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Installing the torch body changeover station - in con-

junction with VR 1500-PAP

Safety

General

Preparation

Unscrew compressed air connection
(1) from junction valve
Screw compressed air connection pro-
vided (2) into junction valve as shown

Seal the compressed air 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 unintentionally. The torch

body changeover station must remain depressurised and de-energised until in-
stallation has been completed.

NOTE!

For wire-feed units with the "Welding torch gas purging" option, limit the

gas purging pressure to max. 6.00 bar (87.02 psi).

(1)

(2)

(3)

Содержание 4,044,008

Страница 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...

Страница 2: ...2...

Страница 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...

Страница 4: ...4...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 15: ...General information...

Страница 16: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 24: ...24...

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

Страница 26: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 35: ...Installation and commissioning...

Страница 36: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 65: ...65 EN 3 3...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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Страница 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...

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Страница 84: ...84...

Страница 85: ...Troubleshooting...

Страница 86: ......

Страница 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...

Страница 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...

Страница 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...

Страница 90: ...90...

Страница 91: ...Care maintenance and disposal...

Страница 92: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 126: ...126...

Страница 127: ...Technical data...

Страница 128: ......

Страница 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...

Страница 130: ...130...

Страница 131: ...Appendix...

Страница 132: ...132 Pneumatic diagram V23072012...

Страница 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...

Страница 134: ...134...

Страница 135: ...135...

Страница 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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