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27

EN

(1)

Wirefeeding hose 1 and 2

(2)

Wire drum 1 and 2

(3)

Power source 1 and 2

(4)

Separate welding potential

Lead power 

source and trail 

power source

The two power sources are referred to as the lead power source and the trail power source 

in the "Drive EasyTwin" process.

-

The welding direction is defined by the wire pairing.

-

The wire electrode of the lead power source is the front wire electrode, in terms of the 

welding direction.

Drive EasyTwin 

application areas

Drive EasyTwin is only used for automated applications, e.g.:

-

In rolling stock manufacturing for longitudinal seams and profiles

-

In shipbuilding for fillet welds and profiles

-

In vehicle manufacturing for lap joints and welding wheel rims

-

In container construction for butt welds, longitudinal seams, lap joints and circumfer

-

ential welds

-

In plant construction for V, X and fillet welds

-

For edge welds on lifting gear

-

For HV and fillet welds on earth-moving machines and in special machine construction

-

For overlay welding

Dimensioning of 

the robot

Please note the following when dimensioning the robot:

-

The torch holder on the robot must be stable. The Drive EasyTwin welding torch with 

CrashBox weighs ??? kg.

-

The robot hose pack and wirefeeding hoses must be routed via a balancer in the robot 

cell.

(1)

(3)

(3)

(4)

(4)

(1)

(2)

Содержание Drive EasyTwin

Страница 1: ...n elemental chlorine free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy 42 0426 0194 EN 005 25052020 Drive EasyTwin Operating Instructions Syst...

Страница 2: ...2...

Страница 3: ...to ensure greater safety when using the product Careful handling of the product will repay you with years of safe and reliable operation These are essential prerequisites for excellent results Explan...

Страница 4: ...4...

Страница 5: ...s 22 Safety measures at the installation location and during transport 22 Safety measures in normal operation 23 Commissioning maintenance and repair 24 Safety inspection 24 Disposal 24 Safety symbols...

Страница 6: ...ap joints 34 Area of application for Drive EasyTwin steel diameter 1 2 mm 1 0 mm 35 Welding technology options 35 Care maintenance and disposal 37 General 37 Example consumption of filler metal 37 Bef...

Страница 7: ...ction of the Ro bacta Drive EasyTwin by means of a wirefeeder The wirefeeding hose is connected to the hosepack by a special holder and hung up using spring balancer suspension devices With the PowerL...

Страница 8: ...8 Installing the CrashBox Drive EasyTwin on the robot 1 2 3 4 5 6 1 2 3 4 5 6...

Страница 9: ...t 3 suitably positioned spring balancer suspension devi ces Standard variant Secure the wirefeeding hose to the ho sepack at a distance of approx 50 cm using a holder item number 44 0350 3952 Importan...

Страница 10: ...e trail hosepack to the trail power source Connect the coolant lines to the cooling unit Connect the gas purging line to the control box Connect the gas line to the control box Connect the control lin...

Страница 11: ...ing wire must be threaded see Threading the welding wire from Figure 3 on page 12 Threading the welding wire NOTE For technical reasons only the inner liners provided in the original equipment kit mus...

Страница 12: ...12 3 Fully open 4 5 6 7 3 4 5 6 7...

Страница 13: ...13 EN 1 2 3 4 5 Set the contact pressure 3 rings must be visible 7 8 9 10 11...

Страница 14: ...14 6 7 12 13...

Страница 15: ...d General in the operating instructions for the device Before switching on the device rectify any faults that could compromise safety This is for your personal safety Proper use The device is to be us...

Страница 16: ...ting instructions especially the Safety rules section and sign to confirm that they have understood them and will follow them Before leaving the workplace ensure that people or property cannot come to...

Страница 17: ...power level of 80 dB A ref 1pW when idling and in the cooling phase following operation at the maximum permissible operating point under maximum rated load conditions according to EN 60974 1 It is no...

Страница 18: ...ire or explosion or near sealed tanks vessels or pipes unless these have been prepared in accordance with the relevant national and international standards Do not carry out welding on containers that...

Страница 19: ...rly legible and easy to understand warning sign to the device to prevent any one from plugging the mains plug back in and switching it on again After opening the device Discharge all live components E...

Страница 20: ...to interfer ence from the device include Safety devices Power signal and data transfer lines IT and telecommunications devices Measuring and calibrating devices Supporting measures for avoidance of E...

Страница 21: ...increased electric risk e g near boilers must carry the Safety sign However the power source must not be located in such areas Risk of scalding from escaping coolant Switch off cooling unit before dis...

Страница 22: ...lectrode Risk of explosion never attempt to weld a pressurised shielding gas cylinder Only use shielding gas cylinders suitable for the application in hand along with the correct and appropriate acces...

Страница 23: ...ensure that no one is likely to be endangered Check the device at least once a week for obvious damage and proper functioning of safety devices Always fasten the shielding gas cylinder securely and r...

Страница 24: ...nal and international standards and di rectives Further details on safety inspection and calibration can be obtained from your service cen tre They will provide you on request with any documents you m...

Страница 25: ...t the time of printing We reserve the right to make changes The contents of the operating instructions shall not provide the ba sis for any claims whatsoever on the part of the purchaser If you have a...

Страница 26: ...ue to short arc which results in a high welding speed Mixed operation is possible e g pulsed arc standard arc Easy operation as it shares the same menu navigation as the TPS 4000 5000 Drive EasyTwin f...

Страница 27: ...ock manufacturing for longitudinal seams and profiles In shipbuilding for fillet welds and profiles In vehicle manufacturing for lap joints and welding wheel rims In container construction for butt we...

Страница 28: ...e of the automated Drive EasyTwin welding process for example Robacta Reamer Twin Mechanical torch cleaning device suitable for all base materials such as steel aluminium CrNi steels copper etc Robact...

Страница 29: ...or single purpose machines e g straight line car riage Exact joint preparation Low component tolerances Seam guidance system with low deviation Due to the system a wirefeeder is not required on the 3r...

Страница 30: ...red gas flow rate on the pressure regulator 2 Wire threading button to thread the wire electrode into the torch hosepack with no accompanying flow of gas or current Thread the wire electrode using the...

Страница 31: ...onsiderably less wear Earth connection Use a separate grounding earthing cable for each power source Separate grounding earthing cable Shared grounding earthing cable earth socket Grounding earthing c...

Страница 32: ...er source is positioned neutrally or slightly forward Arc combination options Different arc types can be combined in the Drive EasyTwin process The welding direction is defined by the wire pairing 1 2...

Страница 33: ...s sections possible Visually excellent weld seams thanks to the pulsed arc of the trail wire electrode Potential applica tions area of ap plication The PCS pulsed arc combination is used for steel app...

Страница 34: ...a 5 angle to the welding direction Alignment of welding torch rel ative to the work piece for lap joints Side view of welding torch workpiece Align welding torch 1 relative to the workpiece 2 as show...

Страница 35: ...ge from Vd 8 5 m min to Vd 10 5 m min is a transition range in which the 1 2 mm filler metal lead power source changes to a modified spray arc This change occurs at Vd 9 m min or Vd 10 m min depending...

Страница 36: ...hnology is recommended Multiple layer fillet welds PB position Sheet thickness from 3 mm a dimension multi ple layer a3 a4 5 Possible deposition rate Up to 13 5 kg Single layer edge welds PA position...

Страница 37: ...s of arc time 10 kg h x 50 h 500 kg filler metal 2 wire drums of 250 kg each Before shift starts before starting up Check the welding torch wearing parts Gas nozzle Contact tip Gas distributor Spatter...

Страница 38: ...38 Replacing wearing parts Preparation replacing the feed rollers and nozzle 1 2 3 Fully open 4 5 6 1 2 3 4 5 6...

Страница 39: ...39 EN 7 8 9 10 11 12 7 8 9 10 11 12...

Страница 40: ...40 Replacing the in let nozzle 1 2 Now the welding wire must be threaded see Threading the welding wire from Figure 5 on page 12 Replacing the feed rollers 1 2 3 4 1 2 1 2 3 4...

Страница 41: ...41 EN 5 6 Now the welding wire must be threaded see Threading the welding wire from Figure 5 on page 12 5 6...

Страница 42: ...42...

Страница 43: ...43 EN...

Страница 44: ...INTERNATIONAL GMBH Froniusstra e 1 A 4643 Pettenbach AUSTRIA contact fronius com www fronius com Under www fronius com contact you will find the addresses of all Fronius Sales Service Partners and lo...

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