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Optionen Robacta TX
Operating Instruction [EN]
104 pgs30.48 Mb0
Operating Instruction [DE]
104 pgs30.44 Mb0

Fronius Optionen Robacta TX Operating Instruction [EN]

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/ Battery Charging Systems / Welding Technology / Solar Electronics
EN
Robacta TX options
Operating Instructions
System extension
42,0426,0109,EN 010-12082013
0
Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the product. Reading the instructions carefully will enable you to learn about the many different features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules 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.
1
2
Contents
Robacta TX cover 7
Safety......................................................................................................................................................... 9
Safety.................................................................................................................................................... 9
General ...................................................................................................................................................... 10
Device concept ..................................................................................................................................... 10
Scope of supply .................................................................................................................................... 10
Tools required ....................................................................................................................................... 10
Fitting the Robacta TX cover ..................................................................................................................... 11
Preparation ........................................................................................................................................... 11
Fitting the Robacta TX cover ................................................................................................................ 13
And finally... .......................................................................................................................................... 14
Locking the Robacta TX cover................................................................................................................... 15
Locking the cover.................................................................................................................................. 15
Robacta TX W with Robacta TX cover program sequence ....................................................................... 16
Safety.................................................................................................................................................... 16
General ................................................................................................................................................. 16
Speed data for the program sequence ................................................................................................. 16
Subprograms in the program sequence................................................................................................ 16
Program sequence................................................................................................................................ 17
Servicing the Robacta TX cover ................................................................................................................ 25
Weekly .................................................................................................................................................. 25
Yearly or after 30,000 torch neck changeover cycles ........................................................................... 25
Pneumatic Robacta TX cover 29
Safety......................................................................................................................................................... 31
Safety.................................................................................................................................................... 31
General ...................................................................................................................................................... 32
Device concept ..................................................................................................................................... 32
Scope of supply .................................................................................................................................... 32
Tools required ....................................................................................................................................... 32
Commissioning the pneumatic Robacta TX cover ..................................................................................... 33
Preparation ........................................................................................................................................... 33
Fitting one pneumatic Robacta TX cover.............................................................................................. 34
Installing one pneumatic Robacta TX cover ......................................................................................... 35
Fitting two pneumatic Robacta TX covers ............................................................................................ 37
Installing two pneumatic Robacta TX covers ........................................................................................ 38
Checking the function of the pneumatic Robacta TX cover .................................................................. 39
Locking the pneumatic Robacta TX cover ................................................................................................. 41
Locking the cover.................................................................................................................................. 41
Robacta TX slide, Robacta TX slide XL 43
Safety......................................................................................................................................................... 45
Safety.................................................................................................................................................... 45
Fitting the Robacta TX slide....................................................................................................................... 46
Preparation ........................................................................................................................................... 46
Safety.................................................................................................................................................... 46
Fit the slide............................................................................................................................................ 46
And finally... .......................................................................................................................................... 47
Fitting the Robacta TX slide XL ................................................................................................................. 48
Preparation ........................................................................................................................................... 48
Safety.................................................................................................................................................... 48
Screw base to the underlying surface................................................................................................... 48
Fit the XL slide ...................................................................................................................................... 49
Fit the standard slide to the XL base .................................................................................................... 49
And finally... .......................................................................................................................................... 49
Commissioning the Robacta TX slide / Robacta TX slide XL .................................................................... 50
3
Placing a torch neck in the Robacta TX slide / Robacta TX slide XL.................................................... 50
Changing the program sequence to account for the Robacta TX slide / Robacta TX slide XL............. 50
Robacta TX W torch neck rack 53
Safety......................................................................................................................................................... 55
Safety.................................................................................................................................................... 55
Fitting a torch neck rack piece ................................................................................................................... 56
Scope of supply .................................................................................................................................... 56
Preparation ........................................................................................................................................... 56
Safety.................................................................................................................................................... 56
Fitting a torch neck rack piece .............................................................................................................. 56
And finally... .......................................................................................................................................... 57
Robacta TX G torch neck rack 59
Safety......................................................................................................................................................... 61
Safety.................................................................................................................................................... 61
Fitting a torch neck rack piece ................................................................................................................... 62
Scope of supply .................................................................................................................................... 62
Preparation ........................................................................................................................................... 62
Safety.................................................................................................................................................... 62
Fitting a torch neck rack piece .............................................................................................................. 62
And finally... .......................................................................................................................................... 63
Torch neck coding 65
Safety......................................................................................................................................................... 67
Safety.................................................................................................................................................... 67
Coding the torch neck ................................................................................................................................ 68
General ................................................................................................................................................. 68
Preparation ........................................................................................................................................... 68
Safety.................................................................................................................................................... 68
Coding the torch neck ........................................................................................................................... 69
And finally... .......................................................................................................................................... 70
Compressed air maintenance unit 71
Safety......................................................................................................................................................... 73
Safety.................................................................................................................................................... 73
General ...................................................................................................................................................... 74
General ................................................................................................................................................. 74
Scope of supply .................................................................................................................................... 74
Tools required ....................................................................................................................................... 74
Fitting the compressed air maintenance unit ............................................................................................. 75
Preparation ........................................................................................................................................... 75
Safety.................................................................................................................................................... 75
Fitting the compressed air maintenance unit ........................................................................................ 75
And finally... .......................................................................................................................................... 77
Wire cutter 79
Safety......................................................................................................................................................... 81
Safety.................................................................................................................................................... 81
Installing the wire cutter ............................................................................................................................. 82
Preparation ........................................................................................................................................... 82
Safety.................................................................................................................................................... 82
Installing the wire cutter ........................................................................................................................ 82
And finally... .......................................................................................................................................... 83
Welding torch cleaning devices 85
Safety......................................................................................................................................................... 87
Safety.................................................................................................................................................... 87
4
Installing the Robacta TC 1000.................................................................................................................. 88
General ................................................................................................................................................. 88
Preparation ........................................................................................................................................... 88
Safety.................................................................................................................................................... 88
Fitting the wire cutter............................................................................................................................. 88
Installing the welding torch cleaning device.......................................................................................... 89
And finally... .......................................................................................................................................... 89
Installing the Robacta Reamer V Easy, Robacta Reamer aluminium brush head..................................... 90
General ................................................................................................................................................. 90
Preparation ........................................................................................................................................... 90
Safety.................................................................................................................................................... 90
Installing the welding torch cleaning device.......................................................................................... 90
And finally... .......................................................................................................................................... 91
Installing the Robacta Reamer V ............................................................................................................... 92
Preparation ........................................................................................................................................... 92
Safety.................................................................................................................................................... 92
Installing the welding torch cleaning device.......................................................................................... 92
And finally... .......................................................................................................................................... 93
Mounting bracket for a TCP measurement unit 95
Safety......................................................................................................................................................... 97
Safety.................................................................................................................................................... 97
Mounting bracket for advintec standard ..................................................................................................... 98
Preparation ........................................................................................................................................... 98
Safety.................................................................................................................................................... 98
Fitting the mounting bracket.................................................................................................................. 98
And finally... .......................................................................................................................................... 99
Mounting bracket for advintec adjustable .................................................................................................. 100
Preparation ........................................................................................................................................... 100
Safety.................................................................................................................................................... 100
Fitting the mounting bracket.................................................................................................................. 100
And finally... .......................................................................................................................................... 101
5
6
Robacta TX cover
Safety
Safety Observe the following safety rules for all work described in the "Robacta TX cover" section.
WARNING! Incorrect operation or shoddy workmanship can cause serious injury
or damage. All activities described in these operating instructions may only be carried out by trained and qualified personnel. All functions described in these op­erating instructions may only be used by trained and qualified personnel. Do not carry out any of the work or use any of the functions described until you have fully read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe­ty rules
WARNING! Machines that start up automatically can cause serious injury and damage. In addition to these operating instructions, the safety rules issued by the manufacturers of the robot and welding systems must also be observed. 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 arm. Ensure there is no one else within the working area of the robot whenever work is carried out.
WARNING! Work that is carried out incorrectly can cause serious injury or dam-
age. Before starting work:
- turn the power source mains switch to the "O" position
- disconnect the power source from the mains
- put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again
CAUTION! Risk of injury from sharp flying parts. During the work described be­low, always wear the following protective equipment:
- protective goggles with side protection
- ear protection
- gloves - electrically insulated and providing protection against heat
CAUTION! Risk of burns from hot torch neck, hot torch neck coupling and other hot welding torch components. Before carrying out work, allow the torch neck, torch neck coupling and all other welding torch components to cool down to room temperature (+25 °C, +77 °F).
9
General
Device concept The Robacta TX cover shields all the torch neck rack pieces on the torch neck changeover
station. To facilitate work on the torch neck rack pieces, the cover can be fixed in place by a locking bolt. An integral sensor monitors the position of the cover.
Scope of supply
(1)
(2)
(3)
(1) Robacta TX cover
(2) Wire sensor fitting panel (3) 2x M5 x 16 mm Allen screws (4) 4x A5 washers (5) 2x M5 self-locking hexagonal nuts (6) 4x M10 hexagon bolts with 1.25
fine-pitch thread
Tools required - TX 25 Torx screwdriver
- Box spanner, size 17
- Box spanner, size 8
- 8 mm Allen key
- 4 mm Allen key
- 2.5 mm Allen key
(4)
(5)
(6)
10
Fitting the Robacta TX cover
1
(1)
Preparation Depressurise the compressed air line of the torch neck changeover station and ensure
that this compressed air line remains depressurised for the duration of the work on the device
Disconnect the compressed air line from compressed air connection "A" on the torch
2
neck changeover station
CAUTION! Risk of injury from escaping compressed air from compressed air connection "A". Compressed air emerges at up to 16 bar (232.06 psi) from com­pressed air connection "A" when the Unlock/Lock button is pressed. While com­pressed air is emerging from compressed air connection "A":
- wear ear protection
- keep the face and all other body parts away from compressed air connection "A"
- ensure that no other persons are in the vicinity of the torch neck changeover station
Press and hold the Unlock/Lock button on the torch neck changeover station until
3
compressed air no longer emerges from compressed air connection "A" on the torch neck changeover station
- compressed-air booster unit in the torch neck changeover station discharges
De-energise the torch neck changeover station
4
CAUTION! Risk of injury from compressed air escaping unintentionally. The torch
neck changeover station must remain depressurised and de-energised until all work is completed.
Undo screws (1)
5
Keep screws, nuts and washers for la-
6
ter use
11
Fit the wire sensor mounting plate (2)
(3)
(2)
7
as shown, using
- 2x M5 x 16 mm screws (3)
- 4x A5 washers
- 2x M5 self-locking hexagonal nuts
Secure the wire sensor (4) to the wire
8
sensor mounting plate as shown
(5) (6)
(5)
(5)(5)
(4)
Undo screws (5)
9
Remove the cover lid (6)
10
12
Fitting the Robac-
(2)
(2)
(2)
(2)
(2)
(2)
(2)
(2)
(3)
2
ta TX cover
(1)
Undo the 8 screws (2)
1
Remove lid (3)
Place the cover onto the torch neck
3
changeover station in such a way that the Robacta TX cover sensor (1) is on the same side of the torch neck chan­geover station as the wire sensor
Underside of cover
(3) (3)(2)
Insert four M10 screws into the holes
4
(3) and secure the cover in place
(3)(3)
13
(4) (5)
5
Guide the sensor cable (4) through the
5
housing opening (5)
Connect the sensor plug to connection
6
X14 on the PC board in the torch neck changeover station
Fit the lid for the Robacta TX cover
7
onto the subframe of the Robacta TX cover
Fit the torch neck changeover station
8
cover onto the torch neck changeover station
And finally...
Attempt to move the cover back and
1
forth
- the cover must be easy to move
Establish the power supply to the torch
2
neck changeover station
When the cover is in a central position:
- the LED (1) on the base of the sensor lights up
- a signal is sent to the robot control
When the cover is not in a central position:
- the LED (1) on the base of the sensor does not light up
(1)
Connect the compressed air line to compressed air connection "A" on the torch neck
3
changeover station
Establish the compressed air supply to the torch neck changeover station
4
Change the position of the wire sensor in the robot program
NOTE! After fitting the cover, program the robot with the Robacta TX W with Ro­bacta TX cover program sequence
- no signal is sent to the robot control
14
Locking the Robacta TX cover
1
2
Locking the cover
NOTE! Do not lock the cover while the torch neck changeover station is in use.
NOTE! Ensure that the cover locking bolt remains in the operating position while
the torch neck changeover station is in use.
(2) (2)(1)
Lock the cover as follows
Push the cover to the desired side
Allow the locking bolt (1) to latch in the
2
respective locking hole (2)
(1)
To unlock, proceed as follows
Hold the cover
1
Remove the locking bolt (1) from the locking hole and move to the position shown
- the locking bolt is in the operating
position
15
Robacta TX W with Robacta TX cover program se­quence
Safety
General
Speed data for the program se­quence
CAUTION! Risk of damage. Do not start in automatic mode until the torch neck
changeover station has been properly installed and started up.
NOTE! After fitting the cover, program the robot with the following program se­quence.
A list of all speeds and corresponding units in the program sequence:
cm/min m/s ipm
1000 = 0.17 = 393.70
600 = 0.1 = 236.22
100 = 0.017 = 39.37
70 = 0.012 = 27.56
50 = 0.008 = 19.69
35 = 0.006 = 13.78
30 = 0.005 = 11.81
Subprograms in the program se­quence
To facilitate programming, the program sequence is split into the following subprograms:
- Cut wire electrode
- Wind back wire electrode
- Set down torch neck
- Pick up torch neck
- Advance wire electrode
- Cut wire electrode
16
Program se-
Wait 0.5
seconds
Move to pos. A
- above torch neck rack
Program stop
- power source error
Reset
- wire cutter signal
Program stop
- wire cutter error
Move to pos. B
- approx. 25 mm (0.98 in.) next to wire cutter
Set
- select job to advance wire electrode
- wire threading speed: 600 cm/min (236.22 ipm)
Move to pos. C
- enter wire cutter
Set
- cut wire electrode signal
Set
- advance wire electrode signal
- duration of signal: 2 seconds
Start
Query
- power
source ready
Query
- wire
cutter open
Query
- wire
cutter open
'False'
'True'
'True'
'False'
'True'
'False'
Cut wire electrode
A
B
25 mm
0.98 in.
C

quence
17
Query
- wire cutter closed
'False'
Program stop
- wire cutter error
(continued)
Cut wire electrode
- cut wire electrode signal
- rewind wire electrode signal
- rewind wire electrode until behind coupling point
Rewind wire electrode
- wire threading speed:
600 cm/min (236.22 ipm)
- duration of signal: calculated using torch neck length
above rack positions
'True'
Reset
Move to pos. D
Query
- torch neck sensor
Set
'True'
D
Program stop
- torch neck change error
'False'
Move to pos. E
- 70 mm (2.76 in.) next to middle of torch neck rack
- 40 mm (1.57 in.) above top of torch neck rack
Set down torch neck
Query
- Robacta TX cover
'True'
'False'
E
40 mm
1.57 in.
70 mm
2.76 in.
Program stop
- torch neck change error
18
Move to pos. F
- move 40 mm (1.57 in.) above middle of torch neck rack
- speed:
max. 100 cm/min (39.37 ipm)
Move to pos. G
- move down into torch neck rack
- speed:
max. 50 cm/min (19.69 ipm)
Wait 0.5
seconds
Query
- torch neck
sensor (torch neck
picked up
flush)
Wait 5
seconds
'False'
F
40 mm
1.57 in.
G
Stop
- enter torch neck rack
'True'
Stop
- enter torch neck rack
Set down torch neck (continued)
Query
- pressure switch
'True'
Set
- change torch neck signal
Wait 1.5 seconds
'False'
Program stop
- torch neck change error
Program stop
- torch neck change error
19
Move to pos. H
- raise 15 mm (0.59 in.) above middle of torch neck rack
- speed:
max. 30 cm/min (11.81 ipm)
H
15 mm
0.59 in.
Move to pos. I
- raise 40 mm (1.57 in.) above middle of torch neck rack
- speed: high
Wait 0.5 seconds
Move to pos. J
- 70 mm (2.76 in.) next to middle of torch neck rack
- 40 mm (1.57 in.) above top of torch neck rack
(continued)
Set down torch neck
Query
Robacta TX
cover
'False'
I
40 mm
1.57 in.
J
40 mm
1.57 in.
Program stop
- torch neck change error
70 mm
2.76 in.
'True'
Query
- torch neck sensor
'False'
'True'
Program stop
- torch neck change error
20
Move to pos. K
- 70 mm (2.76 in.) next to middle of torch neck rack
- 40 mm (1.57 in.) above top of torch neck rack
K
40 mm
1.57 in.
70 mm
2.76 in.
Query
- Robacta TX cover
'True'
Query
- torch neck sensor
'True'
Pick up torch neck
Move to pos. L
- 40 mm (1.57 in.) above middle of torch neck to be picked up
'False'
'False'
Program stop
- torch neck change error
Program stop
- torch neck change error
L
40 mm
1.57 in.
Move to pos. M
- 15 mm (0.59 in.) above middle
of torch neck to be picked up
Move to pos. N
- pick up torch neck flush
max. 70 cm/min (27.56 ipm)
- change torch neck signal
- speed:
Reset
Wait 3 - 4
seconds
M
N
15 mm
0.59 in.
21
Move to pos. R
- raise 40 mm (1.57 in.) above middle of torch neck rack
- speed: high
Wait 0.5 seconds
R
40 mm
1.57 in.
Query
- torch neck sensor
'False'
Query
pressure switch
Pick up torch neck (continued)
- power source reset error (only if using a flow sensor)
- 40 mm (1.57 in.) above top of
- 70 mm (2.76 in.) next to middle
1000 cm/min (393.70 ipm)
'True'
Set
Move to pos. S
torch neck rack
of torch neck rack
- speed: max.
Advance wire electrode
'True'
'False'
Program stop
- torch neck change error
Program stop
- torch neck change error
S
40 mm
70 mm
2.76 in.
1.57 in.
22
Query
- Robacta TX cover
'True'
'False'
Program stop
- torch neck change error
Advance wire electrode (continued)
'True'
Cut wire electrode
Wait 15
seconds
Reset
- advance wire
electrode signal
Program stop
- torch neck change error
Reset
- wire cutter signal
Program stop
- wire cutter error
Move to pos. Q
- align gas nozzle approx. 10 mm (0.39 in.) centrally above wire
sensor
Set
- advance wire electrode signal
- wire threading speed: 600 cm/min (236.22 ipm)
Reset
- advance wire electrode signal
Move to pos. B
- approx. 25 mm (0.98 in.) next to wire cutter
Set
- advance wire electrode signal
- duration of signal: 1 second
'False'
'True'
Query
- wire cutter open
Query
- wire cutter open
'False'
Query
wire sensor
'False'
'True'
Q
10 mm
0.39 in.
B
25 mm
0.98 in.
23
Move to pos. C
- enter wire cutter
Set
- cut wire electrode signal
Reset
- cut wire electrode signal
Wait 0.5
seconds
Program stop
- wire cutter error
Query
- wire cutter closed
'False'
'True'
Program stop
- torch neck change error
Query
- power source ready
'False'
'True'
Cut wire electrode (continued)
End
C
24
Servicing the Robacta TX cover
2
(1) (2)
(1)
(1)(1)
Weekly Check the cover for damage
Yearly or after 30,000 torch neck changeover cy­cles
Clean and lubricate the profiled rail guides:
Depressurise the compressed air line of the torch neck changeover station and ensure
1
that this compressed air line remains depressurised for the duration of the work on the device
Disconnect the compressed air line from compressed air connection "A" on the torch neck changeover station
CAUTION! Risk of injury from escaping compressed air from compressed air connection "A". Compressed air emerges at up to 16 bar (232.06 psi) from com­pressed air connection "A" when the Unlock/Lock button is pressed. While com­pressed air is emerging from compressed air connection "A":
- wear ear protection
- keep the face and all other body parts away from compressed air connection "A"
- ensure that no other persons are in the vicinity of the torch neck changeover station
Press and hold the Unlock/Lock button on the torch neck changeover station until
3
compressed air no longer emerges from compressed air connection "A" on the torch neck changeover station
- compressed-air booster unit in the torch neck changeover station discharges
De-energise the torch neck changeover station
4
CAUTION! Risk of injury from compressed air escaping unintentionally. The torch neck changeover station must remain depressurised and de-energised until all work is completed.
Undo screws (1)
5
Remove the lid (2)
6
25
Undo screws (3) and (4)
8
(9)(9)
7
Remove cover plate (5)
(6)
(3) (4)
(7)
(5)
(8)
(3)
(6)
Clean the profiled rails (6)
9
Clean the centring spindle (7)
10
Clean the centring carriage (8)
11
11
Lubricate the profiled rails (6)
12
Move the trolleys (9) up and down the
13
profiled rails to distribute the lubricant
26
(10) (11)
(12)
(13)
17
(10) (14)
(10)
20
21
22
23
(10)
Screw in the eight screws with
14
washers (10), tighten slightly
- the cover plate (11) must still be able to move on the profiled rail trolleys
Move the cover plate as far as it will go
15
in one direction
- this aligns the cover plate and the profiled rail trolleys with each other
Once the trolleys and cover plate are
16
aligned, tighten the screws (10) to fix the cover plate in this position
Check whether the edges (12) and (13) are parallel to each other
- if not, undo the screws (10) and align the cover plate again
Tighten screws and washers (10)
18
Tighten screws and washers (14)
19
Fit the lid
Check the cover is functioning correct­ly
Connect the compressed air line to compressed air connection "A" on the torch neck changeover station
Establish the compressed air and power supply to the torch neck changeover station
27
28
Pneumatic Robacta TX cover
Safety
Safety Observe the following safety rules for all work described in the "Pneumatic Robacta TX
cover" section.
WARNING! Incorrect operation or shoddy workmanship can cause serious injury or damage. All activities described in these operating instructions may only be carried out by trained and qualified personnel. All functions described in these op­erating instructions may only be used by trained and qualified personnel. Do not carry out any of the work or use any of the functions described until you have fully read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe­ty rules
WARNING! Machines that start up automatically can cause serious injury and damage. In addition to these operating instructions, the safety rules issued by the manufacturers of the robot and welding systems must also be observed. 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 arm. Ensure there is no one else within the working area of the robot whenever work is carried out.
WARNING! Work that is carried out incorrectly can cause serious injury or dam-
age. Before starting work:
- turn the power source mains switch to the "O" position
- disconnect the power source from the mains
- put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again
CAUTION! Risk of injury from sharp flying parts. During the work described be­low, always wear the following protective equipment:
- protective goggles with side protection
- ear protection
- gloves - electrically insulated and providing protection against heat
CAUTION! Risk of burns from hot torch neck, hot torch neck coupling and other hot welding torch components. Before carrying out work, allow the torch neck, torch neck coupling and all other welding torch components to cool down to room temperature (+25 °C, +77 °F).
31
General
(1)
Device concept The pneumatic Robacta TX cover shields up to five torch neck rack pieces on one side of
the torch neck changeover station rack holder. A signal from the robot control opens and closes the cover. An integral sensor monitors the position of the cover. Two covers are needed to shield both sides of the rack holder.
Scope of supply
(2)
(3)
(1) Pneumatic Robacta TX cover
(2) Compressed air line (3) Compressed air distributor
Tools required - TX 25 Torx screwdriver
- 8 mm Allen key
32
Commissioning the pneumatic Robacta TX cover
1
Preparation Depressurise the compressed air line of the torch neck changeover station and ensure
that this compressed air line remains depressurised for the duration of the work on the device
Disconnect the compressed air line from compressed air connection "A" on the torch
2
neck changeover station
CAUTION! Risk of injury from escaping compressed air from compressed air connection "A". Compressed air emerges at up to 16 bar (232.06 psi) from com­pressed air connection "A" when the Unlock/Lock button is pressed. While com­pressed air is emerging from compressed air connection "A":
- wear ear protection
- keep the face and all other body parts away from compressed air connection "A"
- ensure that no other persons are in the vicinity of the torch neck changeover station
Press and hold the Unlock/Lock button on the torch neck changeover station until
3
compressed air no longer emerges from compressed air connection "A" on the torch neck changeover station
- compressed-air booster unit in the torch neck changeover station discharges
De-energise the torch neck changeover station
4
(3)
CAUTION! Risk of injury from compressed air escaping unintentionally. The torch neck changeover station must remain depressurised and de-energised until all work is completed.
Undo screws (3)
(3) (4)
(3)
(3)
5
Remove the cover lid (4)
6
33
(5)
8
2
(5)
Undo screws (5)
7
Remove lid (6)
Fitting one pneu­matic Robacta TX cover
(5)
(5)
(5)
(1)
(2)
(2)
(5)
(6)
(5)
(5)
(1)
Undo screws and washers (1) to fit the
1
cover, if required, for torch neck rack pieces 1-5 Undo screws and washers (2) to fit the cover, if required, for torch neck rack pieces 6-10
- Keep the screws for later use
- The washers may be disposed of
(3)
(4)
Remove blanking plug (3) to fit the co­ver, if required, for torch neck rack pi­eces 1-5 Remove blanking plug (4) to fit the co­ver, if required, for torch neck rack pi­eces 6-10
- The blanking plugs may be dispo­sed of
34
(7)
7
(5)
(7)
(6)
Open the cover
3
Place the cover on the holder retainer
4
as shown
Ensure that the edges of the cover (5)
5
and the holder retainer (6) are parallel to each other
Close the cover
6
NOTE! Screw cover in place with­out washers.
Screw cover in place using the screws (7) previously removed from the holder retainer
Installing one pneumatic Ro­bacta TX cover
(4)
(5)
(3)
Connect the compressed air line sup-
1
(2)(1)
plied (1) to connection (2) and guide through the hole (3) in the torch neck changeover station
Guide the valve (4) and sensor (5)
2
cables through the hole (3) into the torch neck changeover station
Connect the sensor cable (5) to con-
3
nection X14 on the PC board in the torch neck changeover station
Connect the valve cable (4) to connec-
4
tion X16 on the PC board in the torch neck changeover station
35
(6)
(8)
(7)
(6)
Disconnect the compressed air line for
5
the accessory equipment (6)
Fit the compressed air distributor (7) as
6
shown
Connect the compressed air line for
7
the accessory equipment (6) to the compressed air distributor (7) as shown
Connect the compressed air line for
8
the cover (8) to the compressed air dis­tributor (7) as shown
(10)
(10)
(10)
(10)
(10)
(10)
(9)
(10)
(10)
Fit the cover lid
9
Place the lid (9) on the torch neck
10
changeover station
Tighten screws and washers (10)
11
11
36
Fitting two pneu-
(1)
(1)
(2)
(2)
4
matic Robacta TX covers
(4)
Undo screws and washers (1) and (2)
1
- Keep the screws for later use
- The washers may be disposed of
Remove blanking plugs (3) and (4)
2
- The blanking plugs may be dispo­sed of
(3)
(5)
(6)
Open the cover
3
Place the cover on the holder retainer as shown
Ensure that the edges of the cover (5)
5
and the holder retainer (6) are parallel to each other
Close the cover
6
37
(7)
(1)
(3)
(2)
(4)
(6)
(5)
(7)
NOTE! Screw cover in place with­out washers.
Screw cover in place using the screws
7
(7) previously removed from the holder retainer
Repeat steps 3 - 7 with the second co-
8
ver
Installing two pneumatic Ro­bacta TX covers
Connect the compressed air line sup-
1
plied (1) to connection (2) and guide through the hole (3) in the torch neck changeover station
Connect the compressed air line sup-
2
plied (4) to connection (5) and guide through the hole (6) in the torch neck changeover station
Disconnect the compressed air line for
3
the accessory equipment (7)
38
(7)
6
(12)
(11)
(9) (8) (10)
(7)
(12)
Fit the compressed air distributor for
4
the first cover (8) as shown
Connect the compressed air line for
5
the first cover (9) to the compressed air distributor (8) as shown
Fit the compressed air distributor for the second cover (10) as shown
Connect the compressed air line for
7
the cover (11) to the compressed air distributor (10) as shown
Connect the compressed air line for
8
the accessory equipment (7) to the compressed air distributor (10) as shown
Fit the lid to both covers
9
Place the lid (11) on the torch neck
10
changeover station
Tighten screws and washers (12)
11
11
Checking the function of the pneumatic Ro­bacta TX cover
(12)
(12)
(11)
(12)
(12)
Connect the compressed air line to compressed air connection "A" on the torch neck
1
changeover station
Establish the compressed air and power supply to the torch neck changeover station
2
Open and close the cover by sending a signal from the relevant control system
3
- The cover must open and close silently
(1)
(12)
(2)
If necessary, regulate the cover ope-
4
ning speed using a throttle (1)
39
(2)
If necessary, regulate the cover closing
5
speed using a throttle (2)
NOTE! After fitting the pneumatic cover(s), apply the necessary program se­quence additions to the robot program for the respective torch neck changeover station.
40
Locking the pneumatic Robacta TX cover
(1)
(1)
Locking the cover
NOTE! Ensure that the cover locking bolt remains in the operating position while
the torch neck changeover station is in use.
Lock the cover as follows
Allow the locking bolt (1) to lock in po-
1
sition as shown
(1)
NOTE! Do not lock the cover while the torch neck changeover station is in use.
Unlock as follows
Remove the locking bolt (1) from the
1
locking hole and move to the position shown
- the locking bolt is in the operating position
41
42
Robacta TX slide, Robacta TX slide
XL
Safety
Safety Observe the following safety rules for all work described in the "Robacta TX slide, Robacta
TX slide XL" section.
WARNING! Incorrect operation or shoddy workmanship can cause serious injury or damage. All activities described in these operating instructions may only be carried out by trained and qualified personnel. All functions described in these op­erating instructions may only be used by trained and qualified personnel. Do not carry out any of the work or use any of the functions described until you have fully read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe­ty rules
WARNING! Machines that start up automatically can cause serious injury and damage. In addition to these operating instructions, the safety rules issued by the manufacturers of the robot and welding systems must also be observed. 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 arm. Ensure there is no one else within the working area of the robot whenever work is carried out.
WARNING! Work that is carried out incorrectly can cause serious injury or dam-
age. Before starting work:
- turn the power source mains switch to the "O" position
- disconnect the power source from the mains
- put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again
CAUTION! Risk of injury from sharp flying parts. During the work described be­low, always wear the following protective equipment:
- protective goggles with side protection
- ear protection
- gloves - electrically insulated and providing protection against heat
CAUTION! Risk of burns from hot torch neck, hot torch neck coupling and other hot welding torch components. Before carrying out work, allow the torch neck, torch neck coupling and all other welding torch components to cool down to room temperature (+25 °C, +77 °F).
45
Fitting the Robacta TX slide
1
Preparation Depressurise the compressed air line of the torch neck changeover station and make
sure that this compressed air line remains depressurised for the duration of the work on the device
Disconnect the compressed air line from compressed air connection "A" on the torch
2
neck changeover station
CAUTION! Risk of injury from escaping compressed air from compressed air connection "A". Compressed air emerges at up to 16 bar (232.06 psi) from com­pressed air connection "A" when the Unlock/Lock button is pressed. While com­pressed air is emerging from compressed air connection "A":
- wear ear protection
- keep the face and all other body parts away from compressed air connection "A"
- ensure that no other persons are in the vicinity of the torch neck changeover station
Press and hold the Unlock/Lock button on the torch neck changeover station until
3
compressed air no longer emerges from compressed air connection "A" on the torch neck changeover station
- compressed-air booster unit in the torch neck changeover station discharges
De-energise the torch neck changeover station
4
Safety
Fit the slide
CAUTION! Risk of injury from compressed air escaping unintentionally. The torch
neck changeover station must remain depressurised and de-energised until all work is completed.
Undo the screws (1)
1
- Keep the screws and washers for
(1) (1)
(1)
fitting the slide
46
Place the slide on the torch neck chan-
1
2
(1)
(1)
2
geover station as shown
Secure the slide in position using the
3
screws and washers (1) as shown
Connect the sensor cable to the exter-
4
nal power supply connection "A" on the torch neck changeover station
(1)
And finally... Connect the compressed air line to compressed air connection "A" on the torch neck
changeover station
Establish the compressed air and power supply to the torch neck changeover station
47
Fitting the Robacta TX slide XL
1
Preparation Depressurise the compressed air line of the torch neck changeover station and make
sure that this compressed air line remains depressurised for the duration of the work on the device
Disconnect the compressed air line from compressed air connection "A" on the torch
2
neck changeover station
CAUTION! Risk of injury from escaping compressed air from compressed air connection "A". Compressed air emerges at up to 16 bar (232.06 psi) from com­pressed air connection "A" when the Unlock/Lock button is pressed. While com­pressed air is emerging from compressed air connection "A":
- wear ear protection
- keep the face and all other body parts away from compressed air connection "A"
- ensure that no other persons are in the vicinity of the torch neck changeover station
Press and hold the Unlock/Lock button on the torch neck changeover station until
3
compressed air no longer emerges from compressed air connection "A" on the torch neck changeover station
- compressed-air booster unit in the torch neck changeover station discharges
De-energise the torch neck changeover station
4
Safety
Screw base to the underlying sur­face
CAUTION! Risk of injury from compressed air escaping unintentionally. The torch
neck changeover station must remain depressurised and de-energised until all work is completed.
NOTE! Different fixings may be required to fit the base depending on the type of surface. Fixings are therefore not included in the scope of supply of the base. The installer is responsible for selecting the right type of fixing.
Place the base in a suitable location
1
If necessary, align the base horizontal-
2
ly and vertically using adjustment plates
Bolt the base (1) to the underlying sur-
3
face
Once bolted down, check that the base
4
is horizontally and vertically aligned with the underlying surface
(1)
(1)
48
Fit the XL slide The XL slide is an enhanced version of the standard slide. It provides an additional dis-
(2)
(3)
(3)
(4)
(1)
charge area for the torch necks.
Attach the XL slide (1) to the specified positions (3) on the base using the 4 screw con-
1
nections supplied.
- The XL slide can be adjusted as required using the additional holes (4)
Connect the sensor cable (2) to the external power supply connection "A" on the torch
2
neck changeover station
Fit the standard slide to the XL base
And finally... Connect the compressed air line to compressed air connection "A" on the torch neck
The standard slide can also be fitted to the base for the XL slide. It is also possible to fit slides to each side of the base.
Attach the slide (1) to position (2) or (3)
(1) (2) (3)
1
on the base using the 4 screw connec­tions supplied.
Connect the slide sensor cable to the
2
external power supply connection "A" on the torch neck changeover station
1
changeover station
Establish the compressed air and power supply to the torch neck changeover station
2
49
Commissioning the Robacta TX slide / Robacta TX
1
slide XL
Placing a torch neck in the Ro­bacta TX slide / Robacta TX slide XL
WARNING! Risk of severe injury from the robot arm. During the course of the
whole process:
- carry out all work outside of the robot working area
- make sure that there is no-one else within the robot working area
Position the robot arm above the slide as shown
Undo the torch neck coupling
2
- the torch neck will fall from the torch neck coupling
50 mm
1.97 in.
Changing the pro­gram sequence to account for the Robacta TX slide / Robacta TX slide XL
50 mm
1.97 in.
NOTE! The slide can accommodate a maximum of five torch necks.
Change the relevant program sequence for the torch neck changeover as follows:
Set the 'Set down welding torch' signal on the robot
1
Wait until the slide sensor signal is output
2
- the signal confirms that the torch neck has been placed in the slide
Only continue to move the robot once the signal has been output
3
50
NOTE! Use one of the following methods to check the number of torch necks in the slide.
For 1 - 4 torch necks:
- create a counter in the robot program that monitors the signals from the slide sensor.
For 5 torch necks:
- wait until the slide sensor outputs a continuous signal. A continuous signal indicates that the slide is occupied by 5 torch necks and is therefore full.
51
52
Robacta TX W torch neck rack
Safety
Safety Observe the following safety rules for all work described in the "Robacta TX W torch neck
rack" section.
WARNING! Incorrect operation or shoddy workmanship can cause serious injury or damage. All activities described in these operating instructions may only be carried out by trained and qualified personnel. All functions described in these op­erating instructions may only be used by trained and qualified personnel. Do not carry out any of the work or use any of the functions described until you have fully read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe­ty rules
WARNING! Machines that start up automatically can cause serious injury and damage. In addition to these operating instructions, the safety rules issued by the manufacturers of the robot and welding systems must also be observed. 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 arm. Ensure there is no one else within the working area of the robot whenever work is carried out.
WARNING! Work that is carried out incorrectly can cause serious injury or dam-
age. Before starting work:
- turn the power source mains switch to the "O" position
- disconnect the power source from the mains
- put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again
CAUTION! Risk of injury from sharp flying parts. During the work described be­low, always wear the following protective equipment:
- protective goggles with side protection
- ear protection
- gloves - electrically insulated and providing protection against heat
CAUTION! Risk of burns from hot torch neck, hot torch neck coupling and other hot welding torch components. Before carrying out work, allow the torch neck, torch neck coupling and all other welding torch components to cool down to room temperature (+25 °C, +77 °F).
55
Fitting a torch neck rack piece
2
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(2)
1
2
Scope of supply - Torch neck rack piece
- M6 x 20 mm screw
Preparation Depressurise the compressed air line of the torch neck changeover station and make
1
sure that this compressed air line remains depressurised for the duration of the work on the device
Disconnect the compressed air line from compressed air connection "A" on the torch neck changeover station
CAUTION! Risk of injury from escaping compressed air from compressed air connection "A". Compressed air emerges at up to 16 bar (232.06 psi) from com­pressed air connection "A" when the Unlock/Lock button is pressed. While com­pressed air is emerging from compressed air connection "A":
- wear ear protection
- keep the face and all other body parts away from compressed air connection "A"
- ensure that no other persons are in the vicinity of the torch neck changeover station
Press and hold the Unlock/Lock button on the torch neck changeover station until
3
compressed air no longer emerges from compressed air connection "A" on the torch neck changeover station
- compressed-air booster unit in the torch neck changeover station discharges
De-energise the torch neck changeover station
4
Safety
Fitting a torch neck rack piece
CAUTION! Risk of injury from compressed air escaping unintentionally. The torch
neck changeover station must remain depressurised and de-energised until all work is completed.
Undo the 8 screws (1)
Remove lid (2)
56
(3)
7
(5)
(8) (7)
(4)
(6)
Place the torch neck rack piece (3)
3
onto the rack holder (4) as shown
Secure torch neck rack piece in place
4
using the M6 x 20 mm screw supplied (5)
Guide the cable for the torch neck sen-
5
sor through the housing opening (6)
Remove the cable tie (7)
6
Connect the plug to the PC board ac­cording to the position on the rack hol­der. In this case (8)
Example:
- Torch neck rack piece mounted at position 2 on the rack holder - con­nect the plug of the torch neck sensor at connection 'X3 sensor 2' on the PC board in the torch neck changeover station
Fix the torch neck sensor cable using a
8
cable tie as shown
Place the lid (9) on the torch neck
9
changeover station
Tighten 8 screws and washers (10)
(10)
(10)
(10)
(10)
And finally... Connect the compressed air line to compressed air connection "A" on the torch neck
1
changeover station
Establish the compressed air and power supply to the torch neck changeover station
2
(10)
(10)
(9)
(10)
(10)
10
57
58
Robacta TX G torch neck rack
Safety
Safety Observe the following safety rules for all work described in the "Robacta TX G torch neck
rack" section.
WARNING! Incorrect operation or shoddy workmanship can cause serious injury or damage. All activities described in these operating instructions may only be carried out by trained and qualified personnel. All functions described in these op­erating instructions may only be used by trained and qualified personnel. Do not carry out any of the work or use any of the functions described until you have fully read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe­ty rules
WARNING! Machines that start up automatically can cause serious injury and damage. In addition to these operating instructions, the safety rules issued by the manufacturers of the robot and welding systems must also be observed. 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 arm. Ensure there is no one else within the working area of the robot whenever work is carried out.
WARNING! Work that is carried out incorrectly can cause serious injury or dam-
age. Before starting work:
- turn the power source mains switch to the "O" position
- disconnect the power source from the mains
- put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again
CAUTION! Risk of injury from sharp flying parts. During the work described be­low, always wear the following protective equipment:
- protective goggles with side protection
- ear protection
- gloves - electrically insulated and providing protection against heat
CAUTION! Risk of burns from hot torch neck, hot torch neck coupling and other hot welding torch components. Before carrying out work, allow the torch neck, torch neck coupling and all other welding torch components to cool down to room temperature (+25 °C, +77 °F).
61
Fitting a torch neck rack piece
2
(1)
(1)
(2)
(1)
(1)
(1)
(1)
(1)
(1)
1
2
Scope of supply - Torch neck rack piece
- M6 x 20 mm screw
Preparation Depressurise the compressed air line of the torch neck changeover station and make
1
sure that this compressed air line remains depressurised for the duration of the work on the device
Disconnect the compressed air line from compressed air connection "A" on the torch neck changeover station
CAUTION! Risk of injury from escaping compressed air from compressed air connection "A". Compressed air emerges at up to 16 bar (232.06 psi) from com­pressed air connection "A" when the Unlock/Lock button is pressed. While com­pressed air is emerging from compressed air connection "A":
- wear ear protection
- keep the face and all other body parts away from compressed air connection "A"
- ensure that no other persons are in the vicinity of the torch neck changeover station
Press and hold the Unlock/Lock button on the torch neck changeover station until
3
compressed air no longer emerges from compressed air connection "A" on the torch neck changeover station
- compressed-air booster unit in the torch neck changeover station discharges
De-energise the torch neck changeover station
4
Safety
Fitting a torch neck rack piece
CAUTION! Risk of injury from compressed air escaping unintentionally. The torch
neck changeover station must remain depressurised and de-energised until all work is completed.
Undo the 8 screws (1)
Remove lid (2)
62
(6)
7
(4) (3)
(8) (7)
(5)
Place the torch neck rack piece (3)
3
onto the rack holder (4) as shown
Secure torch neck rack piece in place
4
using the M6 x 20 mm screw supplied (5)
Guide the cable for the torch neck sen-
5
sor through the housing opening (6)
Remove the cable tie (7)
6
Connect the plug to the PC board ac­cording to the position on the rack hol­der. In this case (8)
Example:
- Torch neck rack piece mounted at position 4 on the rack holder - con­nect the plug of the torch neck sensor at connection 'X5 sensor 4' on the PC board in the torch neck changeover station
Fix the torch neck sensor cable using a
8
cable tie as shown
Place the lid (9) on the torch neck
9
changeover station
Tighten 8 screws and washers (10)
(10)
10
(10)
(10)
(10)
(9)
(10)
(10)
And finally... Connect the compressed air line to compressed air connection "A" on the torch neck
1
changeover station
Establish the compressed air and power supply to the torch neck changeover station
2
(10)
(10)
63
64
Torch neck coding
Safety
Safety Observe the following safety rules for all work described in the "Torch neck coding" section.
WARNING! Incorrect operation or shoddy workmanship can cause serious injury
or damage. All activities described in these operating instructions may only be carried out by trained and qualified personnel. All functions described in these op­erating instructions may only be used by trained and qualified personnel. Do not carry out any of the work or use any of the functions described until you have fully read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe­ty rules
WARNING! Machines that start up automatically can cause serious injury and damage. In addition to these operating instructions, the safety rules issued by the manufacturers of the robot and welding systems must also be observed. 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 arm. Ensure there is no one else within the working area of the robot whenever work is carried out.
WARNING! Work that is carried out incorrectly can cause serious injury or dam-
age. Before starting work:
- turn the power source mains switch to the "O" position
- disconnect the power source from the mains
- put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again
CAUTION! Risk of injury from sharp flying parts. During the work described be­low, always wear the following protective equipment:
- protective goggles with side protection
- ear protection
- gloves - electrically insulated and providing protection against heat
CAUTION! Risk of burns from hot torch neck, hot torch neck coupling and other hot welding torch components. Before carrying out work, allow the torch neck, torch neck coupling and all other welding torch components to cool down to room temperature (+25 °C, +77 °F).
67
Coding the torch neck
General Coding the torch necks ensures that each torch neck is always stored in the correct torch
neck rack piece. Once the torch necks have been coded it is impossible for them to be placed in the wrong rack piece.
How it works:
- Each torch neck rack piece has holes drilled into it
- Notched pins are then placed in the rack piece holes; the number and position of the notched pin(s) can be chosen by the user
- Holes on the torch neck are exposed to align exactly with the holes containing notched pins on the rack piece
- The torch neck can only be stored in a rack piece if an open hole on the torch neck is aligned exactly with a notched pin in the torch neck rack piece
Preparation Depressurise the compressed air line of the torch neck changeover station and make
1
sure that this compressed air line remains depressurised for the duration of the work on the device
Disconnect the compressed air line from compressed air connection "A" on the torch
2
neck changeover station
CAUTION! Risk of injury from escaping compressed air from compressed air connection "A". Compressed air emerges at up to 16 bar (232.06 psi) from com­pressed air connection "A" when the Unlock/Lock button is pressed. While com­pressed air is emerging from compressed air connection "A":
- wear ear protection
- keep the face and all other body parts away from compressed air connection "A"
- ensure that no other persons are in the vicinity of the torch neck changeover station
Press and hold the Unlock/Lock button on the torch neck changeover station until
3
compressed air no longer emerges from compressed air connection "A" on the torch neck changeover station
- compressed-air booster unit in the torch neck changeover station discharges
De-energise the torch neck changeover station
4
Safety
68
CAUTION! Risk of injury from compressed air escaping unintentionally. The torch neck changeover station must remain depressurised and de-energised until all work is completed.
Coding the torch
(1)
neck
Place a 3 x 20 mm (0.12 in. x 0.79 in.)
1
notched pin (1) the desired hole on the torch neck rack piece
Screw threaded studs into the holes to
2
be closed on the torch neck
Example
- Screw five threaded studs into the holes (2)
- Leave hole (3) open for the not­ched pin
(2)
(2) (3)
(2)
(2)
(2)
Place the torch neck into the torch
3
neck rack piece and check that the not­ched pin is aligned with the open hole
Torch neck coded correctly
69
Torch neck coded incorrectly
Code the remaining torch necks
4
And finally... Connect the compressed air line to compressed air connection "A" on the torch neck
1
changeover station
Establish the compressed air and power supply to the torch neck changeover station
2
70
Compressed air maintenance unit
Safety
Safety Observe the following safety rules for all work described in the "Compressed air mainte-
nance unit" section.
WARNING! Incorrect operation or shoddy workmanship can cause serious injury or damage. All activities described in these operating instructions may only be carried out by trained and qualified personnel. All functions described in these op­erating instructions may only be used by trained and qualified personnel. Do not carry out any of the work or use any of the functions described until you have fully read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe­ty rules
WARNING! Machines that start up automatically can cause serious injury and damage. In addition to these operating instructions, the safety rules issued by the manufacturers of the robot and welding systems must also be observed. 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 arm. Ensure there is no one else within the working area of the robot whenever work is carried out.
WARNING! Work that is carried out incorrectly can cause serious injury or dam-
age. Before starting work:
- turn the power source mains switch to the "O" position
- disconnect the power source from the mains
- put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again
CAUTION! Risk of injury from sharp flying parts. During the work described be­low, always wear the following protective equipment:
- protective goggles with side protection
- ear protection
- gloves - electrically insulated and providing protection against heat
CAUTION! Risk of burns from hot torch neck, hot torch neck coupling and other hot welding torch components. Before carrying out work, allow the torch neck, torch neck coupling and all other welding torch components to cool down to room temperature (+25 °C, +77 °F).
73
General
General The maintenance unit ensures that the compressed air supply to the torch neck changeo-
ver station and corresponding components is properly treated. The integral compressed air filter removes impurities larger than 5 µm from the compressed air. An integral pressure reducing valve can be used to continuously adjust the output pressure.
Scope of supply
Tools required - Box spanner, size 17
- 4 mm Allen key
(1) Compressed air line (2) Maintenance unit
(1)
(3) Compressed air connection (4) Compressed air connection adap-
ter
(2)
(3)
(4)
74
Fitting the compressed air maintenance unit
1
Preparation Depressurise the compressed air line of the torch neck changeover station and make
sure that this compressed air line remains depressurised for the duration of the work on the device
Disconnect the compressed air line from compressed air connection "A" on the torch
2
neck changeover station
CAUTION! Risk of injury from escaping compressed air from compressed air connection "A". Compressed air emerges at up to 16 bar (232.06 psi) from com­pressed air connection "A" when the Unlock/Lock button is pressed. While com­pressed air is emerging from compressed air connection "A":
- wear ear protection
- keep the face and all other body parts away from compressed air connection "A"
- ensure that no other persons are in the vicinity of the torch neck changeover station
Press and hold the Unlock/Lock button on the torch neck changeover station until
3
compressed air no longer emerges from compressed air connection "A" on the torch neck changeover station
- compressed-air booster unit in the torch neck changeover station discharges
De-energise the torch neck changeover station
4
Safety
Fitting the com­pressed air main­tenance unit
(1)
(1)
(1)
(1)
CAUTION! Risk of injury from compressed air escaping unintentionally. The torch neck changeover station must remain depressurised and de-energised until all work is completed.
Undo the 8 screws (1)
1
Remove lid (2)
2
(1)
(1)
(2)
(1)
(1)
75
(3)
(4)
5
(3)
(3)
(3)
Undo the screws, washers and nuts (3)
3
from the torch neck changeover station
Secure the compressed air mainte-
4
nance unit to the torch neck changeo­ver station as shown (using the screws, washers and nuts removed previously (3))
Screw the compressed air connection adapter supplied (4) to compressed air connection "B" on the torch neck chan­geover station as shown
- Seal the compressed air connec­tion adapter using thread sealant
76
Connect the compressed air connec-
(5)
(5)
(6) (8)
(7)
(3)
(4)
6
tion supplied (5) to the compressed air connection adapter as shown
Connect the compressed air connec-
7
tion (6) on the maintenance unit and the compressed air connection (5) on the torch neck changeover station using the compressed air line supplied (7) as shown
If using a wire-feed unit with the "Torch blow-out" option:
Connect the torch blow-out com-
8
pressed air connection on the wire­feed unit to the compressed air con­nection (8) on the maintenance unit
- The "Torch blow-out" option on the wire-feed unit is supplied with compressed air from the com­pressed air maintenance unit
And finally...
Connect the compressed air line to
1
compressed air connection "A" on the torch neck changeover station
Depressurise the compressed air sup-
2
ply line for the maintenance unit
Connect the compressed air supply
3
line to connection (3) on the mainte­nance unit
Supplying the compressed air supply
4
line with compressed air
Set the pressure using the pressure re-
5
ducing valve (4)
Check the pressure on the compressed-air booster unit in the torch neck changeover
6
station. If necessary, follow the torch neck changeover station operating instructions to set the pressure
Connect the power supply to the torch neck changeover station
7
- 0.55 - 0.60 MPa (= 5.50 - 6.00 bar = 79.77 - 87.02 psi)
77
(1)
9
(1)
Place the lid (2) on the torch neck
8
changeover station
Tighten 8 screws and washers (1)
(1)
(1)
(1)
(1)
(2)
(1)
(1)
78
Wire cutter
Safety
Safety Observe the following safety rules for all work described in the "Wire cutter" section.
WARNING! Incorrect operation or shoddy workmanship can cause serious injury
or damage. All activities described in these operating instructions may only be carried out by trained and qualified personnel. All functions described in these op­erating instructions may only be used by trained and qualified personnel. Do not carry out any of the work or use any of the functions described until you have fully read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe­ty rules
WARNING! Machines that start up automatically can cause serious injury and damage. In addition to these operating instructions, the safety rules issued by the manufacturers of the robot and welding systems must also be observed. 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 arm. Ensure there is no one else within the working area of the robot whenever work is carried out.
WARNING! Work that is carried out incorrectly can cause serious injury or dam-
age. Before starting work:
- turn the power source mains switch to the "O" position
- disconnect the power source from the mains
- put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again
CAUTION! Risk of injury from sharp flying parts. During the work described be­low, always wear the following protective equipment:
- protective goggles with side protection
- ear protection
- gloves - electrically insulated and providing protection against heat
CAUTION! Risk of burns from hot torch neck, hot torch neck coupling and other hot welding torch components. Before carrying out work, allow the torch neck, torch neck coupling and all other welding torch components to cool down to room temperature (+25 °C, +77 °F).
81
Installing the wire cutter
1
Preparation Depressurise the compressed air line of the torch neck changeover station and make
sure that this compressed air line remains depressurised for the duration of the work on the device
Disconnect the compressed air line from compressed air connection "A" on the torch
2
neck changeover station
CAUTION! Risk of injury from escaping compressed air from compressed air connection "A". Compressed air emerges at up to 16 bar (232.06 psi) from com­pressed air connection "A" when the Unlock/Lock button is pressed. While com­pressed air is emerging from compressed air connection "A":
- wear ear protection
- keep the face and all other body parts away from compressed air connection "A"
- ensure that no other persons are in the vicinity of the torch neck changeover station
Press and hold the Unlock/Lock button on the torch neck changeover station until
3
compressed air no longer emerges from compressed air connection "A" on the torch neck changeover station
- compressed-air booster unit in the torch neck changeover station discharges
De-energise the torch neck changeover station
4
Safety
Installing the wire cutter
CAUTION! Risk of injury from compressed air escaping unintentionally. The torch
neck changeover station must remain depressurised and de-energised until all work is completed.
NOTE! Use the screws, washers, lockwashers, nuts and spacers supplied with the wire cutter.
Use 2 screws, 2 washers, 2 lock-
1
(1) (1)
2 x
washers, 2 nuts and 2 spacers to se­cure the wire cutter to the holes (1) in the mounting bracket on the torch neck changeover station, as shown
Remove the blanking plug from com-
2
pressed air connection "C" on the torch neck changeover station
82
Connect the wire cutter compressed
1
2
(3)
And finally... Connect the compressed air line to compressed air connection "A" on the torch neck
(4) (2)
changeover station
Establish the compressed air and power supply to the torch neck changeover station
3
air connection and compressed air connection "C" on the torch neck chan­geover station using the compressed air line (2)
Connect the wire cutter connecting
4
plug to the wire cutter plug connection (3) on the connecting lead supplied
Connect the I/O connecting plug (4) on
5
the connecting lead supplied to the I/O connection for accessory equipment on the torch neck changeover station
83
84
Welding torch cleaning devices
Safety
Safety Observe the following safety rules for all work described in the "Welding torch cleaning de-
vices" section.
WARNING! Incorrect operation or shoddy workmanship can cause serious injury or damage. All activities described in these operating instructions may only be carried out by trained and qualified personnel. All functions described in these op­erating instructions may only be used by trained and qualified personnel. Do not carry out any of the work or use any of the functions described until you have fully read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe­ty rules
WARNING! Machines that start up automatically can cause serious injury and damage. In addition to these operating instructions, the safety rules issued by the manufacturers of the robot and welding systems must also be observed. 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 arm. Ensure there is no one else within the working area of the robot whenever work is carried out.
WARNING! Work that is carried out incorrectly can cause serious injury or dam-
age. Before starting work:
- turn the power source mains switch to the "O" position
- disconnect the power source from the mains
- put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again
CAUTION! Risk of injury from sharp flying parts. During the work described be­low, always wear the following protective equipment:
- protective goggles with side protection
- ear protection
- gloves - electrically insulated and providing protection against heat
CAUTION! Risk of burns from hot torch neck, hot torch neck coupling and other hot welding torch components. Before carrying out work, allow the torch neck, torch neck coupling and all other welding torch components to cool down to room temperature (+25 °C, +77 °F).
87
Installing the Robacta TC 1000
1
1
General
Preparation Depressurise the compressed air line of the torch neck changeover station and make
2
3
4
NOTE! If using the Robacta TC 1000, fit the wire cutter to the torch neck change­over station as described below.
sure that this compressed air line remains depressurised for the duration of the work on the device
Disconnect the compressed air line from compressed air connection "A" on the torch neck changeover station
CAUTION! Risk of injury from escaping compressed air from compressed air connection "A". Compressed air emerges at up to 16 bar (232.06 psi) from com­pressed air connection "A" when the Unlock/Lock button is pressed. While com­pressed air is emerging from compressed air connection "A":
- wear ear protection
- keep the face and all other body parts away from compressed air connection "A"
- ensure that no other persons are in the vicinity of the torch neck changeover station
Press and hold the Unlock/Lock button on the torch neck changeover station until compressed air no longer emerges from compressed air connection "A" on the torch neck changeover station
- compressed-air booster unit in the torch neck changeover station discharges
De-energise the torch neck changeover station
Safety
Fitting the wire cutter
CAUTION! Risk of injury from compressed air escaping unintentionally. The torch
neck changeover station must remain depressurised and de-energised until all work is completed.
NOTE! Use the screws, washers, lockwashers, nuts and spacers supplied with the wire cutter.
Use 2 screws, 2 washers, 2 lock-
(1) (1)
2 x
washers, 2 nuts, and 2 spacers to se­cure the wire cutter to the holes (1) in the mounting bracket on the torch neck changeover station, as shown
Remove the blanking plug from com-
2
pressed air connection "C" on the torch neck changeover station
88
Connect the wire cutter compressed
3
air connection and compressed air connection "C" on the torch neck chan­geover station using the compressed air line (2)
Connect the wire cutter connecting
4
plug to the wire cutter connecting plug (3) on the connecting lead supplied
(2)(3)
Installing the welding torch cleaning device
Connect the I/O connecting plug (1) of
1
the connecting lead supplied to the standard I/O connection socket on the welding torch cleaning device
Connect the I/O connecting plug (2) on
2
the connecting lead supplied to the I/O connection for accessory equipment on the torch neck changeover station
(2) (1)
And finally... Connect the compressed air line to compressed air connection "A" on the torch neck
1
changeover station
Establish the compressed air and power supply to the torch neck changeover station
2
89
Installing the Robacta Reamer V Easy, Robacta Reamer aluminium brush head
General
Preparation Depressurise the compressed air line of the torch neck changeover station and make
1
2
3
4
NOTE! The installation procedure for the Robacta Reamer aluminium brush head is described below. The Robacta Reamer V Easy is installed in exactly the same way.
sure that this compressed air line remains depressurised for the duration of the work on the device
Disconnect the compressed air line from compressed air connection "A" on the torch neck changeover station
CAUTION! Risk of injury from escaping compressed air from compressed air connection "A". Compressed air emerges at up to 16 bar (232.06 psi) from com­pressed air connection "A" when the Unlock/Lock button is pressed. While com­pressed air is emerging from compressed air connection "A":
- wear ear protection
- keep the face and all other body parts away from compressed air connection "A"
- ensure that no other persons are in the vicinity of the torch neck changeover station
Press and hold the Unlock/Lock button on the torch neck changeover station until compressed air no longer emerges from compressed air connection "A" on the torch neck changeover station
- compressed-air booster unit in the torch neck changeover station discharges
De-energise the torch neck changeover station
Safety
Installing the welding torch cleaning device
(1)
(1)
CAUTION! Risk of injury from compressed air escaping unintentionally. The torch neck changeover station must remain depressurised and de-energised until all work is completed.
NOTE! Use the screws, washers, lockwashers and nuts supplied with the welding torch cleaning de­vice.
Use 4 screws, 4 washers, 4 lock-
4 x
(1)
(1)
1
washers and 4 nuts to secure the wel­ding torch cleaning device to the holes (1) in the mounting bracket on the torch neck changeover station, as shown
90
Screw the compressed air connection
(3)
5
6
7
(4) (5)(2)
Connect the I/O connecting plug (3) of the connecting lead supplied to the standard I/ O connection on the welding torch cleaning device
Connect the wire cutter connecting plug to the wire cutter connecting plug (4) on the connecting lead supplied
Connect the I/O connecting plug (5) on the connecting lead supplied to the I/O con­nection for accessory equipment on the torch neck changeover station
2
supplied to the compressed air con­nection on the welding torch cleaning device
- see the operating instructions for the welding torch cleaning device for an exact description of the cleaning device
Remove the blanking plug from com-
3
pressed air connection "C" on the torch neck changeover station
Connect the compressed air connec-
4
tion of the welding torch cleaning de­vice and compressed air connection "C" on the torch neck changeover sta­tion using the compressed air line (2)
And finally... Connect the compressed air line to compressed air connection "A" on the torch neck
1
changeover station
Establish the compressed air and power supply to the torch neck changeover station
2
91
Installing the Robacta Reamer V
1
Preparation Depressurise the compressed air line of the torch neck changeover station and make
sure that this compressed air line remains depressurised for the duration of the work on the device
Disconnect the compressed air line from compressed air connection "A" on the torch
2
neck changeover station
CAUTION! Risk of injury from escaping compressed air from compressed air connection "A". Compressed air emerges at up to 16 bar (232.06 psi) from com­pressed air connection "A" when the Unlock/Lock button is pressed. While com­pressed air is emerging from compressed air connection "A":
- wear ear protection
- keep the face and all other body parts away from compressed air connection "A"
- ensure that no other persons are in the vicinity of the torch neck changeover station
Press and hold the Unlock/Lock button on the torch neck changeover station until
3
compressed air no longer emerges from compressed air connection "A" on the torch neck changeover station
- compressed-air booster unit in the torch neck changeover station discharges
De-energise the torch neck changeover station
4
Safety
Installing the welding torch cleaning device
4 x
(1)
(1)
CAUTION! Risk of injury from compressed air escaping unintentionally. The torch neck changeover station must remain depressurised and de-energised until all work is completed.
NOTE! Use the screws, washers, lockwashers and nuts supplied with the welding torch cleaning de­vice.
Use 4 screws, 4 washers, 4 lock-
1
washers and 4 nuts to secure the wel­ding torch cleaning device to the holes (1) in the mounting bracket on the torch neck changeover station, as shown
(1)
(1)
92
Screw the compressed air connection
2
supplied to the compressed air con­nection on the welding torch cleaning device
- see the operating instructions for the welding torch cleaning device for an exact description of the cleaning device
Remove the blanking plug from com-
3
pressed air connection "C" on the torch neck changeover station
Connect the compressed air connec-
4
tion of the welding torch cleaning de-
(3) (2) (4)
Connect the I/O connecting plug (3) of the connecting lead supplied to the standard I/
5
O connection on the welding torch cleaning device
Connect the I/O connecting plug for accessory equipment (4) on the connecting lead
6
supplied to the I/O connection for accessory equipment on the torch neck changeover station
vice and compressed air connection "C" on the torch neck changeover sta­tion using the compressed air line (2)
And finally... Connect the compressed air line to compressed air connection "A" on the torch neck
1
changeover station
Establish the compressed air and power supply to the torch neck changeover station
2
93
94
Mounting bracket for a TCP measure-
ment unit
Safety
Safety Observe the following safety rules for all work described in the "Mounting bracket for a TCP
measurement unit" section.
WARNING! Incorrect operation or shoddy workmanship can cause serious injury or damage. All activities described in these operating instructions may only be carried out by trained and qualified personnel. All functions described in these op­erating instructions may only be used by trained and qualified personnel. Do not carry out any of the work or use any of the functions described until you have fully read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe­ty rules
WARNING! Machines that start up automatically can cause serious injury and damage. In addition to these operating instructions, the safety rules issued by the manufacturers of the robot and welding systems must also be observed. 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 arm. Ensure there is no one else within the working area of the robot whenever work is carried out.
WARNING! Work that is carried out incorrectly can cause serious injury or dam-
age. Before starting work:
- turn the power source mains switch to the "O" position
- disconnect the power source from the mains
- put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again
CAUTION! Risk of injury from sharp flying parts. During the work described be­low, always wear the following protective equipment:
- protective goggles with side protection
- ear protection
- gloves - electrically insulated and providing protection against heat
CAUTION! Risk of burns from hot torch neck, hot torch neck coupling and other hot welding torch components. Before carrying out work, allow the torch neck, torch neck coupling and all other welding torch components to cool down to room temperature (+25 °C, +77 °F).
97
Mounting bracket for advintec standard
1
(1)
Preparation Depressurise the compressed air line of the torch neck changeover station and make
sure that this compressed air line remains depressurised for the duration of the work on the device
Disconnect the compressed air line from compressed air connection "A" on the torch
2
neck changeover station
CAUTION! Risk of injury from escaping compressed air from compressed air connection "A". Compressed air emerges at up to 16 bar (232.06 psi) from com­pressed air connection "A" when the Unlock/Lock button is pressed. While com­pressed air is emerging from compressed air connection "A":
- wear ear protection
- keep the face and all other body parts away from compressed air connection "A"
- ensure that no other persons are in the vicinity of the torch neck changeover station
Press and hold the Unlock/Lock button on the torch neck changeover station until
3
compressed air no longer emerges from compressed air connection "A" on the torch neck changeover station
- compressed-air booster unit in the torch neck changeover station discharges
De-energise the torch neck changeover station
4
Safety
Fitting the mount­ing bracket
CAUTION! Risk of injury from compressed air escaping unintentionally. The torch
neck changeover station must remain depressurised and de-energised until all work is completed.
Undo screws, nuts and washers (1)
1
Keep screws, nuts and washers for la-
2
ter use
98
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