How it Works
Fronius
Loading...
R
S
Loading...
Loading...
Robacta TX 10i/G/W console
Operating Instruction [EN]
104 pgs10.46 Mb0
Operating Instruction [DE]
104 pgs10.48 Mb0
Operating Instruction [ZH]
100 pgs10.65 Mb0

Fronius Robacta TX 10i/G/W console Operating Instruction [EN]

Download
Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Perfect Charging / Perfect Welding / Solar Energy
Robacta TX 10i/G/W console
Operating instructions
EN
42,0426,0170,EN 008-27102021
Contents
Safety rules 6
General information 13
EN
General 15
Warning notices on the device 19
Transport 20
Controls, connections and mechanical components 21
Controls, connections and mechanical components 23
Pin assignments and signal descriptions 25
Installation and commissioning 31
Safety 33
Before installation and commissioning 35
Operators, maintenance personnel 35 Setup regulations 35 Compressed air supply specifications 35
Application example 36
Installing the torch body change station 37
Bolting the torch body change station to the underlying surface (foundation) 37 Installing the torch body change station 37
3
Preparing the torch body 39
Preparing torch bodies with steel inner liners 39 Preparing torch bodies with plastic inner liners 40
Configuring the torch-body racks 41
Checking the torch body sensor and setting the wire sensor 43
Safety 43 Connecting the torch body change station to the robot control 43 Checking the torch body sensor 43 Setting the wire sensor 44
Fitting the torch body coupling to the MHP R hosepack 45
Safety 45 Fitting the torch body coupling 45
Fitting the torch body coupling to the WF 25i Robacta Drive / WF 60i Robacta Drive CMT drive unit 47
Manually unlocking / locking the torch body coupling 49
Checking the torch body coupling function 50
Converting the torch body coupling from TX/i low to TX/i high 51
Setting up the robot 53
Start-up 57
Program sequence 58
53
Options 67
Safety 69
Safety 69
Fitting the torch-body rack 71
Fitting the compressed air maintenance unit 73
Fitting the wire cutter 74
Fitting the wire cutter 74
Fitting the Robacta Reamer V Easy, Robacta Reamer brush head Alu edition 75
Fitting the Robacta Reamer V Easy, Robacta Reamer brush head Alu edition 75
Fitting the Robacta Reamer V 76
Connecting the torch body change station to the Robacta TC 1000 / Robacta TC 2000 77
Connecting the torch body change station to the Robacta TC 1000 / Robacta TC 2000 77
Installing the pneumatic Robacta TX cover 78
Installing the pneumatic Robacta TX cover 78
4
Troubleshooting 81
Safety 83
Troubleshooting 85
Troubleshooting 85
Care, maintenance and disposal 87
Safety 89
Replacing the inner liner in the torch body 91
Replacing a steel inner liner in the torch body 91 Replacing a plastic inner liner in the torch body 92
Replacing the inner liner in the core bolt 94
Replacing the inner liner in the MHP R hosepack 96
Replacing the inner liner 96
Replacing the O-rings in the torch body coupling 98
Replacing the O-rings in the torch body coupling 98
Changing coolant stops 99
Replacing coolant stops 99
Disposal 100
Technical data 101
EN
Technical data 103
5
Safety rules
Explanation of safety notices
DANGER!
Indicates immediate danger.
If not avoided, death or serious injury will result.
▶
WARNING!
Indicates a potentially hazardous situation.
If not avoided, death or serious injury may result.
▶
CAUTION!
Indicates a situation where damage or injury could occur.
If not avoided, minor injury and/or damage to property may result.
▶
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
General The device is manufactured using state-of-the-art technology and according to recog-
nised safety standards. If used incorrectly or misused, however, it can cause:
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operating com­pany,
- inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing the device must:
- be suitably qualified,
- have sufficient knowledge of automated welding, and
- read and carefully follow these operating instructions as well as the operating in­structions for all system components.
The operating instructions must always be at hand wherever the device is being used. In addition to the operating instructions, attention must also be paid to any generally applic­able and local regulations regarding accident prevention and environmental protection.
All safety and danger notices on the device
- must be in a legible state,
- must not be damaged,
- must not be removed,
- must not be covered, pasted or painted over.
For the location of the safety and danger notices on the device, refer to the section headed "General" in the operating instructions for the device. Before commissioning the device, rectify any faults that could compromise safety.
This is for your personal safety!
6
Proper use The device is to be used exclusively for its intended purpose.
Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage.
Proper use includes:
- carefully reading and following all the instructions given in the operating instructions
- studying and obeying all safety and danger notices carefully
- performing all stipulated inspection and servicing work.
The device is designed for use in industry and the workshop. The manufacturer accepts no responsibility for any damage caused through use in a domestic setting.
The manufacturer likewise accepts no liability for unexpected or incorrect results.
EN
Environmental conditions
Obligations of the operator
Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage.
Ambient temperature range:
- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
Relative humidity:
- up to 50% at 40 °C (104 °F)
- up to 90% at 20 °C (68 °F)
The surrounding air must be free from dust, acids, corrosive gases or substances, etc. Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)
The operator must only allow persons to work with the device who:
- are familiar with the fundamental instructions regarding safety at work and accident prevention and have been instructed in how to use the device
- have read and understood these operating instructions, especially the section "safety rules", and have confirmed as much with their signatures
- are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are working in a safety-conscious manner.
Obligations of personnel
Specific hazards
Before using the device, all persons instructed to do so undertake:
- to observe the basic instructions regarding safety at work and accident prevention
- to read these operating instructions, especially the "Safety rules" section and sign to confirm that they have understood them and will follow them.
Before leaving the workplace, ensure that people or property cannot come to any harm in your absence.
Stay out of the working area of the robot.
The device must be incorporated into a higher-level safety system within a secured area.
7
If this area has to be accessed when setup and maintenance work is carried out, make sure that
- the entire system is switched off for the duration of the work in this area
- and that it is prevented from starting up accidentally, e.g. as the result of a control fault
In addition to these operating instructions, the robot manufacturer's operating instructions and safety instructions must also be observed.
Covers may only be opened/removed for the duration of any maintenance, installation or repair work.
If this area has to be accessed when setup and maintenance work is carried out, make sure that
- the entire system is switched off for the duration of the work in this area
- and that it is prevented from starting up accidentally, e.g. as the result of a control fault
Protecting your­self and others
EMC Device Clas­sifications
When welding, you expose yourself to numerous dangers. In addition to these operating instructions, the safety instructions of the manufacturer of the entire welding system must also be observed.
Keep all persons, especially children, out of the working area while any devices are in operation or welding is in progress. If, however, there are people in the vicinity,
- make them aware of all the dangers and health risks (crushing by mechanically­powered parts, flying shavings and similar matter, escaping compressed air, flying sparks, dazzling by arc, inhalation of harmful welding fumes, noise, possible danger from mains or welding current, etc.),
- provide suitable protective equipment or
- erect suitable safety screens/curtains.
Devices in emission class A:
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:
- Satisfy the emissions criteria for residential and industrial areas. This is also true for residential areas in which the energy is supplied from the public low-voltage mains.
EMC device classification as per the rating plate or technical data.
EMC measures In certain cases, even though a device complies with the standard limit values for emis-
sions, it may affect the application area for which it was designed (e.g. when there is sensitive equipment at the same location, or if the site where the device is installed is close to either radio or television receivers). If this is the case, then the operator is obliged to take appropriate action to rectify the situation.
Check for possible problems, and check and evaluate neighbouring devices' resistance to interference according to national and international requirements:
- Safety devices
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
8
Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite correct mains connection, addi-
tional measures are necessary (e.g. use a suitable line filter).
2. Control lines
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
3. Equipotential bonding
4. Shield, if necessary
- Shield off other nearby devices
- Shield off entire welding installation
EMF measures Electromagnetic fields may pose as yet unknown risks to health:
- effects on the health of others in the vicinity, e.g. wearers of pacemakers and hear­ing aids
- wearers of pacemakers must seek advice from their doctor before approaching the device or any welding that is in progress
- for safety reasons, keep distances between the welding cables and the welder's head/torso as large as possible
- do not carry welding cables and hosepacks over the shoulders or wind them around any part of the body
EN
Safety measures at the installation location and dur­ing transport
Safety measures in normal opera­tion
A device toppling over could easily kill someone. Place the device on a solid, level sur­face such that it remains stable
- The maximum permissible tilt angle is 10°.
Special regulations apply in rooms at risk of fire or explosion
- Observe relevant national and international regulations.
Use internal directives and checks to ensure that the workplace environment is always clean and clearly laid out.
Only set up and operate the device in accordance with the protection class shown on the rating plate.
When transporting the device, observe the relevant national and local guidelines and ac­cident prevention regulations. This applies especially to guidelines regarding the risks arising during transport.
After transporting the device, the device must be visually inspected for damage before commissioning. Any damage must be repaired by trained service technicians before commissioning the device.
Only operate the device when all safety devices are fully functional. If the safety devices are not fully functional, there is a risk of
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operator,
- inefficient operation of the device.
Any safety devices that are not functioning properly must be repaired before switching on the device.
Never bypass or disable safety components.
Before switching on the device, ensure that no one is likely to be endangered.
9
Check the device at least once a week for obvious damage and proper functioning of safety devices.
Commissioning, maintenance and repair
Safety inspection The manufacturer recommends that a safety inspection of the device is performed at
It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made of them, or that they satisfy safety requirements.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without the manu­facturer's consent.
- Components that are not in perfect condition must be replaced immediately.
- When ordering, please give the exact designation and part number as shown in the spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the housing parts. Only use original housing screws in the correct number and tightened to the specified torque.
least once every 12 months.
A safety inspection should be carried out by a qualified electrician
- after any changes are made
- after any additional parts are installed, or after any conversions
- after repair, care and maintenance has been carried out
- at least every twelve months.
For safety inspections, follow the appropriate national and international standards and directives.
Further details on safety inspection and calibration can be obtained from your service centre. They will provide you on request with any documents you may require.
Disposal Do not dispose of this device with normal domestic waste! To comply with the European
Directive on Waste Electrical and Electronic Equipment and its implementation as nation­al law, electrical equipment that has reached the end of its life must be collected separ­ately and returned to an approved recycling facility. Any device that you no longer require must either be returned to your dealer or given to one of the approved collection and re­cycling facilities in your area. Ignoring this European Directive may have potentially ad­verse affects on the environment and your health!
Safety symbols Devices with the CSA test mark satisfy the requirements of the relevant standards in
Canada and the USA.
Data protection The user is responsible for the safekeeping of any changes made to the factory settings.
The manufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these operating instructions remains with the manufacturer.
10
The text and illustrations are all technically correct at the time of printing. We reserve the right to make changes. The contents of the operating instructions shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any sugges­tions for improvement, or can point out any mistakes that you have found in the instruc­tions, we will be most grateful for your comments.
EN
11
12
General information
13
14
General
Device concept Robacta TX/i is an automatic torch body
change system comprising:
- Torch body change station Robacta TX10i/G/W console
- Torch body coupling TX/i
- Core bolt TX/i G or core bolt TX/i W ­depending on the system
- Torch body MTB G R TX / torch body MTB W R TX - depending on the sys­tem
With Robacta TX/i, robots are used to automatically place worn torch bodies onto the torch body change station and replace them with new torch bodies. Even switch­ing between different torch body geomet­ries is easy with Robacta TX/i.
In conjunction with a welding-torch clean­ing device, Robacta TX/i is converted into a fully autonomous torch body mainten­ance station that increases system avail­ability and significantly reduces setup time.
EN
Necessary sys­tem components
To operate the torch body change station, the following system components are needed in addition to the welding system:
- Torch body change station Robacta TX 10i/G/W console
- Tool kit TX/i
- Torch body coupling TX/i
- Core bolt TX/i G or core bolt TX/i W - depending on the system
- Torch body MTB G R TX or torch body MTB W R TX - depending on the system
- Wire cutter
- The wirefeeder of the WF 15i/25i/30i R and R PAP series with the "16 bar gas pur­ging" option
- Compressed air maintenance unit with filter
- Robot
15
Torch body change station
(3)
(1)
(2)
(4)
(5)
(6)
(1)(2)(3)
The torch body change station is used
to:
- hold up to 10 torch bodies
- hold a welding-torch cleaning device
- hold a wire cutter
- hold a TCP measurement system
Tool kit TX/i comprising:
(1) Robot programming aid (2 parts) (2) Installation tool for torch body
coupling TX/i (3) 3 TCP tips (4) Bit insert for coolant stop (5) Cutting aid (6) Key for fume extraction torch
body
Tool kit TX/i
Torch body coupling, core bolt TX/i G / core bolt TX/i W
- The core bolt (1) is for media transfer in the torch body coupling (2)
- The torch body coupling (2) enables the torch body to be changed
- Length of the coupling = 67.5 mm
(2.66 in.)
- The TCP moves by 47 mm (1.85
in.) with the coupling.
NOTE!
The locking balls (3) are intended for dry operation.
Do not lubricate the locking balls.
16
Torch body MTB G R TX / torch body MTB W R TX Wire cutter
(1)
(2)
(3)
(4)
(5)
(6)
(7)
EN
Compatible sys­tem components for the overall welding system
Scope of supply
Only use the torch body change system in conjunction with the following system com­ponents:
- Any power source from the TPS/i series
- Any Fronius robot wirefeeder from the WF R and WF R PAP series
- Any Fronius unreeling wirefeeder from the WF REEL R series that is synchronised by the power source
- Any MHP R hosepack
- Any MHP RD hosepack and the associated drive units
- WF 25i Robacta Drive G, WF 25i Robacta Drive W
- WF 60i Robacta Drive CMT G, WF 60i Robacta Drive CMT W
- Any MTB G R TX and MTB W R TX torch body
- Robacta Reamer V Easy, Robacta Reamer V
- Robacta Reamer brush head Alu edition
- Any device from the Robacta TC series
(1) Torch body change station (with
3 torch-body racks in the stand­ard version)
(2) Torch body coupling TX/i with
core bolt TX/i G or core bolt TX/i
W - depending on the system (3) 2 wire cutter holders (4) 4 screws for wire cutter holders (5) 4 washers for wire cutter holders (6) 4 adjustment plates 1 mm (0.04
inch) (7) 4 adjustment plates 1.5 mm
(0.06 inch) (8) Operating instructions (not
shown)
Proper use The device is intended solely for changing Fronius torch bodies.
17
The device is intended solely for use in conjunction with Fronius system components. This applies to the cooling units and coolant in particular - only use the device in con­junction with Fronius cooling units and Fronius coolant.
Any use above and beyond this purpose is deemed improper. The manufacturer is not liable for any damage, inadequate or incorrect results arising out of such misuse.
Proper use also includes
- carefully reading and obeying all operating instructions and safety and danger no­tices
- performing all stipulated inspection and servicing work
The device is designed for use in industry and the workshop. The manufacturer shall not be liable for any damage resulting from use of the welding torch in residential premises.
Note on wire feeding
NOTE!
The use of wire drums is required for a perfect workflow.
18
Warning notices on the device
24 VDC
Ser.No.
Model No.
Art.No.
U
I max
1,5 A
Pmax
6 bar
IP23
www.fronius.com
EN
Warning notices on the device
The device is fitted with safety symbols and a rating plate. The safety symbols and rating plate must not be removed or painted over. The symbols warn against operating the equipment incorrectly, as this may result in serious injury and damage.
WARNING! Risk of serious injury from mechanically powered parts. Keep the device free from current and pressure during maintenance and servi­cing.
Do not use the functions described here until you have thoroughly read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safety rules
For indoor use only
19
Transport
Transport devices
Transport notices on the packaging
The device is to be transported by the following devices:
- on pallets using a forklift truck
- on pallets using a lift truck
WARNING!
Danger from equipement toppling over or falling.
This can result in serious personal injury and damage to property.
Secure the device to prevent it from falling over when transporting on a forklift truck
▶
or lift truck Do not suddenly change direction, brake or accelerate
▶
CAUTION!
Danger due to improper transport.
This can result in damage to property.
Observe the transport notices on the device packaging.
▶
20
Controls, connections and mechan-
ical components
21
22
Controls, connections and mechanical components
(5)
(4)
(3)
(2)
(1)
EN
Safety
Controls and connections
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by
▶
technically trained and qualified personnel. Read and understand this document in full.
▶
Read and understand all safety rules and user documentation for this device and all
▶
system components.
(1) Connection for external op-
tions
(2) Standard I/O connection for
robot control
For connecting the robot control to the torch body change station
(3) Blanking cover
Preparation for installation of an optional interface for connection to the robot control
(4) Blanking cover
Preparation for installation of an optional interface for connection to the robot control
(5) Blanking cover
Preparation for installation of an optional interface for connection to the robot control
23
(8)
(7)
(9)
(6)
(6) Compressed air connection
(3)
(1)
(2)
"A"
Connection to supply the torch body change station with dry and oil-free compressed air at
5.50 - 6.00 bar (79.77 - 87.02 psi)
- Size: 3/8" (0.375 in.)
(7) Wire sensor
Checks whether the wire elec­trode is protruding from the welding torch
(8) Compressed air connection
"B"
Connection for supplying the Fronius accessory equipment with compressed air (wire cut­ters, welding-torch cleaning devices)
Mechanical com­ponents
(9) I/O connection for accessory equipment
To connect Fronius accessory equipment to the torch body change station
(1) Rack holder
for holding up to 10 torch-body racks
(2) Bracket
for attaching accessory equipment
(3) Torch-body rack
for depositing a torch body
24
Pin assignments and signal descriptions
1234
9 8 7 6 5
101112131415
22 21 20 19 18 17 16
28 27 26 25 24 23
33 32 31 30 29
37 36 35 34
EN
Safety
Assignment of standard I/O con­nection for robot control
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by
▶
technically trained and qualified personnel. Read and understand this document in full.
▶
Read and understand all safety rules and user documentation for this device and all
▶
system components.
WARNING!
Danger from machines that start up automatically.
This can result in serious personal injury and damage to property.
The device may only be powered through an Emergency Stop circuit.
▶
CAUTION!
Danger due to overcurrent.
Damage to connection supply can be the result.
Secure supply against overcurrent with a 1.5 A slow-blow fuse.
▶
To avoid faults, keep the cable between the torch body change station and the ro­bot control as short as possible.
NOTE!
Pin Input* Output** Signal
1 X + 24 V
2 X GND
3 X Torch body sensor 1
25
Pin Input* Output** Signal
4 X Torch body sensor 2
5 X Torch body sensor 3
6 X Torch body sensor 4
7 X Torch body sensor 5
8 X Torch body sensor 6
9 X Torch body sensor 7
10 X Torch body sensor 8
11 X Torch body sensor 9
12 X Torch body sensor 10
13 X Sensor 1st Robacta TX cover
14 X Sensor 2nd Robacta TX cover
15 X Valve 1st Robacta TX cover
16 X Valve 2nd Robacta TX cover
17 X 'C-Act. 3' signal 1
18 X Chute signal
19 X Wire sensor signal
20 X 'C-Sens. 4' signal 2
21 X 'C-Sens. 4' signal 1
22 X 'C-Sens. 22' signal 1
23 X 'C-Act. 23' signal 2
24 X Reserve relay OUT
25 X 'C-Sens. 5' signal 1
26 X Clamp gas nozzle and cleaning motor on /
Start cleaning
27 X Gas nozzle free / 'TC Ready'
28 X Gas nozzle free / cleaning motor lowered
29 X Cleaning motor running
30 X Spraying in parting agent
31 X Fill level of parting agent OK
32 X Cleaning motor up
33 X Cleaning motor lowered / 'Cleaning Error'
34 X Cleaning motor raised
35 X Cut wire electrode
26
36 X Wire cutter closed
37 X Wire cutter open
* from the torch body change station to the robot ** from the robot to the torch body change station
Signal descrip­tions
Pin Signal Signal description
3 Torch body sensor 1 The respective torch body is deposited in the cor-
4 Torch body sensor 2
5 Torch body sensor 3
6 Torch body sensor 4
7 Torch body sensor 5
8 Torch body sensor 6
9 Torch body sensor 7
10 Torch body sensor 8
11 Torch body sensor 9
12 Torch body sensor 10
responding torch-body rack
EN
13 Sensor 1st Robacta TX
cover
14 Sensor 2nd Robacta TX
cover
15 Valve 1st Robacta TX
cover
16 Valve 2nd Robacta TX
cover
17 'C-Act. 3' signal 1 Reserve signal for actuator
18 Chute signal Signal only available as an option.
19 Wire sensor signal Indicates that the wire electrode is protruding from
20 'C-Sens. 4' signal 2 Reserve signal for sensor
21 'C-Sens. 4' signal 1 Reserve signal for sensor
22 'C-Sens. 22' signal 1 Reserve signal for sensor
23 'C-Act. 23' signal 1 Reserve signal for actuator
Signal only available as an option.
- 1st Robacta TX cover is open
Signal only available as an option.
- 2nd Robacta TX cover is open
Signal only available as an option.
- Opens and closes the 1st Robacta TX cover
Signal only available as an option.
- Opens and closes the 2nd Robacta TX cover
- Torch body has been deposited in the Robacta TX chute / Robacta TX XL chute
the torch body after a successful torch body change
24 Reserve relay OUT Reserve signal for actuator (relay contact)
25 'C-Sens. 5' signal 1 Reserve signal for sensor
26 Clamp gas nozzle and
cleaning motor on / Start cleaning
Signal only available as an option.
"Clamp gas nozzle and cleaning motor on" signal for Robacta Reamer V only:
- Activates the gas nozzle clamping device and the cleaning motor
"Start cleaning" signal for Robacta Reamer devices (excluding Robacta Reamer V), Robacta TC devices:
- Activates the cleaning process
27
Pin Signal Signal description
27 Gas nozzle free / 'TC
Ready'
28 Gas nozzle free / cleaning
motor lowered
29 Cleaning motor running Signal is only available for Robacta Reamer V:
30 Spraying in parting agent Signal is only available for Robacta Reamer V:
Signal only available as an option.
"Gas nozzle free" signal for Robacta Reamer V only:
- Gas nozzle clamping device on welding-torch cleaning device is not holding a gas nozzle
'TC Ready' signal for Robacta TC devices only:
- Welding-torch cleaning device is ready
Signal only available as an option.
"Gas nozzle free" signal for Robacta Reamer V Easy only:
- Gas nozzle clamping device on welding-torch cleaning device is not holding a gas nozzle
"Cleaning motor lowered" signal for Robacta Reamer brush head Alu edition only:
- Cleaning motor was lowered
- Cleaning motor running and emitting constant pulses
- Activates the spraying in of the parting agent
31 Fill level of parting agentOKSignal is only available for Robacta Reamer V:
- Parting agent is in the parting agent container
32 Cleaning motor up Signal is only available for Robacta Reamer V:
- Activates the upward movement of the clean­ing motor
33 Cleaning motor lowered /
'Cleaning Error'
34 Cleaning motor raised Signal is only available for Robacta Reamer V:
35 Cut wire electrode Signal only available as an option:
36 Wire cutter closed Signal only available as an option:
37 Wire cutter open Signal only available as an option:
Signal only available as an option.
"Cleaning motor lowered" signal for Robacta Reamer V and Robacta Reamer brush head Alu edition only:
- Cleaning motor was lowered
'Cleaning Error' signal for Robacta TC devices only:
- Error during cleaning
- Cleaning motor was raised
- Activates the wire cutter
- Wire cutter is closed
- Wire cutter is open
28
Assignment of
1
2
3
4
5
connection to ex­ternal options
CAUTION!
Danger due to overcurrent.
Damage to connection supply can be the result.
Secure supply against overcurrent with a 1.5 A slow-blow fuse.
▶
NOTE!
To avoid faults, keep the cable between the torch body change station and the ro­bot control as short as possible.
1 + 24 V
2 GND
3 -
4 -
5 -
EN
29
30
Installation and commissioning
31
32
Safety
Safety Observe the following safety rules for all work described in the "Installation and start-up"
section.
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by
▶
technically trained and qualified personnel. Read and understand this document in full.
▶
Read and understand all safety rules and user documentation for this device and all
▶
system components.
WARNING!
Danger due to machines that start up automatically.
This can result in serious personal injury and damage to property.
In addition to these Operating Instructions, the safety rules issued by the manufac-
▶
turer of the robot and welding system 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.
EN
WARNING!
Danger from the robot arm.
This can result in serious personal injury and damage to property.
Ensure there is no one else within the working area of the robot whenever work is
▶
carried out.
WARNING!
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved and disconnect
▶
them from the grid. Secure all devices and components involved so they cannot be switched back on.
▶
After opening the device, use a suitable measuring instrument to check that electric-
▶
ally charged components (such as capacitors) have been discharged.
WARNING!
Danger due to hot system components and/or equipment.
Can result in serious burns or scalding.
Before starting work, allow all hot system components and/or equipment to cool to
▶
+25°C/+77°F (e.g., coolant, water-cooled system components, wirefeeder drive mo­tor, etc.) Wear suitable protective equipment (e.g., heat-resistant gloves, safety goggles, etc.)
▶
if cooling down is not possible.
33
WARNING!
Danger from compressed air escaping from the torch body coupling, flying parts, and sharp components.
This can result in serious personal injury and damage to property.
During the work described below, always wear the following protective equipment:
▶
Protective goggles with side protection, Gloves - electrically insulated and providing protection against heat, Safety helmet.
34
Before installation and commissioning
EN
Operators, main­tenance person­nel
Setup regulations
WARNING!
Risk of machines starting automatically.
This can result in serious injury and damage to property.
The device must only be used by 1 person at a time. It is also necessary to ensure
▶
that no one else is within the working area of the device when the device is being used. The device must only be serviced by 1 person at a time. It is also necessary to en-
▶
sure that no one else is within the working area of the device when the device is be­ing serviced.
NOTE!
The torch body change station must be incorporated into a higher-level safety sys­tem within a secured area.
If this area has to be accessed when setup and maintenance work is carried out, make sure that
the entire system is switched off for the duration of the work in this area.
▶
and that it is prevented from starting up accidentally, for example as the result of a
▶
control fault
Compressed air supply specifica­tions
The device is tested to degree of protection IP 23, meaning:
- protection against penetration by solid foreign bodies with diameters > 12.5 mm (0.49 in.)
- protection against spraywater at any angle up to 60° to the vertical
Dust
Make sure that metallic dust cannot accumulate directly on the device (for example from grinding work).
To ensure that the torch body change system functions correctly, the following com­pressed air supply specifications must be met:
- Compressed air is free of oil
- Compressed air is free of dust - no dirt particles larger than 5 µm
- Compressed air is free of water
- Compressed air supply at 5.50 - 6.00 bar (79.77 - 87.02 psi)
- Minimum inner diameter of compressed air lines 5.5 mm (0.22 in.)
35
Application example
(8)(13) (12) (10) (9)(11)
(1) (2) (3) (4)
(7) (6) (5)
Application ex­ample
NOTE!
Irrespective of the overall welding system setup
adhere to the compressed air specifications
▶
provide the compressed air supply to the torch body change station as shown
▶
(1) Interconnecting hosepack (8) Robot
(2) Wirefeeding hose (9) Wire drum
(3) Wirefeeder with "16 bar gas pur-
ging" option
(4) Torch hosepack with torch body
coupling and torch body MTB G R TX / MTB W R TX
(5) Compressed air supply line for
torch body change station 5.50 -
6.00 bar (79.77 - 87.02 psi) - for supplying the accessory equip­ment
(6) Compressed air maintenance unit
with filter
(7) Torch body change station
(10) Power source with cooling unit
(11) Data cable
(12) Data cable
(13) Robot control
36
Installing the torch body change station
EN
Bolting the torch body change sta­tion to the under­lying surface (foundation)
WARNING!
Danger from mechanically powered parts and escaping compressed air.
This can result in serious personal injury and damage to property.
Before starting any work, take the measures listed below and make sure that these
▶
measures remain in effect until all work is completed: disconnect the compressed air supply line to the torch body change station from the
▶
compressed air supply disconnect the "16 bar gas purging" option connection for the wirefeeder from the
▶
compressed air supply
NOTE!
Different fixings may be required to set up the device depending on the type of un­derlying surface (foundation).
Fixings are therefore not included in the scope of supply of the device. The installer is responsible for selecting the right type of fixing.
1 2
Installing the torch body change station
* only use the adjustment plates if necessary
WARNING!
Danger from mechanically powered parts and escaping compressed air.
This can result in serious personal injury and damage to property.
Make sure that the compressed air supply line to the torch body change station re-
▶
mains free of compressed air until the installation and start-up are concluded Make sure that the compressed air supply line to the "16 bar gas purging" option for
▶
the wirefeeder remains free of compressed air until the installation and start-up are concluded .
37
1 2
38
Preparing the torch body
(1) (2)
EN
Preparing torch bodies with steel inner liners
1
Make sure when fitting that the inner liner (1) is pushed in as far as it will go against the contact tip (2).
2 3
NOTE!
NOTE!
The coupling surface of the torch body must always be free of oil, grease, dust and moisture.
39
Preparing torch
(1) (2)
bodies with plastic inner liners
1
Make sure when fitting that the inner liner (1) is pushed in as far as it will go against the contact tip (2).
2 3
NOTE!
NOTE!
The coupling surface of the torch body must always be free of oil, grease, dust and moisture.
40
Configuring the torch-body racks
EN
Safety
General
WARNING!
Danger due to mechanical moving parts moving unexpectedly.
This can result in serious personal injury and damage to property.
Before starting work, disconnect all devices and system components involved from
▶
all pneumatic and/or hydraulic supply lines and ensure that the supply lines remain disconnected until the work is completed. Before starting work, disconnect all devices and system components involved from
▶
the power supply and ensure that the power supply remains disconnected until the work is completed.
- Every torch-body rack is equipped with a locating element
- Every torch body has a groove in which the locating element of the torch-body rack engages when the torch body is deposited in the torch­body rack. The torch body must al­ways be deposited in the torch-body rack so that the locating element of the torch-body rack engages in the groove in the torch body.
Some examples for orientation of the torch body at +90°, 0°, -90°
- The locating element may be attached at various positions in the torch-body rack.
- At the factory, the locating element is attached in the torch-body rack in the 0° posi­tion - if the torch body in the 0° position is deposited in the torch-body rack, this shows that the end of the torch body is away from the torch body change station.
- To change the orientation of the deposited torch body, the locating element may be moved in the torch-body rack in 45° increments (-90°, -45°, 0°, +45°, +90°)
41
Configuring the torch-body rack
1 2
42
Checking the torch body sensor and setting the wire sensor
Safety
Danger due to mechanical moving parts moving unexpectedly.
This can result in serious personal injury and damage to property.
▶
▶
Connecting the torch body change station to the robot control
1
EN
WARNING!
Before starting work, disconnect all devices and system components involved from all pneumatic and/or hydraulic supply lines and ensure that the supply lines remain disconnected until the work is completed. Before starting work, disconnect all devices and system components involved from the power supply and ensure that the power supply remains disconnected until the work is completed.
NOTE!
The torch body change station can also be connected to the robot control via a field-bus system.
Checking the torch body sensor
1
2
43
* Check that the LED lights up on the torch body sensor. If the LED does not
(2) (1)
(4) (3)
light up, check the connection between the robot control and the torch body change station
Check all the other torch body sensors
3
Setting the wire sensor
Rotate the wire electrode in the open-
1
ing (2) of the wire sensor (1) during the entire setting process
- LED (4) lights up if the wire sensor (1) detects the wire elec­trode
Turn the adjusting screw (3) back until
2
the LED (4) goes out
- Wire sensor is deactivated
Keep turning the adjusting screw (3)
3
only until the LED (4) lights up again
- Wire sensor (1) is now set at the lowest sensitivity level
- This prevents the wire sensor from being triggered accidentally
44
Fitting the torch body coupling to the MHP R
1
2
hosepack
Safety
Fitting the torch body coupling
WARNING!
Danger due to mechanical moving parts moving unexpectedly.
This can result in serious personal injury and damage to property.
Before starting work, disconnect all devices and system components involved from
▶
all pneumatic and/or hydraulic supply lines and ensure that the supply lines remain disconnected until the work is completed. Before starting work, disconnect all devices and system components involved from
▶
the power supply and ensure that the power supply remains disconnected until the work is completed.
NOTE!
The coupling surfaces between the torch body coupling and torch body must al­ways be free of oil, grease, dust and moisture.
EN
1 2
3 4
45
5 6
**
*
1
1
1
***
7 8
* Steel inner liner ** Plastic inner liner
9
10
*** Screw the cap onto the inner liner
as far as it will go. The inner liner must be visible through the hole in the cap.
46
Fitting the torch body coupling to the WF 25i Robacta Drive / WF 60i Robacta Drive CMT drive unit
Safety
Preparing the torch body coup­ling for plastic in­ner liners
Danger due to mechanical moving parts moving unexpectedly.
This can result in serious personal injury and damage to property.
▶
▶
1
WARNING!
Before starting work, disconnect all devices and system components involved from all pneumatic and/or hydraulic supply lines and ensure that the supply lines remain disconnected until the work is completed. Before starting work, disconnect all devices and system components involved from the power supply and ensure that the power supply remains disconnected until the work is completed.
2
EN
* use the cutting pipe from the original equipment kit for the drive unit used
3
47
Preparing the torch body coup­ling for steel in­ner liners
1
2
* use the cutting pipe from the original equipment kit for the drive unit used
Fitting the torch body coupling
3
1
NOTE!
The coupling surfaces between the torch body coupling and torch body must always be free of oil, grease, dust and moisture.
48
Manually unlocking / locking the torch body coup-
(1)
(1)
ling
Manually unlock­ing / locking the torch body coup­ling
EN
NOTE!
When the torch body coupling is un­locked, the locking balls (1) do not pro­trude out of the inside of the torch body coupling.
Unlocking the torch body coupling
NOTE!
Locking the torch body coupling
When the torch body coupling is locked, the locking balls (1) protrude out of the inside of the torch body coupling as shown.
NOTE!
To lock a torch body in the torch body coupling, insert the torch body into the unlocked torch body coupling and turn the handle of the torch body coupling to the right as far as it will go (end posi­tion).
Locking the torch body in the torch body coupling
If there is a torch body in the torch body coupling, the handle of the torch body coupling can be turned through roughly 90° before it reaches the end position.
49
Checking the torch body coupling function
Checking the torch body coup­ling function
Actuate the torch body coupling 5 times with a robot signal and check that the torch
1
body coupling opens and closes
- If the torch body coupling opens and closes correctly, then check that a torch body can be locked in the torch body coupling manually
Torch body coupling closed Torch body coupling open
2
NOTE!
If the torch body can be locked in the torch body coupling manually, the torch body coupling is ready to use.
50
Converting the torch body coupling from TX/i low
1
to TX/i high
General Robacta TX/i can be operated with a system pressure of 5-16 bar.
There are two versions here:
Robacta TX/i low
- For system pressures of 5-7.5 bar
- With vent valve in the torch body coupling
Robacta TX/i high
- For system pressures of 8-16 bar
- Without vent valve in the torch body coupling
NOTE!
Avoid pressures between 7.
5 and 8.5 bar where possible!
Converting the torch body coup­ling from TX/i low to TX/i high
The torch body coupling must be converted from TX/i low to TX/i high for pressures in excess of 8 bar. The vent valve is then removed as follows:
Manually unlock the torch body coup-
1
ling (see page 49)
EN
51
2
3
44,0450,1443
Insert fitting tool 44,0450,1443 into the
4
2
1
6
7
13 mm
5
2
torch body coupling
Unscrew the brass washer from the
3
torch body coupling
Remove the vent valve (e.g. with a
4
scriber or needle-nosed pliers or with a 1.5 mm drill)
Insert the brass washer into the torch
5
body coupling
Insert fitting tool
6
Secure brass washer with the fitting
7
tool
52
Setting up the robot
EN
General
Dimensions of the rack holder including torch­body racks
NOTE!
Before starting automated operation, set up the robot with the robot programming aid supplied.
Determining the TCP of the weld­ing torch, determ­ining the X-axis and Y-axis of the torch body change station
CAUTION!
Risk of injury from razor-sharp TCP tips.
Do not touch the pointed end of the TCP tips.
53
(1)(1)(1)
Screw 3 TCP tips into the holes (1) of
(1)
(1)
(1)
1
the rack holder
Measure TCP of the welding torch be-
2
ing used
Determine the X-axis and Y-axis of the
3
torch body change station using the TCP tips and record in the coordinate system of the robot
Functions of the robot program­ming aid
- The notch (1) on the robot program­ming aid symbolises the gas nozzle of the torch body - the gas nozzle of the torch body would point in the same direction as the notch (1) if there were a torch body locked in the torch body coupling.
- When setting up the robot, make sure that the two parts of the robot pro­gramming aid lie flat and flush with one another as shown.
- In automated mode, use the end posi­tion of the robot programming aid on the respective torch-body rack as the end position for depositing the torch body (end position of robot program­ming aid on the torch-body rack = end position of torch body in the torch­body rack).
54
Setting up the ro­bot
1 2
3 4
EN
5 6
55
7
If present, set up the robot for all further torch-body racks
8
56
Start-up
EN
Prerequisites for start-up
Start-up The torch body change station is started up by an active signal from the robot control.
The following prerequisites must be fulfilled for start-up:
- Torch body change station installed
- All torch body sensors checked and wire sensor set
- All torch bodies prepared
- Torch body coupling fitted
- Torch bodies oriented for special rack positions (only if necessary)
- Torch body coupling function checked
- Robot set up using robot programming aid
57
Program sequence
Safety
Speed data for the program se­quence
CAUTION!
Danger from incomplete installations.
This can result in serious damage to property.
Do not start in automated mode until the torch body change system has been prop-
▶
erly installed and started up.
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
10 = 0,0017 = 3.94
Subprograms in the program se­quence
To facilitate programming, the program sequence is split into the following subprograms:
- Cut wire electrode
- Wind back wire electrode
- Deposit torch body
- Pick up torch body
- Advance wire electrode
- Cut wire electrode
58
Program se­quence
EN
Start
Move to pos. A
- above torch-body rack
Query power source ready
'True'
Set
- Select job to advance wire electrode
- Feeder inching speed:
600 cm/min (236.22 ipm)
Move to pos. B
- approx. 25 mm (0.98 in.) next to the wire cutter
Set
- "Advance wire electrode" signal
Cut wire electrode
- Signal duration: 2 seconds
Query wire cutter
open
'False'
'False'
Stop program
- Power source error
Reset
- "Cut wire" signal
'True'
Move to pos. C
Enter wire cutter
Set
- "Cut wire electrode" signal
Wait 0.5 seconds
'True'
Query wire cutter
open
'False'
Stop program
- Wire cutter error
59
- 5 mm (0.2 in.) above wire cutter
(continued)
Cut wire electrode
"Cut wire electrode" signal
- "Wind back wire electrode" signal
- Wind back wire electrode until behind coupling point
- Feeder inching speed:
Wind back
wire electrode
600 cm/min (236.22 ipm)
- Signal duration: calculated using torch body length
Query wire
cutter
closed
'True'
Move to pos. D
Reset
Set
'False'
Stop program
- Wire cutter error
Move to pos. E
Above the rack positions
Query torch
body sensor
(torch-body rack
empty)
'False'
Set
- "Valve 1st Robacta TX cover" signal
Deposit torch body
Query
sensor 1st
Robacta TX
cover
TX
'True'
Wait 10
seconds
Stop program
- Torch body change error
Stop program
'False'
- Robacta TX cover error
60
'True'
Move to pos. F
- 50 mm (1.97 in.) next to centre of torch-body rack
- 75 mm (2.95 in.) above top of torch­body rack
Only with Robacta TX cover option
Move to pos. G
- Insert 75 mm (2.95 in.) above centre of torch-body rack
- Speed:
max. 100 cm/min (39.37 ipm)
Move to pos. H
- Move down into torch-body rack Speed:
max. 50 cm/min (19.69 ipm)
Wait 0.5 seconds
Query torch body
sensor (torch body
inserted into torch-body
rack)
'True'
Wait 0.5 seconds
'False'
EN
Stop inserting into torch-
body rack
Stop program
- Torch body change error
Stop
Insert into torch-body rack
Set
Deposit torch body (continued)
- "Change torch body" signal
Wait 2.5 seconds
Move to pos. I
- Raise 25 mm (0.98 in.) above centre of torch-body rack
- Speed:
max. 30 cm/min (11.81 in.)
Move to pos. J
- Raise 75 mm (2.95 in.) above centre of torch-body rack
- Speed: high speed
61
Wait 0.5 seconds
Query
torch body
sensor (new
torch body
present)
'True'
Move to pos. K
- 75 mm (2.95 in.) above centre of torch body to be picked up
Query torch
body sensor
'True'
Reset
- "Valve 1st Robacta TX cover" signal
'False'
'False'
Stop program
- Torch body change error
Stop program
- Torch body change error
Pick up torch body
Query sensor
1st Robacta TX
- "Valve 2nd Robacta TX cover"
Query sensor
2nd Robacta TX
cover
'False'
Set
signal
cover
'True'
Wait 10
seconds
Wait 10
seconds
'True'
'False'
Stop program
- Robacta TX cover error
Stop program
- Robacta TX cover error
62
Move to pos. L
- 25 mm (0.98 in.) above centre of torch body to be picked up
Move to pos. M
- Pick up torch body flush
- Speed: max. 100 cm/min (39.37 ipm)
Reset
- "Change torch body" signal
Wait 2 - 3 seconds
Move to pos. N
- Raise 75 mm (2.95 in.) above centre of torch-body rack
- Speed: max. 100 cm/min (39.37 ipm)
EN
Pick up torch body (continued)
Wait 0.5 seconds
Query torch body
sensor (torch body
successfully
picked up)
'False'
'True'
Stop program
- Torch body change error
63
Move to pos. O
- 75 mm (2.95 in.) above top of torch­body rack
- 50 mm (1.97 in.) next to centre of torch-body rack
- Speed: max. 1000 cm/min (393.70 ipm)
Reset
- "Valve 2nd Robacta TX cover" signal
Pick up torch body (continued)
- Align gas nozzle approx. 10 mm
(0.39 in.) above centre of wire sensor
- "Advance wire electrode" signal
Query sensor
2nd Robacta TX
cover
'False'
Move to pos. P
Set
- Feeder inching speed:
600 cm/min (236.22 ipm)
Wait 10
seconds
Only with Robacta TX cover option
Stop program
'True'
- Robacta TX cover error
Query wire
sensor (wire
electrode
Advance wire electrode
- "Advance wire electrode" signal
- approx. 25 mm (0.98 in.) next to the
Cut
wire electrode
present)
'True'
Reset
Move to pos. B
wire cutter
Wait 10
seconds
'False'
Reset
- "Advance wire
electrode" signal
Stop program
- Torch body change
error
64
Set
- "Advance wire electrode" signal
- Signal duration: 1 second
EN
- Enter wire cutter
- "Cut wire electrode"
Wait 0.5 seconds
Cut wire electrode
Query wire
cutter open
'True'
Move to pos. C
Set
signal
Query wire
cutter closed
'False'
'True'
'False'
Reset
- "Cut wire" signal
Query wire
cutter open
'False'
Stop program
- Wire cutter error
Stop program
- Wire cutter error
'True'
Move to pos. D
- 5 mm (0.2 in.) above wire cutter
Reset
- "Cut wire electrode" signal
Query power source ready
'True'
End
'False'
Stop program
- Torch body change error
65
66
Options
67
68
Safety
Safety Observe the following safety rules for all work described in the "Options" section.
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by
▶
technically trained and qualified personnel. Read and understand this document in full.
▶
Read and understand all safety rules and user documentation for this device and all
▶
system components.
WARNING!
Danger from machines that start up automatically.
This can result in serious personal injury and damage to property.
In addition to these operating instructions, the safety rules issued by the manufac-
▶
turer of the robot and welding system 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.
EN
WARNING!
Danger from the robot arm.
This can result in serious personal injury and damage to property.
Ensure there is no one else within the working area of the robot whenever work is
▶
carried out.
WARNING!
Danger from mechanically powered parts and escaping compressed air.
This can result in serious personal injury and damage to property.
disconnect the torch body change station from the compressed air supply
▶
disconnect the torch body change station from the power supply
▶
disconnect the "16 bar gas purging" option connection for the wirefeeder from the
▶
compressed air supply make sure that these measures remain in effect until all work is completed.
▶
WARNING!
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved and disconnect
▶
them from the grid. Secure all devices and components involved so they cannot be switched back on.
▶
After opening the device, use a suitable measuring instrument to check that electric-
▶
ally charged components (such as capacitors) have been discharged.
69
WARNING!
Danger due to mechanical moving parts moving unexpectedly.
This can result in serious personal injury and damage to property.
Before starting work, disconnect all devices and system components involved from
▶
all pneumatic and/or hydraulic supply lines and ensure that the supply lines remain disconnected until the work is completed. Before starting work, disconnect all devices and system components involved from
▶
the power supply and ensure that the power supply remains disconnected until the work is completed.
WARNING!
Danger from compressed air escaping from the torch body coupling, flying parts and sharp components.
This can result in serious personal injury and damage to property.
During the work described below, always wear the following protective equipment:
▶
protective goggles with side protection, gloves - electrically insulated and providing protection against heat, Safety helmet.
70
Fitting the torch-body rack
EN
Fitting the torch­body rack
1 2
3 4
5 6
NOTE!
Connect the torch-body rack to the torch body change station as shown in the cir­cuit diagram.
71
7 8
9
72
Fitting the compressed air maintenance unit
EN
Fitting the com­pressed air main­tenance unit
1 2
73
Fitting the wire cutter
Fitting the wire cutter
1
* Use the screws supplied with the torch body change station
3 4
2
74
Fitting the Robacta Reamer V Easy, Robacta Ream­er brush head Alu edition
Fitting the Robacta Reamer V Easy, Robacta Reamer brush head Alu edition
1
3 4
EN
2
75
Fitting the Robacta Reamer V
Fitting the Robacta Reamer V
1
3 4
2
76
Connecting the torch body change station to the Robacta TC 1000 / Robacta TC 2000
Connecting the torch body change station to the Robacta TC 1000 / Robacta TC 2000
1
* Use the screws supplied with the torch body change station
3
2
EN
4
77
Installing the pneumatic Robacta TX cover
Installing the pneumatic Robacta TX cover
1 2
3
4
NOTE!
Reuse the two screws shown to screw down the pneumatic cover - just the screws, not the washers.
78
5 6
7 8
EN
9
NOTE!
Connect the cover connectors to the PC board in the torch body change sta­tion as shown in the circuit diagram.
79
10 11
12
If present, install the second cover in the same way
13
14 15
80
Troubleshooting
81
82
Safety
Safety Observe the following safety rules for all work described in the "Troubleshooting" section.
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by
▶
technically trained and qualified personnel. Read and understand this document in full.
▶
Read and understand all safety rules and user documentation for this device and all
▶
system components.
WARNING!
Danger from machines that start up automatically.
This can result in serious personal injury and damage to property.
In addition to these Operating Instructions, the safety rules issued by the manufac-
▶
turer of the robot and welding system 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.
EN
WARNING!
Danger from the robot arm.
This can result in serious personal injury and damage to property.
Ensure there is no one else within the working area of the robot whenever work is
▶
carried out.
WARNING!
Danger from mechanically powered parts and escaping compressed air.
This can result in serious personal injury and damage to property.
Disconnect the torch body change system from the compressed air supply
▶
Disconnect the torch body change system from the power supply
▶
Disconnect the connection for the "16 bar gas purging" option of the wirefeeder from
▶
the compressed air supply Make sure that these measures remain in effect until all work is completed.
▶
WARNING!
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved and disconnect
▶
them from the grid. Secure all devices and components involved so they cannot be switched back on.
▶
After opening the device, use a suitable measuring instrument to check that electric-
▶
ally charged components (such as capacitors) have been discharged.
83
WARNING!
Danger due to hot system components and/or equipment.
Can result in serious burns or scalding.
Before starting work, allow all hot system components and/or equipment to cool to
▶
+25°C/+77°F (e.g., coolant, water-cooled system components, wirefeeder drive mo­tor, etc.) Wear suitable protective equipment (e.g., heat-resistant gloves, safety goggles, etc.)
▶
if cooling down is not possible.
WARNING!
Danger from compressed air escaping from the torch body coupling, flying parts and sharp components.
This can result in serious personal injury and damage to property.
During the work described below, always wear the following protective equipment:
▶
protective goggles with side protection, gloves - electrically insulated and providing protection against heat, Safety helmet.
84
Troubleshooting
EN
Troubleshooting
Only for a water-cooled welding torch: After a torch body has been changed, there is some residual coolant on the torch body
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Only for a water-cooled welding torch: After the torch body has been deposited, coolant sprays out of the torch body
Cause:
Remedy:
Torch body coupling does not open
Cause:
Remedy:
Torch body coupling is worn
Send the torch body coupling to the manufacturer's service department
Compressed air escaping from the torch body coupling is causing coolant to be blown out of the deposited torch body when the torch body coupling is locked
Do not lock the torch body coupling until it is beside the torch body change station
Robot speed too fast when picking up and depositing the torch body
Reduce robot speed when picking up and depositing the torch body
Torch body is very hot
Use water-cooled gas nozzle
Compressed air supply to torch body coupling is too low
Ensure compressed air supply is as per the specifications in the operating instructions
Torch body coupling does not open
Cause:
Remedy:
Torch body coupling is faulty
Unlock the torch body coupling manually and send the torch body coupling to the manufacturer's service department.
85
86
Care, maintenance and disposal
87
88
Safety
Safety Observe the following safety rules for all work described in the "Care, maintenance and
disposal" section.
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by
▶
technically trained and qualified personnel. Read and understand this document in full.
▶
Read and understand all safety rules and user documentation for this device and all
▶
system components.
WARNING!
Danger from machines that start up automatically.
This can result in serious personal injury and damage to property.
In addition to these Operating Instructions, the safety rules issued by the manufac-
▶
turer of the robot and welding system 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.
EN
WARNING!
Danger from the robot arm
This can result in serious personal injury and damage to property.
Ensure there is no one else within the working area of the robot whenever work is
▶
carried out.
WARNING!
Danger from mechanically powered parts and escaping compressed air.
This can result in serious personal injury and damage to property.
Disconnect the torch body change system from the compressed air supply
▶
Disconnect the torch body change system from the power supply
▶
Disconnect the connection for the "16 bar gas purging" option of the wirefeeder from
▶
the compressed air supply Make sure that these measures remain in effect until all work is completed.
▶
WARNING!
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved and disconnect
▶
them from the grid. Secure all devices and components involved so they cannot be switched back on.
▶
After opening the device, use a suitable measuring instrument to check that electric-
▶
ally charged components (such as capacitors) have been discharged.
89
WARNING!
Danger due to hot system components and/or equipment.
Can result in serious burns or scalding.
Before starting work, allow all hot system components and/or equipment to cool to
▶
+25°C/+77°F (e.g., coolant, water-cooled system components, wirefeeder drive mo­tor, etc.) Wear suitable protective equipment (e.g., heat-resistant gloves, safety goggles, etc.)
▶
if cooling down is not possible.
WARNING!
Danger from compressed air escaping from the torch body coupling, flying parts and sharp components.
This can result in serious personal injury and damage to property.
During the work described below, always wear the following protective equipment:
▶
protective goggles with side protection, gloves - electrically insulated and providing protection against heat, Safety helmet.
90
Replacing the inner liner in the torch body
(1) (2)
EN
Replacing a steel inner liner in the torch body
Removing the torch body from the torch body coupling
1
2 3
4
5
NOTE!
When refitting, make sure that the inner liner (1) is pushed in as far as it will go against the contact tip (2).
91
6 7
NOTE!
The coupling surface of the torch body must always be free of oil, grease, dust and moisture.
Replacing a plastic inner liner in the torch body
Removing the torch body from the torch body coupling
1
2 3
4
92
(1) (2)
5
NOTE!
When refitting, make sure that the inner liner (1) is pushed in as far as it will go against the contact tip (2).
6 7
EN
NOTE!
The coupling surface of the torch body must always be free of oil, grease, dust and moisture.
93
Replacing the inner liner in the core bolt
Replacing a steel inner liner in the core bolt
Removing the torch body from the torch body coupling
1
Unscrew the torch body coupling from the drive unit
2
3
4
* use the cutting pipe from the ori-
ginal equipment kit for the drive unit used
Replacing a plastic inner liner in the core bolt
94
Fit the torch body coupling correctly on the drive unit
5
(see section "Fitting the torch body coupling to the WF 25i Robacta Drive / WF 60i Robacta Drive CMT drive unit", depending on which hosepack is used)
Removing the torch body from the torch body coupling
1
Unscrew the torch body coupling from the drive unit
2
3
4
* use the cutting pipe from the ori-
ginal equipment kit for the drive unit used
EN
Fit the torch body coupling correctly on the drive unit
5
(see section "Fitting the torch body coupling to the WF 25i Robacta Drive / WF 60i Robacta Drive CMT drive unit", depending on which hosepack is used)
95
Replacing the inner liner in the MHP R hosepack
1
2
1
2
**
*
1
1
1
Replacing the in­ner liner
Removing the torch body from the torch body coupling
1
Disconnect the hosepack from all system components
2
For water-cooled hosepacks: Close the coolant connections on the hosepack with
3
the cover provided
4 5
6 7
8
9
96
10
***
11
* Steel inner liner ** Plastic inner liner *** Screw the cap onto the inner liner as far as it will go. The inner liner must be vis-
ible through the hole in the cap.
12
EN
Connect the hosepack to the system components once more
13
97
Replacing the O-rings in the torch body coupling
Replacing the O­rings in the torch body coupling
Removing the torch body from the torch body coupling
1
Unscrew the torch body coupling from the drive unit / hosepack
2
3 4
Fit the torch body coupling correctly on the hosepack / drive unit
5
(see section "Fitting the torch body coupling to the MHP R hosepack" or "Fitting the torch body coupling to the WF 25i Robacta Drive / WF 60i Robacta Drive CMT drive unit", depending on which hosepack is used)
98
Changing coolant stops
EN
Replacing coolant stops
Removing the torch body from the torch body coupling
1
Unscrew the torch body coupling from the drive unit / hosepack
2
Remove the core bolt from the torch body coupling
3
4 5
6 7
Fit the torch body coupling correctly on the hosepack / drive unit
8
(see section "Fitting the torch body coupling to the MHP R hosepack" or "Fitting the torch body coupling to the WF 25i Robacta Drive / WF 60i Robacta Drive CMT drive unit", depending on which hosepack is used)
99
Disposal
Disposal Dispose of in accordance with the applicable national and local regulations.
100
Loading...
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use