/ Battery Charging Systems / Welding Technology / Solar Electronics
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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.
EN
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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
EN
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
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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
EN
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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.
EN
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).
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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)
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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
EN
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
EN
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
EN
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
EN
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
EN
'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
EN
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.
EN
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
EN
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
EN
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
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