical data 127 Technical data 129 Torch body changeover station 129 Torch body coupling 129 Appendix 13...

Page 9: ...al protection All safety and danger notices on the device must be in a legible state must not be damaged must not be removed must not be covered pasted or painted over For the location of the safety a...

Page 10: ...n a safety conscious manner Before using the device all persons instructed to do so undertake to observe the basic instructions regarding safety at work and accident prevention to read these operating...

Page 11: ...which the energy is sup plied from the public low voltage mains EMC device classification as per the rating plate or technical data In certain cases even though a device complies with the standard lim...

Page 12: ...nvironment is always clean and clearly laid out Only set up and operate the device in accordance with the protection class shown on the rating plate When transporting the device observe the relevant n...

Page 13: ...ried out by a qualified electrician after any changes are made after any additional parts are installed or after any conversions after repair care and maintenance has been carried out at least every t...

Page 14: ...remains with the manufacturer The text and illustrations are all technically correct at the time of printing We reserve the right to make changes The contents of the operating instructions shall not...

Page 15: ...General information...

Page 16: ......

Page 17: ...aning device Robacta TX is converted into a fully autonomous torch body maintenance stati on that increases system availability and si gnificantly reduces setup time Scope of supply 1 Torch body chang...

Page 18: ...air maintenance unit with filter Robot Torch body changeover station The torch body changeover station is used to hold up to 10 torch bodies hold a welding torch cleaning device hold a wire cutter hol...

Page 19: ...com ponents Any power source from the TS TPS series Any Fronius robot wire feed unit Robacta hosepacks Robacta Drive hosepacks Robacta Drive CMT hosepacks Robacta Reamer V Easy Robacta Reamer V Robact...

Page 20: ...use the device in conjunction with Fronius cooling units and Fronius coolant Any use above and beyond this purpose is deemed improper The manufacturer is not lia ble for any damage inadequate or incor...

Page 21: ...s injury and damage WARNING Risk of serious injury from mechanically powered parts Keep device free from current and pressure during maintenance and servicing Do not use the functions described here u...

Page 22: ...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 ha...

Page 23: ...otices on the packaging 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 l...

Page 24: ...24...

Page 25: ...Controls connections and mechani cal components...

Page 26: ......

Page 27: ...ng 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 thoro...

Page 28: ...ontrol via standard I O connection for robot control field bus coupler 8 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 an...

Page 29: ...orch body 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 descr...

Page 30: ...nd damage The device may only be powered through an Emergency Stop circuit CAUTION Risk of damage to connection supply due to overcurrent Secure sup ply against overcurrent with a 1 5 A slow blow fuse...

Page 31: ...least 500 mA Change torch body valve 1 24 X Reserve relay OUT 25 X C Sens 5 signal 1 26 X Clamp gas nozzle and cleaning motor on Start cleaning 27 X Gas nozzle free TC Ready 28 X Gas nozzle free Clean...

Page 32: ...has been deposited in the Ro bacta TX slide Robacta TX slide XL 19 Wire sensor signal Verification whether the wire electrode pro trudes from the torch body after a successful change of the torch body...

Page 33: ...urning signal for Robacta Reamer V only cleaning motor is turning and emitting constant pulses 30 Spraying in parting agent Signal only available as an option Spray in parting agent signal for Robacta...

Page 34: ...cta Reamer V only cleaning motor is raised 35 Cut wire Signal only available as an option activates the wire cutter 36 Wire cutter closed Signal only available as an option wire cutter is closed 37 Wi...

Page 35: ...Installation and commissioning...

Page 36: ......

Page 37: ...nal safety ensure that all protective measures have been taken and will remain in place while you are in the working area of the robot WARNING Risk of severe injury from the robot arm Ensure there is...

Page 38: ...device must only be used by one person at a time It is also necessary to ensure that no one else is within the working area of the device when the device is being used NOTE The device must only be ser...

Page 39: ...functions correctly the following com pressed air supply specifications must be met Compressed air is free of oil Compressed air is free of dust no dirt particles larger than 5 m Compressed air is fre...

Page 40: ...for wire feed unit max 6 00 bar 87 02 psi 11 Data cable 3 Wire feed unit 12 Robot 4 Junction valve 13 Drum coil 5 Compressed air supply line from torch body changeover station to torch body coupling...

Page 41: ...ace foundation Once bolted down check whether the torch body changeover station is hori zontally and vertically aligned with the underlying surface CAUTION Risk of injury from compressed air escaping...

Page 42: ...nction valve as shown using the screws washers and nuts provided CAUTION Risk of injury from compressed air escaping unintentionally The torch body changeover station must remain depressurised and de...

Page 43: ...ction 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 o...

Page 44: ...tion Insert compressed air line into com pressed air connection A on the torch body changeover station and into connection 1 on the junction valve Insert gas purging line from the hose pack 2 into co...

Page 45: ...vided Undo screws 3 Disconnect compressed air line from welding torch gas purging connection 4 CAUTION Risk of injury from compressed air escaping unintentionally The torch body changeover station mus...

Page 46: ...onnection 6 on the junction valve and into the welding torch gas purging connection 7 Installing the torch body changeover sta tion Insert compressed air line into com pressed air connection A on the...

Page 47: ...connecti on using thread sealing tape Secure junction valve on the mounting plate 2 as shown using the screws 3 washers and nuts provided CAUTION Risk of injury from compressed air escaping unintenti...

Page 48: ...valve onto wire feed unit and secure using the two TX 25 screws 6 provided Insert the compressed air line with an outer diameter of 8 mm into the wel ding torch gas purging connection 7 and into conn...

Page 49: ...49 EN Installing the torch body changeover sta tion Insert compressed air line into com pressed air connection A on the torch body changeover station and into connection 1 on the junction valve 1 1...

Page 50: ...upler see Profinet Robacta TX operating instructions Insert torch body as far as it will go into the torch body rack 1 LED 2 comes on A signal is sent to the robot control If the above points do not a...

Page 51: ...he wire sen sor 1 detects the wire electrode Turn the adjusting screw 3 in the re verse direction until the LED 4 goes off Wire sensor is deactivated Only turn the adjusting screw 3 until the LED 4 co...

Page 52: ...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 Pull the inner liner 1 and cutting aid 2 out of the torch body do not change...

Page 53: ...53 EN 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 4 7 8...

Page 54: ...nto 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 Pull the inner liner 1 and cutting aid 2 out of the torch body do not...

Page 55: ...55 EN 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 4 7 8...

Page 56: ...a hosepacks Press centre bolt 1 out of the torch body coupling 2 Unscrew run off plate 3 from centre bolt using a 6 mm socket wrench insert CAUTION Risk of injury from compressed air escaping unintent...

Page 57: ...rew run off plate 3 into centre bolt Push centre bolt 1 into torch body coupling 2 Preparing the in ner liner for Ro bacta hosepacks 4 5 3 3 4 2 1 5 NOTE More detailed information about fitting the in...

Page 58: ...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...

Page 59: ...eing used 1 as far as it will go into the torch body coupling 2 as shown Insert cutting pipe 3 of the hosepack being used onto the inner liner Cutting pipe item number 42 0001 5910 Cut off the inner l...

Page 60: ...k being used 1 as far as it will go into the torch body coupling 2 as shown Insert cutting pipe 3 of the hosepack being used onto the inner liner Cutting pipe item number 42 0001 5910 Cut off the inne...

Page 61: ...reparing the power source On the power source being used create a new job for advancing and winding back the wire electrode Wire threading speed 600 cm min 236 22 ipm Set filter time for flow watchdog...

Page 62: ...ling 2 and inner liner onto drive unit Screw torch body coupling 2 as far as possible onto drive unit by hand Tighten torch body coupling 3 using installation tool 4 Tightening torque 20 Nm For Robact...

Page 63: ...is bolted to the torch body insulation The torch body insulation must always be deposited in the same position in the torch body rack so that it cannot be rotated Only the torch body can be rotated in...

Page 64: ...rch body insulation by tightening the four previously loosened screws 1 using an Allen key Tightening torque 1 Nm Aligning the robot programming aid 1 2 5 5 3 4 5 NOTE Always tighten the oppo site scr...

Page 65: ...65 EN 3 3...

Page 66: ...sup ply line and make sure that this com pressed air supply line remains depressurised for the duration of the work on the device Connect compressed air supply line to compressed air connection B on t...

Page 67: ...the pres 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 1 6 MPa 16 bar 232 06 psi Press control dial 1 to lock it And finally Place t...

Page 68: ...body changeover stati on Torch body coupling lock 2 opens Remove torch body from torch body coupling Place torch body back onto the torch body coupling press against the torch body coupling and hold i...

Page 69: ...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 tor...

Page 70: ...in 150 mm 5 91 in 334 mm 13 15 in 170 mm 6 69 in 175 mm 6 69 in 150 mm 5 91 in 75 mm 2 95 in 167 mm 6 57 in 85 mm 3 35 in 1 NOTE Whenever installing the robot programming aid always check that all fiv...

Page 71: ...on can be pressed with one hand the torch body can be placed onto or removed from the torch body coupling with the other hand Hold the torch body on the robot arm with one hand CAUTION Risk of injury...

Page 72: ...gram 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 lock closes the top part of the robot program ming ai...

Page 73: ...Check the following both parts of the robot program ming aid must be the same distan ce to each other around the entire perimeter Save this position for later use as posi tion H in the program sequenc...

Page 74: ...each other Move the robot into the second part of the robot programming aid until both parts are on top of each other end position has been reached Save this position for later use as posi tion G in...

Page 75: ...a hosepack system components for Robacta hosepack pre pared When using a Robacta Drive or Robacta Drive CMT hosepack torch body coupling has been prepared Power source has been prepared Torch body cou...

Page 76: ...into the following subprograms Cut wire electrode Wind back wire electrode Set down torch body Pick up torch body Advance wire electrode Cut wire electrode CAUTION Risk of damage Do not start in autom...

Page 77: ...WR SRV DSSUR PP LQ QH W WR ZLUH FXWWHU 6HW VHOHFW MRE WR DGYDQFH ZLUH HOHFWURGH ZLUH WKUHDGLQJ VSHHG FP PLQ LSP 0RYH WR SRV HQWHU ZLUH FXWWHU 6HW FXW ZLUH HOHFWURGH VLJQDO 6HW DGYDQFH ZLUH HOHFWURGH...

Page 78: ...JQDO UHZLQG ZLUH HOHFWURGH XQWLO EHKLQG FRXSOLQJ SRLQW ZLUH WKUHDGLQJ VSHHG FP PLQ LSP GXUDWLRQ RI VLJQDO FDOFXODWHG IURP WRUFK ERG OHQJWK 4XHU ZLUH FXWWHU FORVHG 4XHU WRUFK ERG VHQVRU PP LQ PP LQ DOV...

Page 79: ...V UDLVH PP LQ DERYH PLGGOH RI WRUFK ERG UDFN VSHHG PD FP PLQ LSP 4XHU WRUFK ERG VHQVRU WRUFK QHFN SLFNHG XS IOXVK 4XHU SUHVVXUH VZLWFK PP LQ DOVH 7UXH DOVH 7UXH 6HW GRZQ WRUFK ERG FRQWLQXHG 0RYH WR SR...

Page 80: ...G VHQVRU PP LQ DOVH 7UXH DOVH 7UXH 6HW GRZQ WRUFK ERG FRQWLQXHG 3LFN XS WRUFK ERG DLW VHFRQGV 6HW 5REDFWD 7 YDOYH FRYHU VLJQDO 4XHU 5REDFWD 7 VHQVRU FRYHU 7UXH DOVH DLW VHFRQGV 3URJUDP VWRS 5REDFWD 7...

Page 81: ...WRUFK ERG VHQVRU 4XHU SUHVVXUH VZLWFK 5HVHW FKDQJH WRUFK ERG VLJQDO 7UXH DOVH DOVH 7UXH 3LFN XS WRUFK ERG FRQWLQXHG 0RYH WR SRV 0 UDLVH PP LQ DERYH PLGGOH RI WRUFK ERG UDFN VSHHG KLJK 0RYH WR SRV SLF...

Page 82: ...V 2 DOLJQ JDV QR OH DSSUR PP LQ FHQWUDOO DERYH ZLUH VHQVRU 6HW DGYDQFH ZLUH HOHFWURGH VLJQDO ZLUH WKUHDGLQJ VSHHG FP PLQ LSP 0RYH WR SRV 1 PP LQ DERYH WRS RI WRUFK ERG UDFN PP LQ QH W WR PLGGOH RI WRU...

Page 83: ...G 4XHU SRZHU VRXUFH UHDG DOVH 7UXH DOVH 7UXH XW ZLUH HOHFWURGH FRQWLQXHG QG 5HVHW ZLUH FXWWHU VLJQDO 3URJUDP VWRS ZLUH FXWWHU HUURU 6HW DGYDQFH ZLUH HOHFWURGH VLJQDO GXUDWLRQ RI VLJQDO VHFRQG 0RYH WR...

Page 84: ...84...

Page 85: ...Troubleshooting...

Page 86: ......

Page 87: ...he robot arm Ensure there is no one else within the working area of the robot whenever work is carried out WARNING Risk of severe injury from compressed air escaping unexpectedly torch body falling un...

Page 88: ...when picking up and setting down the torch body Remedy Reduce robot speed when picking up and setting down the torch body After a torch body has been changed there is some residual coolant on the torc...

Page 89: ...se Incorrect output pressure set on the compressed air amplifier Remedy Adjust compressed air amplifier as per the specifications in the operating in structions Torch body coupling does not open Cause...

Page 90: ...90...

Page 91: ...Care maintenance and disposal...

Page 92: ......

Page 93: ...rved For your personal safety ensure that all protective measures have been taken and will remain in place while you are in the working area of the robot WARNING Risk of severe injury from the robot a...

Page 94: ...the torch body changeover station Press and hold the Unlock Lock button on the torch body changeover station until compressed air no longer emerges from compressed air connection A on the torch body c...

Page 95: ...coupling to the manufactu rer s service department Check the TX inlet outlet nozzle 4 for wear and replace if necessary Check the O ring 5 on the wire guide pin for damage and replace if neces sary C...

Page 96: ...t Check whether there is coolant residue on the surface within the marked area 1 If coolant residue is found replace the coolant stop see Replacing coolant stops For Robacta Drive and Robacta Drive CM...

Page 97: ...ozzle 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 Tigh...

Page 98: ...at both ends 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 8 11 12 4 NOTE Replac...

Page 99: ...nner liner in the torch body Remove the gas nozzle from 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 t...

Page 100: ...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 Tighten the locking screw 7 of the cutting aid Pull the in...

Page 101: ...ly 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...

Page 102: ...A on the torch body changeover station Press and hold the Unlock Lock button on the torch body changeover station until compressed air no longer emerges from compressed air connection A on the torch b...

Page 103: ...entre bolt 2 using a 6 mm socket wrench insert Remove run off plate 1 and worn in ner liner from centre bolt 2 Cut new inner liner using cutting pliers Robacta Drive 96 mm 3 78 in Robacta Drive CMT 80...

Page 104: ...ve and Robac ta Drive CMT hosepacks Unscrew run off plate 1 from centre bolt 2 using a 6 mm socket wrench insert Remove run off plate 1 and worn in ner liner from centre bolt 2 Cut new inner liner usi...

Page 105: ...entre 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...

Page 106: ...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...

Page 107: ...n A on the torch body changeover station Press and hold the Unlock Lock button on the torch body changeover station until compressed air no longer emerges from compressed air connection A on the torch...

Page 108: ...art ment Check the O ring 4 on the gas pin for damage and replace if necessary Check the O rings 5 on the coolant pin for damage and replace if neces sary Check the O ring 6 on the wire guide pin for...

Page 109: ...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 on the torch bo...

Page 110: ...hangeover station Press and hold the Unlock Lock button on the torch body changeover station until compressed air no longer emerges from compressed air connection A on the torch body changeover statio...

Page 111: ...screw coolant stops 3 from the torch body coupling using the manual torque wrench Preparing new coolant stops Insert the 6 x 1 5 mm O ring into the groove 1 on the inside of the coupling crown 1 2 1 3...

Page 112: ...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 Insert the...

Page 113: ...will not da mage the O ring Tighten coolant stop Tightening torque 3 Nm Repeat the steps listed above on the second coolant stop And finally Thread the wire electrode into the hosepack Connect the com...

Page 114: ...on the torch body changeover station Press and hold the Unlock Lock button on the torch body changeover station until compressed air no longer emerges from compressed air connection A on the torch bod...

Page 115: ...2 and spring under the control slide off the core bolt Clean the control slide 2 and spring 3 CAUTION Risk of injury from compressed air escaping unintentionally The torch body changeover station must...

Page 116: ...it 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 on the torch body changeover...

Page 117: ...body changeover station Press and hold the Unlock Lock button on the torch body changeover station until compressed air no longer emerges from compressed air connection A on the torch body changeover...

Page 118: ...ew welding torch flange 4 as far as it will go onto the torch body Tighten all six grub screws 3 on the welding torch flange 4 Tightening torque 1 5 Nm Remove the assembly aid 5 1 1 2 1 1 1 2 3 4 3 3...

Page 119: ...e torch body insulation by tightening the four previously loosened screws 1 using an Allen key Tightening torque 1 Nm And finally Thread the wire electrode into the hosepack Connect the compressed air...

Page 120: ...in the torch body changeover station discharges De energise the torch body changeover station Safety NOTE Only press the emergency release button if the torch body does not come off the torch body cou...

Page 121: ...ress the compressed air pistol 4 firmly into the plastic sleeve on the torch body coupling Actuate the compressed air pistol and at the same time pull the torch body off the torch body coupling Send t...

Page 122: ...harges De energise the torch body changeover station Safety Removing the old torch body sen sor Undo the 8 screws 1 Remove lid 2 CAUTION Risk of injury from escaping compressed air from compressed air...

Page 123: ...angeover sta tion Remove the cable tie 5 Undo screw 6 using a 4 mm Allen key Feed out the sensor cable from the torch body changeover station Unscrew the torch body sensor 7 from the torch body rack F...

Page 124: ...tion X3 sensor 2 on the PC board in the torch body changeover station Fix sensor cable using cable tie 3 as shown Place lid onto the torch body changeo ver station and secure with 8 screws and washers...

Page 125: ...125 EN Disposal Disposal Dispose of in accordance with the applicable national and local regulations...

Page 126: ...126...

Page 127: ...Technical data...

Page 128: ......

Page 129: ...al pressure 6 bar 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 A Dimensions l x w x h 477 x 759 x 785 mm 18 78 x 29 88 x 30 91...

Page 130: ...130...

Page 131: ...Appendix...

Page 132: ...132 Pneumatic diagram V23072012...

Page 133: ...42 EU The product is intended exclusively for installation in machinery or partly completed machinery It therefore does not yet fully conform to all the requirements of the Machinery Directive It is n...

Page 134: ...134...

Page 135: ...135...

Page 136: ...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...

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