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Robacta TX W
Operating Instruction [EN]
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Operating Instruction [DE]
140 pgs14.38 Mb0

Fronius Robacta TX W Operating Instruction [EN]

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Robacta TX W
Operating instructions
EN
42,0426,0091,EN 021-20102021
Contents
Safety rules 7
General information 13
EN
General 15
System components 16
Necessary system components 16 Contact tip recommendation 17 Note on wirefeeding 17 Compatible system components for the overall welding system 18 TCP measurement system 18 Proper use 18
Warning notices on the device 19
Transport 21
Controls, connections and mechanical components 23
Control elements and connections 25
Mechanical components 27
Pin assignments and signal descriptions 28
Installation and commissioning 33
Safety 35
Before installation and commissioning 37
Operators, maintenance personnel 37 Setup regulations 37 Specifications for water-cooled hosepacks 37
Compressed air supply requirements 38
3
Compressed air supply specifications 38
Application example 39
Bolt torch body changeover station to the underlying surface (foundation) 41
Installing the torch body changeover station - in conjunction with VR 7000 / VR 7000 CMT 42
Installing the torch body changeover station - in conjunction with VR 1500 / VR 1530 / VR 1550 45
Installing the torch body changeover station - in conjunction with VR 1500-PAP 47
Checking the torch body sensor, setting the wire sensor 50
Preparing torch body with steel inner liner 52
Preparing the torch body with plastic inner liner 54
Preparing system components for Robacta hosepacks 56
Preparing the torch body coupling for Robacta Drive and Robacta Drive CMT hosepacks 59 Preparing the torch body coupling for Robacta Drive and Robacta Drive CMT hosepacks with plastic inner liners
Preparing the torch body coupling for Robacta Drive and Robacta Drive CMT hosepacks 60 Preparing the power source 61
Preparing the power source 61 Fitting the torch body coupling 62
Safety 62
Fitting the torch body coupling 62 Aligning torch body for special rack positions 63
General 63
Aligning the torch body 63
Aligning the robot programming aid 64 Connecting and adjusting the compressed air amplifier 66
General 66
Connecting the compressed-air booster unit 66
Adjusting the compressed-air booster unit 67
And finally... 67 Changing the torch body manually 68
Safety 68
Changing the torch body manually 68 Setting up the robot 70
Dimensions of the rack holder including torch body racks 70
Preparing the robot programming aid 70
Safety 71
Determining the TCP of the welding torch, determining the X-axis and Y-axis of the torch body
changeover station
59
60
71
4
Fitting the robot programming aid 71
Setting up the robot 73 Start-up 75
Prerequisites for start-up 75
Start-up 75 Program sequence 76
Safety 76
Speed data for the program sequence 76
Subprograms in the program sequence 76
Program sequence 77
Troubleshooting 85
Safety 87
Care, maintenance and disposal 91
Safety 93
Checking the torch body for damage and wear 96
Checking the torch body coupling 97
Changing the steel inner liner in the torch body 97
Changing the steel inner liners for Robacta Drive and Robacta Drive CMT hosepacks 104
Changing the plastic inner liners for Robacta Drive and Robacta Drive CMT hosepacks 105
And finally... 106 Maintenance when required 107
Maintenance when required 107 Servicing the centre bolt 108
Preparation 108
Servicing the core bolt 109
And finally... 110 Changing coolant stops 111
Preparing new coolant stops 112
Preparation 119
Changing the welding torch flange 120
And finally... 121 Pressing the emergency release button 122
General 122
Preparation 122
EN
5
Pressing the emergency release button 123 Replacing the torch body sensor 124
Preparation 124
Safety 124
Removing the old torch body sensor 124
Technical data 129
Technical data 131
Torch body changeover station 131
Torch body coupling 131
Appendix 133
Pneumatic diagram 135
135
Declaration of installation 136
136
6
Safety rules
EN
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!
7
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.
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
8
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.
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
EN
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
9
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
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.
10
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.
Check the device at least once a week for obvious damage and proper functioning of safety devices.
EN
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.
11
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.
12
General information
13
14
General
(1)
(2) (3)
(5)
(6) (7)
(8) (9)
(10)
(11)
(12)
(13)
Device concept Robacta TX is an automatic torch body
changeover system, comprising:
- Torch body changeover station
- Torch body coupling
- Robacta TX torch body
With Robacta TX, robots are used to auto­matically place worn torch bodies onto the torch body changeover station and replace them with new torch bodies. Even switch­ing between different torch body geomet­ries is easy with Robacta TX.
In conjunction with a welding torch clean­ing device, Robacta TX is converted into a fully autonomous torch body maintenance station that increases system availability and significantly reduces setup time.
EN
Scope of supply
(1) Torch body changeover station
with 3 torch body racks
(2) 4 adjustment plates 1 mm (0.04
inch)
(3) 4 adjustment plates 1.5 mm (0.06
inch)
(4) Operating instructions (not shown)
(5) Junction valve (6) Compressed air line, outer diamet-
er 6 mm
(7) Compressed air line, outer diamet-
er 8 mm (8) 2x M5 self-locking hexagon nuts (9) Fitting panel (10) 2x A5 washers (11) 2x TX25 screws (12) 2x M5 x 30 mm Allen screws (13) Compressed air connection, dia-
meter 8 mm
15
System components
(4)
(5)
(6)
(1)
(2)
(3)
Necessary sys­tem components
To operate the torch body changeover station, the following system components are also needed in addition to the welding system:
- Robacta TX W torch body changeover station
- TX W tool kit
- Torch body coupling
- Robacta TX W torch body
- Wire cutter
- Compressed air maintenance unit with filter
- Robot
The torch body changeover 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
Torch body changeover station
TX W tool kit
TX W tool kit, comprising
(1) Installation tool for torch body
coupling (2) Assembly aid for torch body insula-
tion, welding torch flange and robot
programming aid (3) Robot programming aid (2 parts) (4) 3 TCP tips (5) Bit insert for coolant stop (6) Cutting aid
16
(1)
Torch body coupling
- The torch body coupling enables the
torch body to be changed, length of coupling = 50 mm (1.97 in.)
NOTE!
The locking balls (1) are intended for dry operation.
Do not lubricate the locking balls.
EN
Contact tip re­commendation
Note on wirefeed­ing
Robacta TX W torch body Wire cutter
NOTE!
In conjunction with the torch body changeover system, we recommend that you use the 'CB' contact tip.
NOTE!
The torch body changeover system can only be used in conjunction with wirefeed­ing from the drum coil.
17
Compatible sys­tem components for the overall welding system
Only use the torch body changeover system in conjunction with the following system components:
- Any power source from the TS/TPS series
- Any Fronius robot wire-feed unit
- Robacta hosepacks
- Robacta Drive hosepacks
- Robacta Drive CMT hosepacks
- Robacta Reamer V Easy, Robacta Reamer V
- Robacta Reamer aluminium brush head
- Robacta TC series
TCP measure­ment system
Proper use The device is intended solely for changing Fronius torch bodies.
Use a TCP measurement system in order to achieve the best possible accuracy from the welding system and torch body changeover system.
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.
18
Warning notices on the device
24 VDC
Ser.No.
Model No.
Art.No.
4,044,008
U
I max
1,5 A
Pmax
6 bar
IP20
Robacta TX W
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 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 instructions
For indoor use only
19
WARNING! Risk of severe injury from torch body falling. Pressing the Un­lock/Lock button will release the torch body from the torch body coupling, causing it to fall to the ground. When pressing the Unlock/Lock button, make sure that
- the torch body is held in one hand or has been put down in a safe place
- there are no other persons in the working area of the robot
20
Transport
EN
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.
▶
21
22
Controls, connections and mechan-
ical components
23
24
Control elements and connections
(2)
(3)
(1)
(8) (9)
(7)
(6)
(4)
(5)
EN
Safety
Control elements 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) Wire sensor
checks whether the wire electrode is protruding from the welding torch
(2) I/O connection for accessory equipment
to connect Fronius accessory equipment to the torch body changeover station
(3) Compressed air connection "C"
(4) Unlock/Lock button
for manual operation of the torch body coupling
WARNING!
Danger from falling torch body. Pressing the Unlock/Lock button will release the torch body from the torch body coupling, causing it to fall to the ground.
This can cause serious injury or damage.
When pressing the Unlock/Lock button, make sure that the torch body is held in one
▶
hand or has been put down in a safe place. Ensure that there are no other persons in the working area of the robot
▶
(5) Compressed air connection "A"
to supply the torch body coupling with compressed air
(6) External power supply connection "A"
supplied with 24 V DC
25
(7) Robot control connection compartment
for optionally connecting the torch body changeover station to the robot control via
- standard I/O connection for robot control
- field bus coupler
(8) Compressed air connection "B"
connection to supply the torch body changeover station with 5.50 - 6.00 bar (79.77 - 87.02 psi) of dry and oil-free compressed air
- Size: 3/8" (0.375 in.)
(9) External power supply connection "B", optional only
supplied with 24 V DC
26
Mechanical components
(1)
(2)
(3)
EN
Safety
Mechanical com­ponents
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) Rack holder
for holding the torch body racks
(2) Mounting bracket
for attaching accessory equipment
(3) Torch body rack
for holding a torch body
27
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
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 due 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.
This can result in damage to connection supply.
Secure supply against overcurrent with a 1.5 A slow-blow fuse.
▶
NOTE!
To avoid faults, keep the cable between the torch body changeover station and the robot control as short as possible.
28
Pin Input (from the
torch body changeover station to the robot)
1 X + 24 V
2 X GND
3 X Torch body sensor 1
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 Robacta TX sensor 1 cover
Output (from the robot to the torch body changeover station)
Signal
EN
14 X Robacta TX sensor 2 cover
15 X Robacta TX valve 1 cover
16 X Robacta TX valve 2 cover
17 X 'C-Act. 3' signal 1
18 X Slide signal
19 X Wire sensor signal
20 X 'C-Sens. 4' signal 2
21 X 'C-Sens. 4' signal 1
22 X Pressure switch signal
23 X
24 X Reserve relay OUT
25 X 'C-Sens. 5' signal 1
NOTE!
Switch the valve via a relay, as the current input of the valve is at least 500 mA.
Change torch body valve 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 turning
30 X Spraying in parting agent
31 X Fill level of parting agent OK
29
Pin Input (from the
torch body changeover station to the robot)
32 X Cleaning motor up
33 X Cleaning motor lowered / 'Cleaning Error'
34 X Cleaning motor raised
35 X Cut wire
36 X Wire cutter closed
37 X Wire cutter open
Output (from the robot to the torch body changeover station)
Signal
Signal descrip­tions
Pin Signal Signal description
3 Torch body sensor 1 The respective torch body is deposited in the
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
13 Robacta TX sensor 1 cov-erSignal only available as an option.
14 Robacta TX sensor 2 cov-erSignal only available as an option.
15 Robacta TX valve 1 cover Signal only available as an option.
16 Robacta TX valve 2 cover Signal only available as an option.
corresponding torch body rack
- Robacta TX cover 1 is open
- Robacta TX cover 2 is open
- opens and closes a Robacta TX cover
- opens and closes a Robacta TX cover
30
17 'C-Act. 3' signal 1 Reserve signal for actuator
18 Slide signal Signal only available as an option.
- torch body has been deposited in the Robacta TX slide / Robacta TX slide XL
19 Wire sensor signal Verification whether the wire electrode pro-
trudes from the torch body after a successful change of the torch body.
20 'C-Sens. 4' signal 2 Reserve signal for sensor
21 'C-Sens. 4' signal 1 Reserve signal for sensor
22 Pressure switch signal Compressed air supply to torch body
changeover station is OK. The signal is output in a range of 12.5 - 13 bar.
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