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ROBACTA CTC Operating Instructions
Spare parts list
Contact Tip Changer
- 4,050,001 Robacta CTC ø25 M6
- 4,050,002 Robacta CTC ø25 M8x1,5
- 4,050,003 Robacta CTC ø27 M6
- 4,050,004 Robacta CTC ø27 M8x1,5
Version: 2021/05
Revision: 1.2
42,0426,0373,EN
Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
KYOKUTOH Europe GmbH
©
Radlkoferstraße 2
81373 München/Germany
Phone: +49-89-741185-313
Fax: +49-89-741185-315
Office Unna
Max-Planck-Straße 4
59423 Unna/Germany
Phone: +49-2303-93615-00
Fax: +49-2303-93615-29
info@kyokutoh.de
www.kyokutoh.de
Foreword
Foreword
This operating manual contains all information pursuant to § 3 Equipment Safety Act "Conditions for
putting into circulation" (in conjunction with Machinery Directive 2006/42/EC as amended).
The operating manual is intended for persons who will be/are tasked with working on/with the
machine described here.
Only through knowledge of this operating manual can errors be avoided at the machine and fault-free
operation guaranteed. It is therefore necessary that this operating manual be known to the responsible
persons.
The operating manual is part of the user information when putting the machine on the market and
must be stored in such a way that it is accessible to the operator and the user. Should the location of
the machine change, then the operating and/or user instructions (including those provided by the
supplier) must be moved with the machine. The instructions in the operating and/or user instructions
(including those provided by the supplier) must be adhered to during all phases of product life.
Carefully read through the corresponding chapter in the operating manual before commencing work.
We accept no liability for damages and faults that arise as the result of failure to adhere to this
operating manual.
IT must be clearly and unequivocally established in-house who is responsible for the machine
(operator) and who is permitted to work at it (users).
For the staff deployed for the transport, installation, preparation, set-up, operation, care, maintenance
and repair, the corresponding responsibilities must be clearly established.
The PLUG & PLAY SETs from Tipman Co., Ltd, which belongs to the KYOKUTOH Group, are robust and
reliable complete systems for changing contact tips. They are easy and quick to integrate. Thanks to
their compact design the Contact Tip Changer can be operated intuitively. Highest quality and
durability, easy maintenance and reliable contact tip change, even under the most demanding
conditions guarantee the greatest possible economic and simplify maintenance.
Equipped with remover and fastening units for both nozzle inserts, a cutting device to shorten the
worn down welding wire, a mechanically changing magazine for ten contact tips including monitoring
sensor and a rotating cleaning unit for cleaning the contact tip.
I
Table of Content
Table of content
1 Declaration of Conformity ............................................................................................................... 1
2 Technical Specifications ................................................................................................................... 2
2.1 Type ......................................................................................................................................... 3
2.2 Dimension ................................................................................................................................ 4
2.3 Sensor Technology .................................................................................................................. 5
3 Basic Saftey Instructions .................................................................................................................. 7
3.1 Explanation of symbols and instructions ................................................................................. 7
3.2 Proper use ............................................................................................................................... 8
3.3 Improper use ........................................................................................................................... 8
3.4 Obligation to instruct .............................................................................................................. 9
3.5 Safety devices .......................................................................................................................... 9
3.6 Systems with servo- and frequency inverters ......................................................................... 9
3.7 Inspection obligation ............................................................................................................... 9
3.8 Conduct in case of hazards and faults .................................................................................... 10
3.9 Information regarding residual risks ..................................................................................... 10
3.10 Special hazard points ............................................................................................................. 10
3.11 Safety and protection devices ............................................................................................... 10
3.12 Special safety instructions ..................................................................................................... 11
3.13 Hazards during maintenance, repair and similar work .......................................................... 12
3.14 Product monitoring ............................................................................................................... 12
4 SETUP AND ASSEMBLY .................................................................................................................. 13
4.1 Place of installation, place of use .......................................................................................... 13
4.2 Alignment and mounting ....................................................................................................... 13
4.3 Protective conductor connection on the stand..................................................................... 13
5 COMMISSIONING / SETUP ............................................................................................................. 14
5.1 Safety requirements .............................................................................................................. 14
5.2 Initial commissioning ............................................................................................................. 14
5.3 Preparation for operation ..................................................................................................... 15
5.3.1 Tolerance for centering and parallelism ....................................................................... 15
5.3.2 Process preparation for teaching .................................................................................. 16
5.3.3 Signals ............................................................................................................................ 17
5.3.4 Spacer ............................................................................................................................ 17
5.3.5 Change Spacer ............................................................................................................... 19
5.4 Teaching process ................................................................................................................... 20
II
Table of Content
5.4.1 Preparation process....................................................................................................... 20
5.4.2 Confirmation of engine running .................................................................................... 21
5.4.3 Cut off welding wire ...................................................................................................... 22
5.4.4 Turn off and remove the nozzle .................................................................................... 24
5.4.5 Cleaning the contact tip ................................................................................................ 26
5.4.6 Actuation of the magazine (revolver) ............................................................................ 27
5.4.7 Remove contact tip ....................................................................................................... 27
5.4.8 Contact tip attachement ............................................................................................... 30
5.4.9 Attachment nozzle ......................................................................................................... 31
6 STORAGE AND TRANSPORT ........................................................................................................... 35
6.1 Safety regulations .................................................................................................................. 35
6.2 Symbols on the cargo ............................................................................................................ 35
6.3 Transport type ....................................................................................................................... 35
6.4 Handover and Inspection ...................................................................................................... 36
6.5 Unpacking and Storage .......................................................................................................... 36
7 Maintenance and Repair ............................................................................................................... 37
7.1 Maintenance.......................................................................................................................... 37
7.2 Cleaning ................................................................................................................................. 39
7.3 Repair .................................................................................................................................... 39
7.4 Safety regulations .................................................................................................................. 39
8 Decommissioning/Dismantling...................................................................................................... 41
8.1 Safety regulations .................................................................................................................. 41
8.2 Decommissioning .................................................................................................................. 41
9 SPAREPARTS .................................................................................................................................. 42
9.1 Patrlist ................................................................................................................................... 43
10 SERVICE ...................................................................................................................................... 44
10.1 Troubleshooting .................................................................................................................... 44
11 APPENDIX .................................................................................................................................. 46
11.1 Data on the different contact tips ......................................................................................... 46
11.2 Data on different nozzles ...................................................................................................... 47
11.3 Elektronic ............................................................................................................................... 48
III
Table of Content
Rev. Description
Date
Editor
Department
Revision of chap. 5
- various corrections
05.10.2020
M. Swientek
Technology
Correction / addition chap. 9
– Ballplunger added,
05.10.2020
M. Swientek
Technology
Supplement chap. 10.1
- alarm 46 added
05.10.2020
M. Swientek
Technology
E-Plan change chap. 11.3
- Lin
05.10.2020
M. Swientek
Technology
Change chap. 2.1 Contact & Gas Nozzle
21.05.2021
G.Heimann
Technology
Change chap. 5.3.4 Fronius
item number added
t. 21.05.2021
G.Heimann
Technology
Change chap. 9.1 List of spare parts
21.05.2021
G.Heimann
Technology
Amendment Appendix E
-
Plan updated
21.05.2021
G.Heimann
Technology
1.1
1.2
corrected wire brush
e filter added, additional information added
IV
1. Declaration of Conformity
1 Declaration of Conformity
EG-Konformitätserklärung
nach der EG-Maschinenrichtlinie 2006/42/EG
EC-Declaration of Conformity
Hiermit erklärt die
Herewith we
dass die nachfolgend bezeichneten Maschinen, aufgrund ihrer Konzeption und Bauart, soweit
in der von uns in Verkehr gebrachten Ausführung, den einschlägigen grundlegenden
Sicherheits– und Gesundheitsanforderungen der EG-Richtlinie entspricht.
Bei einer nicht mit uns abgestimmten Änderung der Maschinen, verliert diese Erklärung ihre
Gültigkeit.
declare that the machinery designated below, on the basis of its design and construction in the form brought onto the market by
us is in accordance with the relevant safety and health requirements of the EC Council Directive on Machinery.
If alterations are made to the machinery without prior consultations with us, this declaration becomes invalid
KYOKUTOH Europe GmbH
Radlkoferstraße 2
D –81373 München
Produktbezeichnung: Stromkontaktdüsen Wechsler
Designation Auto Contact Tip Changer
Maschinentyp: CTC-Serie Robacta
Machinery type CTC-Series Robacta
Einschlägige EG-Maschinenrichtlinie (2006/42/EG)
EG-Maschinenrichtlinien:
Relevant EC Council Directives
EC-Low Voltage Directive (2014/35/EU)
EC-Machinery Directive (2006/42/EG)
EG-Niederspannungsrichtlinie (2014/35/EU)
EG-Richtlinie Elektromagnetische Verträglichkeit (2014/30/EU)
EMC-Guideline (2014/30/EU)
EMV Geräteklasse: Klasse A für den Einsatz in industrieller
Umgebung
EMC – Device Class: Class A for use in an industrial environment
Hersteller-Unterschrift:
Signature
Datum: 05.09.2020
Date:
Angaben zum Unterzeichner: Johannes Okubo, Prokurist
Details signee Johannes Okubo, authorised Officer
KYOKUTOH Europe GmbH
info@kyokutoh.de
1
2. Technical Specifications
Motor designation
BLM460SHP
-
GFV
Supply voltage
0-
240V/AC
Control voltage
24V/
DC
Power supply
connection
Without plug (cable)
Rotation sensor
Indu
c
tive
Power line 24V
Without plug (cable)
Motor Power
60 W
Torque
about
34Nm
Type of drive
electrical
Confirmation sensor
Electric motor
tips
Holder for contact
Mechanical magazine
Cleaning unit /
Wire cutter
2 Technical Specifications
CTC-001 Contact Tip Changer
Splash guard
Gearbox
Removal unit for nozzle
Removal unit for contact
tips
switch
wire brush
2
2. Technical Specifications
Robacta CTC ø27 M6
Robacta CTC
Robacta CTC
Robacta CTC
Nozzle
Nozzle
Nozzle
Nozzle
Contact tip
Contact tip
Contact tip
Contact tip
2.1 Type
ø27 M8x1,5
ø25 M6
ø25 M8x1,5
3
2. Technical Specifications
2.2 Dimension
4
2. Technical Specifications
Note
!
E3T Photoelectric
E3Z photoelectric sensor /
Lower blade does
Upper
blade
Lower blade
does
2.3 Sensor Technology
Please pay attention to the correct cable connection.
sensor /
magazine query
1- E2E:
Determining the position of the cutter before cutting the welding wire in the cutting unit. (Output
signal: SS1)
not block the
insertion of the
welding wire.
The insertion into
the cutting position
is possible!
Lower
blade /
rotating
control request
block the insertion
of the welding wire.
The insertion into
the cutting position
is not possible!
Gear shaft
E2E proximity sensor /
cutter query
Proximity
sensor
5
2 x Sensor detector
2. Technical Specifications
2- E3Z:
To check the presence of nozzle and contact tip.
To check the complete removal of nozzle and contact tip.
For checking incomplete fastening of the contact tip up to 0.5 mm with the mounting thread.
(Output signal: LS)
*For example, if the length of the thread of the contact tip is 7.0mm, the sensor determines the contact
tip from 6.5 to 7.0mm to the tip body.
3- E3T:
For checking the magazines for complete filling with contact tips. To check if the magazine cover is in
closed position. (Output signal: SS2)
6
3. Basic Saftey Instructions
Note!
Warning: hazard point!
Warning: hazardous electrical voltage!
Warning: rotating parts
Wear eye protection
Wear gloves
Wear protective footwear
3 Basic Saftey Instructions
The health and safety of employees can only be guaranteed provided the described safety measures
are adhered to during all phases of life (construction, transport, installation etc.). Generally speaking,
the usual accident prevention regulations (Accident prevention regulations, UUV) apply, in particular the
UUV regarding safety at machines.
The operator is obliged to adhere to the valid laws and regulations, in particular in case of use outside
of the EU. This applies in particular if enhanced requirements must be implemented on account of
corresponding changes to laws and regulations.
3.1 Explanation of symbols and instructions
This symbol indicates general information for users
This symbol indicates a threatened or imminent danger to the life and health of
people. Failure to heed this warning instruction can result in material damage and
minor injuries but may also result in severe adverse health effects to lifethreatening injuries.
Failure to heed this notice may result in serious injuries or death!
Failure to heed this notice may result in serious injuries!
Appropriate eye protection must be worn. Failure to adhere to this instruction can
result in serious injuries!
Appropriate protective equipment must be worn. Failure to adhere to this
instruction can result in injuries!
Protective footwear with a steel toecap and oil-proof safety soles.
7
3. Basic Saftey Instructions
Note!
Caution!
3.2 Proper use
The operational safety of the supplied machine is only guaranteed in case of proper
use.
This product is only for use to change specified contact tips.
Proper use also includes adherence to the operating and/or user instructions (including those provided
by the supplier) and adherence to all maintenance and service intervals.
Structural and technical changes to the machine and its accessories generally require written approval
from KYOKUTOH Europe GmbH. In case of infringements, any liability on the part of the manufacturer
and any manufacturer warranties shall become void!
No other objects (e.g. screwdrivers etc.), which are not explicitly intended for this purpose and
included within the scope of delivery, may be present in the machine (e.g. mix-ups in the parts listed
above, etc.); likewise, no non-production parts may be present around the machine. These objects can
cause damage to people and machinery. KYOKUTOH Europe GmbH accepts no liability for resulting
damage. In case of damage, liability remains with the operator and cannot be transferred to KYOKUTOH
Europe GmbH. This product should only be used for the milling of the identified electrodes.
3.3 Improper use
Warranty and liability claim in case of personal injury and material damage are
excluded if they are the result of one or more of the following causes:
– Improper installation, commissioning, operation and maintenance of the machine
– Operation of the machine while in faulty condition, without protective cover
– Installation in explosive areas
– Improper use of devices, accessories, peripherals etc.
– Operation without safety devices
– Operation with safety devices that are not in flawless condition, are short-circuited or out of
service
– Use of operating materials that are not approved by the manufacturer
– Insufficient monitoring of machine parts that are subject to wear
– Improperly performed repairs
– Emergencies caused by the impact of foreign bodies and force majeure
– Self-performed structural changes to the machine
– Self-performed changes to the
speeds, air pressure, engine speed…)
performance characteristics
(e.g. drive conditions, cylinder
8
3. Basic Saftey Instructions
Caution!
Warning!
3.4 Obligation to instruct
The operator must instruct his employees regarding the possible risks, residual risks and the measures
to be taken in order to avoid these risks prior to the initial commissioning. This instruction must be
issued to every employee who operates the system or is in immediate proximity of these hazards.
3.5 Safety devices
The machine may only be operated if all safety devices are in functional condition.
The removal, bypassing and/or rendering ineffective of these safety devices is prohibited. The safety
devices also include the safety program contained in the software. Changes to this safety program are
prohibited.
All components of the machine, especially safety components, may only be replaced with original
components or other components subject to the written consent of KYOKUTOH Europe GmbH. In the
event that faults, and defects are identified in the safety devices, the machine must be shut down
immediately.
The safety devices must undergo the following checks prior to each time the machine is switched on,
or daily, and following every fault correction:
- Visual inspection of the safety devices, regarding the general appropriate condition and
functional safety (e.g. any bridging must be removed immediately)
- Checking of all locking systems, if present. With each check of the safety devices, it must be
ensured that no body parts or objects protrude into the hazard areas exposed by the opened
covers and that no parts can escape from the machine.
3.6 Systems with servo- and frequency inverters
We expressly point out that the integrated “Safe restart lock” does not interrupt
the power supply to the motor.
It only stops the development of a rotating field and thus safely prevents the startup of the motor. If
electrical work is carried out on the motor, then the mains power supply must be cut off using a mains
contactor or main switch. Also note the intermediate circuit discharge time of at least 5 minutes before
electrical work can be performed. LEDs switching off are no indication that the voltage supplies are
switched off and that the intermediate circuit has discharged to below 24V!
3.7 Inspection obligation
With the handover of the machine by the operator, responsibility regarding the maintenance and
inspection obligation, and in particular regarding the safety devices, is transferred to the operator of
the machine!
9
Warning!
Warning!
3.8 Conduct in case of hazards and faults
Shut down system using EMERGENCY STOP.
Additional measures must be specified by the operator.
In the event of hazards or faults (irregularities) stop working; shut down the system and wait until it is
stationary. If there is no visual contact with the main switch, this must be secured against being
switched on again using a lock. In addition, a sign must be posted referring to the work on the system.
Correct the fault and if necessary, inform a manager / customer service / the service department.
3.9 Information regarding residual risks
Ensure the complete dissipation of residual energy.
The power supply to the control panel and ultimately to the main switch is always live.
Even when the main switch is switched off, individual components in the control cabinet may be live.
Live parts in the control cabinet and junction boxes are designed to be finger-safe, however touching
them with tools still poses the risk of contact with live parts. If work on live parts is required for
troubleshooting purposes, a second supervisor with electrical engineering training must be
brought in as an observer, in accordance with BGV A2, who will switch off the main switch and
seek help if necessary.
– Pneumatics components may drop to their starting position when the compressed air is switched
off. (Caution – residual energy!)
3.10 Special hazard points
– Entire electrical area
– Entire pneumatics area (N/A)
– Entire hydraulics area (N/A)
3.11 Safety and protection devices
– Protective doors with safety switches (safe)
– Emergency stop switch
– Main switch
10
3. Basic Saftey Instructions
Note!
Caution!
3.12 Special safety instructions
Adhere to any user manuals for individual components that may be included in
the appendix.
Never place your hand or finger into the terminal opening while the machine is in
operation. This will result in serious injury.
This special manual is a significant component of this overall operating manual and must be observed
and adhered to. In this special manual you will find any safety instructions that protect against
potentially fatal hazards.
1. Attempt to limit contact with water as far as possible. Consequences could include operating
malfunctions (short circuit), electric shocks or short circuits.
2. Note that weld spatter does not damage the wiring. This prevents the melting of the wire
membrane and electric shock.
3. Remove any oil that accumulates on the tip dresser. Weld spatter can result in short circuits and
potential injuries.
4. Do not use any power supply other than that stated. Excessive heat can result in malfunctions and
short circuits.
5. Ensure that the power supply cable has the correct capacity. (10A/1 unit) Incorrect cabling can
result in malfunctions or short circuits.
6. Use a cable with a sufficient thickness (2 mm² or more). An incorrect cable can result in
malfunctions and short circuits.
7. Ensure that the power supply wiring is not damaged. Damaged cabling can result in malfunctions
and short circuits.
8. Secure the tip dresser firmly on the stand. If the tip dresser is not securely fixed, defective milling
operations and other problems can occur.
9. Ensure that the motor is not blocked. This could result in overheating and a potential short circuit.
10. Do not install the welding machine in the vicinity of the thermal generation source. This may result
in problems and accidents.
11. Do not install between a welding machine and a transformer. Strong magnetic forces and heat can
be dangerous and may cause malfunctions and short circuits.
11
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