Fronius TX/i TWIN Operating Instruction [EN]

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Operating Instructions

Upright console TXi TWIN Wall-mounted console TXi TWIN

EN-US

Operating instructions

42,0426,0284,EA 007-05082022

Table of contents

Safety Instructions 5

Explanation of Safety Instructions 5 General 5 Intended Use 6 Environmental Conditions 6 Obligations of the Operating Company 6 Obligations of Personnel 6 Particular Hazard Areas 6 Personal Protection and Protection of Others 7 EMC Device Classifications 7 EMC Measures 7 EMF measures 8 Safety Measures at the Setup Location and During Transport 8 Safety Measures in Normal Operation 8 Maintenance and repair 9 Safety Inspection 9 Disposal 9 Safety symbols 9 Data backup 9 Copyright 10

General 11

Device concept 11 Intended use 11 Required system components 12 Application example 13

Scope of Supply 14

Upright console scope of supply 14 Wall-mounted console scope of supply 14 Tools Scope of Supply 15

Warning notices affixed to the device 16

Warning notices on the device (upright console) 16 Warning notices on the device (wall-mounted console) 17

Transport 18

Transport Equipment 18 Transport Instructions on the packaging 18

Operating controls, connections and mechanical components 19

Safety 19 Operating controls, connections, and mechanical components of the upright console 19 Operating controls, connections, and mechanical components of the wall-mounted console

Tactile sensor (option) 22

General 22 How it works 22

Connector pin assignments and signal descriptions 23

Safety 23 Pin assignment of standard I/O connection for robot controller 24 Assignment of I/O connection for add-on devices 27

Before installation and initial operation 28

Safety 28 Operating personnel, maintenance personnel 29 Setup Regulations 29 Specifications for the Compressed Air Supply 29

Installing the Torch Body Change Station 30

Fastening the upright console TXi TWIN to the surface (foundation) 30 Mounting the wall-mounted console TXi TWIN 31 Supply the torch body change station with compressed air 32

Installing the Torch Body Coupling 33

Safety 33 Installing the torch body coupling 33 Checking the function of the torch body coupling 34

EN-US

Setting up the robot 36

General 36 Setting up the robot 36

Measuring the torch-body racks using the tactile sensor 39

Commissioning 41

Requirements for commissioning 41 Start-up 41 Important information regarding operation 41

Program sequence 43

Safety 43 Speed Specifications for the Program Sequence 43 Program Sequence 44

Installing Optional Equipment 50

Safety 50 Installing the Torch-body Rack 51 Installing the Wire Cutter 54 Installing the Robacta Reamer V Twin 54 Installing the coding ring 55

Troubleshooting 58

Safety 58 Troubleshooting 59

Service, maintenance and disposal 61

Safety 61 Maintenance activities 62 Changing the O-rings in the torch body coupling 63 Adjusting the pneumatic cover 63 Disposal 64

Technical data 65

Upright console TXi TWIN 65 Wall-mounted console TXi TWIN 65 Torch body coupling 65

Declaration of Incorporation 66

Safety Instructions

EN-US

Explanation of Safety Instructions

DANGER!

Indicates an immediate danger.

Death or serious injury may result if appropriate precautions are not taken.

▶

WARNING!

Indicates a possibly dangerous situation.

Death or serious injury may result if appropriate precautions are not taken.

▶

CAUTION!

Indicates a situation where damage or injury could occur.

Minor injury or damage to property may result if appropriate precautions are

▶

not taken.

NOTE!

Indicates the possibility of ﬂawed results and damage to the equipment.

General The device has been manufactured using state-of-the-art technology and ac-

cording to recognized 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 the commissioning, operation, maintenance, and servicing of the device must

be suitably qualified,

have knowledge of automated welding and

have read these Operating Instructions and any system component operating

instructions in full and follow them carefully.

The Operating Instructions must always be at hand wherever the device is being used. In addition to the Operating Instructions, all applicable local rules and regulations regarding accident prevention and environmental protection must also be followed.

All safety and danger notices on the device must

must be kept in a legible state

not be damaged/marked

not be removed

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 switching on the device, remove any faults that could compromise safety.

Your personal safety is at stake!

Intended Use The device must only be used for its intended purpose.

Utilization for any other purpose, or in any other manner, shall be deemed to be not in accordance with the intended purpose. The manufacturer accepts no liability for any damage resulting from improper use.

Intended use also means:

Reading and adhering to all instructions in the Operating Instructions

Reading and adhering to all safety instructions and danger notices

Carrying out all the specified inspection and maintenance work

The device is designed for operation in industry and business. The manufacturer shall not be liable for any damage resulting from use in a living area.

The manufacturer shall also not be liable for faulty or incorrect work results.

Environmental Conditions

Obligations of the Operating Company

Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer accepts no liability for any damage resulting from improper use.

Temperature range of the ambient air:

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)

Ambient air: free of dust, acids, corrosive gases or substances, etc. Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)

The operating company must only allow persons to work with the device if they

Are familiar with the basic occupational safety and accident prevention regu-

lations and are trained in handling the device Have read and understood these Operating Instructions, especially the sec-

tion "Safety Rules," and have confirmed this with their signature Are trained according to the requirements for the work results

The safety-conscious work of the personnel must be checked regularly.

Obligations of Personnel

Particular Hazard Areas

All persons who are assigned to work with the device must do the following before beginning the work:

Follow the basic regulations for occupational safety and accident prevention

Read these Operating Instructions, especially the section "Safety Rules," and

confirm that they have understood and will follow them by signing

Before leaving the workplace, ensure that no personal injury or property damage can occur in one's absence.

Do not linger in the operating area of the robot.

Always integrate the device into a higher-level safety system in a secured area.

If this area has to be accessed for preparatory or maintenance work, ensure that

the entire system is shut down for the duration of access to this area

and remains shut down to prevent unintended operation, e.g., as a result of a

control error

In addition to these Operating Instructions, the operating instructions and safety rules of the robot manufacturer must be followed.

Covers must only be opened/removed during maintenance, installation and repair work.

During operation:

Ensure that all covers are closed and all side parts have been mounted prop-

erly Keep all covers closed

EN-US

Personal Protection and Protection of Others

EMC Device Classifications

You are exposed to numerous hazards while welding. In addition to these Operating Instructions, the safety rules of the manufacturer of the entire welding system must be followed.

Keep persons, especially children, away during the operation of the devices and during the welding process. However, if persons are in the vicinity:

Inform them about all hazards (crush hazard posed by moving mechanical

parts, ﬂying chips or similar, escaping compressed air, injury hazard due to ﬂying sparks, blinding hazard due to arcs, welding fumes that are hazardous

to health, noise exposure, possible hazard due to mains current or welding current, etc.) Provide suitable protective equipment, or

Construct suitable protective walls and 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 lowvoltage grid.

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

emissions, 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 operating company is obliged to take appropriate action to rectify the situation.

Check and evaluate possible problems and the interference immunity of equipment in the vicinity according to national and international regulations:

Safety devices

Grid power lines, signal lines, and data transfer lines

EMC and telecommunications equipment

Devices for measuring and calibrating

Supporting measures to avoid EMC problems:

Grid power supply

1. If electromagnetic interference occurs despite a grid connection that

complies with regulations, take additional measures (e.g., use a suitable grid filter).

Control lines

2. Keep them as short as possible

Route them close together (also to avoid EMF problems)

Route them far from other lines

Equipotential bonding

Shield, if necessary

4. Shield other devices in the vicinity

Shield the entire welding installation

EMF measures Electromagnetic fields may cause health problems that are not yet known:

Effects on the health of persons close by, e.g., those with pacemakers and

hearing aids Persons with pacemakers must seek advice from their doctor before staying

in the immediate vicinity of the device and the welding process Keep distances between welding power-leads and the head/torso of the

welder as great as possible for safety reasons Do not carry welding power-leads and hosepacks over your shoulder or wrap

them around your body or body parts

Safety Measures at the Setup Location and During Transport

Safety Measures in Normal Operation

A toppling device can be deadly! Set up the device securely on an even, solid surface

The maximum permitted tilt angle is 10°.

Special regulations apply in areas at risk of fire or explosion

Follow the appropriate national and international regulations.

Use instructions and checks within the company to ensure that the vicinity of the workplace is always clean and organized.

Only set up and operate the device in accordance with the protection class shown on the rating plate.

Take care to ensure that the applicable national and regional guidelines and accident prevention regulations are observed when transporting the device, especially guidelines concerning hazards during transport and shipment.

It is essential to conduct a visual inspection of the device to check for damage after it has been transported but before commissioning. Have any damage 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 danger of:

Serious or fatal injury 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

Safety devices that are not fully functional must be repaired before the device is switched on.

Never bypass or disable safety devices.

Before starting up the device, ensure that no one can be put in danger.

The device must be examined at least once a week for externally detectable damage and functionality of the safety devices.

EN-US

Maintenance and repair

Safety Inspection

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.

The manufacturer recommends that a safety inspection of the device be performed at least every 12 months.

A safety inspection by a certified electrician is recommended:

after changes

after alterations

after repair, care, and maintenance

at least every 12 months.

For the safety inspection, follow the appropriate national and international standards and guidelines.

You can obtain more information about the safety inspection and calibration from your service center. The service center will provide the necessary documents upon request.

Disposal To comply with European directives and national law, waste electrical and elec-

tronic equipment must be collected separately and sent for environmentallyfriendly recycling. Used devices must be returned to a distributor or an approved collection and recycling facility in your area. Proper disposal of used devices promotes the sustainable recycling of material resources. Ignoring this may have potentially adverse effects on the environment and your health.

Packaging materials

Materials collected separately. Check the regulations in your area. Reduce the volume of cardboard.

Safety symbols Devices marked with the CSA test mark satisfy the requirements of the relevant

standards for Canada and the USA.

Data backup The user is responsible for backing up any changes made to the factory settings.

The manufacturer accepts no liability for any deleted personal settings.

Text and illustrations were accurate at the time of printing. Fronius reserves 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 Operating Instructions, we will be most grateful for your comments.

General

Device concept The TXi TWIN is a torch body change station for twin welding systems. Two ver-

sions are available:

Upright console TXi TWIN

Wall-mounted console TXi TWIN

EN-US

Upright console Wall-mounted console

The torch body change station is used:

to store up to 8 torch bodies

to hold a welding torch cleaning device

to hold a wire cutter

to hold a TCP measuring system

Worn torch bodies are placed on the torch body change station by the robot and replaced with new torch bodies. Even switching between different torch body geometries can be carried out easily.

In conjunction with a welding torch cleaning device, the upright console TXi TWIN becomes a completely autonomous torch body maintenance station that increases the system availability and considerably reduces retooling costs.

Intended use The device is intended exclusively for changing Fronius standard torch bodies up

to 350 mm in length. For torch bodies with excess lengths or special geometries, approval from Fronius is required.

The device is intended only for use in conjunction with Fronius system components. This applies especially to cooling units and coolant – the device must only be used with Fronius cooling units and Fronius coolant.

Utilization for any other purpose, or in any other manner, shall be deemed to be not in accordance with the intended purpose. The manufacturer shall not be liable for damage resulting from this nor for faulty or incorrect work results.

Intended use also means

Reading and obeying in full the Operating Instructions and all safety instruc-

tions and danger notices Carrying out all the specified inspection and maintenance work

The device is designed for operation in industry and business. The manufacturer shall not be liable for any damage resulting from use in a residential area.

Required system components

The OPT/i WF Twin Torch Change (4,101,171,IK) option must be installed in the twin wirefeeder.

Twin welding system with conventional robot

TXi TWIN torch body change station

Upright console 4,044,030 Wall-mounted console 4,044,038

Fieldbus connection (optional)

ProfiNet 4,100,707 ProfiBus 4,100,127 DeviceNet 4,100,331 EtherCAT 4,100,539 Ethernet IP 4,100,785

Torch body coupling 44,0350,3985

Twin - Single adapter MTB TPSi 44,0350,4485 (optional)

Wire cutter V 44,0450,1027

Twin torch body MTB 2x500i

44,0350,5500,636 MTB 2x500i PA/30°/L328/11°/TX 44,0350,5504,636 MTB 2x500i PA/30°/L328/8°/TX 44,0350,5501,636 MTB 2x500i PB 30°/L328/11°/TX 44,0350,5505,636 MTB 2x500i PB 30°/L328/8°/TX 44,0350,5503,636 MTB 2x500i PA 45°/L328/11°/TX 44,0350,5506,636 MTB 2x500i PA 45°/L328/8°/TX 44,0350,5502,636 MTB 2x500i PB 45°/L328/11°/TX 44,0350,5507,636 MTB 2x500i PB 45°/L328/8°/TX

Application ex-

(1) (1) (2)

(3)

(4)

(4) (5) (6) (7) (8)(8) (9) (11)(10)

ample

NOTE!

Regardless of the setup of the entire welding system

Adhere to the compressed air specifications

▶

Implement the compressed air supply of the torch body change station as

▶

shown

EN-US

(1) Wirefeeding hose (2) Wirefeeder WF 30i Twin (3) Torch hosepack with torch body coupling and torch body MTB 2x500i W (4) Wire drum (5) Robot controls (6) Data cable (7) Data cable (8) Power source with cooling unit * (9) Interconnecting hosepack (10) Torch body change station (11) Compressed air supply line for torch body change station 6.00 bar (87.02

psi) - used to supply the add-on devices

* IMPORTANT! Cooling units of the welding system must not be positioned

higher than the torch body change station!

Scope of Supply

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(1)

(2)

(3)

(4)

(5)

Upright console scope of supply

Wall-mounted console scope of supply

(1) Torch body change station

incl. (2) 3x torch-body racks (3) 2x wire cutter holders (4) Base plate for add-on devices (5) Compressed air maintenance

unit

(on the rear of the device)

(6) 4x adjusting shim 1 mm (0.04

inch) (7) 4x adjusting shim 1.5 mm (0.06

inch)

Not shown: these Operating Instructions

(1) Torch body change station

incl. (2) 3x torch-body racks (3) 2x wire cutter holders (4) Compressed air maintenance

unit (5) Mounting bracket

Not shown: these Operating Instructions

Tools Scope of

BY2,0201,4862

BY2,0201,4863

44,0350,4076

Supply

EN-US

Warning notices affixed to the device

24 VDC

Ser.No.

Model No.

Art.No.

I max

1,5 A

Pmax

6 bar

IP23

www.fronius.com

Warning notices on the device (upright console)

The device has safety symbols and a rating plate fitted. These safety symbols and the 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 to property.

WARNING! Danger of serious injuries due to mechanically moving parts. During maintenance and servicing, keep the device de-energized and depressurized.

Do not use the functions described here until you have fully read and understood the following documents:

These Operating Instructions

All system component Operating Instructions, especially the safety rules

For indoor use only

Warning notices

24 VDC

Ser.No.

Model No.

Art.No.

I max

1,5 A

Pmax

6 bar

IP23

www.fronius.com

on the device (wall-mounted console)

EN-US

WARNING! Danger of serious injuries due to mechanically moving parts. During

maintenance and servicing, keep the device de-energized and depressurized.

Do not use the functions described here until you have fully read and understood the following documents:

These Operating Instructions

All system component Operating Instructions, especially the safety rules

For indoor use only

Transport

Transport Equipment

Transport Instructions on the packaging

Transport the device using the following transport equipment:

On a pallet using a counterbalanced lift truck

On a pallet using a lift truck

WARNING!

Danger from falling or toppling devices.

This can result in severe personal injury and damage to property.

When transporting the device by counterbalanced lift truck or lift truck, se-

▶

cure the device to prevent it from falling Do not turn, brake, or accelerate in a sudden, jerking manner

▶

CAUTION!

Danger due to improper transport.

This can result in damage to property.

Follow the transport instructions on the device packaging.

▶

Operating controls, connections and mechanical

(12)

(11)

(13) (14)

(1)

(2)

(3) (4)

(5)

(6)

(7)

(8)

(9)

(10)

components

Safety

Danger from incorrect operation and work that is not carried out properly.

This can result in serious personal injury and damage to property.

▶ ▶

▶

Operating controls, connections, and mechanical components of the upright console

EN-US

WARNING!

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 equipment and all system components.

(1) Robacta TX pneumatic cover

incl. 4 torch caps (protection against contamination of the suspended torch bodies)

(2) Torch-body racks

(3) Dummy cover

In preparation for the installation of an optional interface to connect to the robot controller

(4) Standard I/O connection for robot controller

To connect the robot controller to the torch body change station

(5) Dummy cover

In preparation for the installation of an optional interface to connect to the robot controller

(6) Dummy cover

In preparation for the installation of an optional interface to connect to the robot controller

(7) Compressed air maintenance unit

(8) Compressed air connection "A", size: 3/8" (0.375 inch)

(1) (2)

(3)

(4) (5) (6) (7) (8)

(9)

(10)

(11)

Connection for supplying the torch body change station with 6.00 bar (87.02 psi) of dry and oil-free compressed air

(9) Ground connection

Threaded bolt M5 x 20 mm

(10) Locking pin

To manually open the pneumatic cover:

Pull out the pin - the pneumatic cover can be opened

To lock the cover in place, rotate the pin 90°

When closing the cover, make sure the pin is back in its original posi-

tion

(11) Holder retainer

To hold up to 8 torch-body racks

(12) Fixing bracket

For mounting add-on devices

(13) Compressed air connection "B"

Connection used for supplying the Fronius add-on devices with compressed air (wire cutter, welding torch cleaning devices)

Operating controls, connections, and mechanical components of the wallmounted console

(14) I/O connection for add-on devices

To connect the Fronius add-on devices to the torch body change station

(1) Torch-body racks

(2) Front cover

(3) Robacta TX pneumatic cover

incl. 4 torch caps (protection against contamination of the suspended torch bodies)

(4) Ring bolt for transporting by crane

(5) Ground connection

Threaded bolt M5 x 20 mm

(6) I/O connection for add-on devices

To connect the Fronius add-on devices to the torch body change station

(7) Compressed air maintenance unit

In preparation for the installation of an optional interface to connect to the robot controller

(8) Compressed air connection for wire cutter

(9) Compressed air connection "A"

Size: 3/8" (0.375 inch) Connection for supplying the torch body change station with 6.00 bar (87.02 psi) of dry and oil-free compressed air

(10) Fixing bracket

For mounting add-on devices

(11) Locking pin

To manually open the pneumatic cover:

Pull out the pin - the pneumatic cover can be opened

To lock the cover in place, rotate the pin 90°

When closing the cover, make sure the pin is back in its original posi-

tion

EN-US

Tactile sensor (option)

General The optional tactile sensor is a teach-

ing tool for robot integrators for measuring the torch-body racks.

Applications:

Before robot programming

For commissioning

For periodic checks

For maintenance

After a crash

For new torch bodies

IMPORTANT!

The tactile sensor is intended exclusively for automated operation!

The robot cell may only be entered for teaching by the user after conscious

approval (access only for specialist personnel).

How it works The tactile sensor works according to the TouchSensing principle:

A voltage of approx. 70 V (max. 3 A) is applied to the sensor.

In the event of a short circuit due to contact, a signal is transmitted to the

robot controller.

Connector pin assignments and signal descriptions

Safety

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 equip-

▶

ment and all system components.

WARNING!

Danger due to machines starting automatically.

This can result in severe personal injury and damage to property.

The device must only be supplied with power using an emergency stop cir-

▶

cuit.

EN-US

Pin assignment

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

of standard I/O connection for robot controller

CAUTION!

Danger from overcurrent.

Damage to the connection power supply may result.

Provide the power supply with 1.5 A fuse protection against overcurrent.

▶

NOTE!

To avoid interference, keep the line length between the torch body change station and the robot controller as short as possible.

Input signals – from the robot to the torch body change station

Pin Signal Description

1 +24 V -

2 GND -

15 Valve first Robacta TX cover Optional signal.

Opens and closes the first Robacta TX cover.

16 Valve second Robacta TX cover Optional signal.

Opens and closes the second Robacta TX cover.

17 Reserve (connection to X23.4) -

23 Reserve (connection to X23.2) -

24 Reserve relay OUT (connection to

X23.2)

25 Disconnected -

Pin Signal Description

26 Connection to X11.1.1

"Start cleaning" signal (when using Robacta Reamer Twin)

„Reinigung starten“ signal (when using Robacta TC)

30 Connection to X11.1.4

„Spray In“ signal (when using Robacta TC)

32 Reserve -

35 Connection to X11.1.12

Cut wire electrode (when using a separate wire cutter)

Output signals – from the torch body change station to the robot

Pin Signal Description

3 Torch body sensor 1

Optional signal.

On Robacta Reamer Twin: starts the cleaning process.

On Robacta TC: starts the cleaning process.

Optional signal.

On Robacta TC: activates the spraying of parting agent.

Optional signal.

Activates the wire cutter.

EN-US

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 Reserve -

12 Reserve -

13 Sensor first Robacta TX cover Optional signal.

14 Sensor second Robacta TX cover Optional signal.

18 Reserve -

19 Wire sensor signal Indicates that the wire electrode

Each torch body is stored in the corresponding torch-body rack.

First Robacta TX cover is open.

Second Robacta TX cover is open.

protrudes from the torch body after a successful torch body change.

20 Reserve (connection to X28.2) -

21 Reserve (connection to X28.4) -

22 Reserve -

25 Disconnected -

Pin Signal Description

27 Connection to X11.1.6

"Gas nozzle free" signal (when using Robacta Reamer Twin)

TC Ready (when using Robacta TC)

28 Reserve -

29 Reserve -

31 Connection to X11.1.4

„Fluid Level Control“ signal (when using Robacta TC)

33 Connection to X11.1.10

„Cleaning Error“ signal (when using Robacta TC)

34 Reserve

36 Reserve -

Optional signal.

On Robacta Reamer Twin: indicates that the gas nozzle clamping device is not holding a gas nozzle.

On Robacta TC: indicates that Robacta TC is ready for a cleaning operation.

Optional signal.

On Robacta TC: indicates that there is parting agent in the dipping bowl.

Optional signal.

On Robacta TC: indicates an error during cleaning.

37 Reserve -

Assignment of

I/O connection for add-on devices

CAUTION!

Danger due to overcurrent.

Damage to the connection power supply can be the result.

Provide the power supply with 1.5 A fuse protection against overcurrent.

▶

NOTE!

To avoid interference, keep the line length between the torch body change station and the robot controller as short as possible.

1 +24 V 2 GND 3 4 5 -

EN-US

Before installation and initial operation

Safety Please follow the safety rules below when carrying out all the tasks described in

the "Installation and Commissioning" chapter.

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 equip-

▶

ment and all system components.

WARNING!

Danger from machines that start automatically.

This can result in serious personal injury and damage to property.

In addition to these Operating Instructions, observe the safety rules of the

▶

robot manufacturer and welding system manufacturer. For your personal safety, make sure that all protective measures have been

▶

taken in the robot's operating area and remain in effect while you are in this area.

WARNING!

Danger caused by the robot arm.

This can result in serious personal injury and damage to property.

Ensure that no third parties are located in the operating area of the robot

▶

while any work is taking place.

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

▶

electrically charged components (such as capacitors) have been discharged.

WARNING!

Danger due to hot system components and/or equipment.

This 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!

Operating personnel, maintenance personnel

Setup Regulations

Danger from compressed air escaping from the torch body coupling, ﬂying debris, and sharp components.

This can result in serious personal injury and damage to property.

Always wear the following protective equipment when carrying out the work

▶

described below: Safety glasses with side guards, Gloves - electrically insulating and heat protective, Protective helmet.

WARNING!

Danger due to machines starting automatically.

This can result in severe personal injury and damage to property.

In all situations, the device must only ever be operated by one person. In ad-

▶

dition, make sure that there are no other people in the device's operating area while it is in operation. In all situations, the device must only ever be maintained by one person. In

▶

addition, make sure that there are no other people in the device's operating area while work on it is ongoing.

NOTE!

Always integrate the torch body change station into a higher-level safety system in a secured area.

If this area has to be accessed for tooling or maintenance work, ensure that:

The entire system is shut down for the duration of access to this area.

▶

The system remains shut down to prevent unintended operation, for example,

▶

as a result of a control error.

EN-US

Specifications for the Compressed Air Supply

The device has been tested according to protection class IP 23. This means:

Protection against solid foreign bodies larger than Ø 12.5 mm (0.49 in.)

Protection against spraywater up to an inclined angle of 60°

Dust

Make sure that metal dust cannot accumulate directly on the device (e.g. during grinding work).

The following specifications for the compressed air supply must be fulfilled to ensure that the torch body change system functions correctly:

Compressed air free of oil

Compressed air free of dust – no contaminants larger than 5 µm

Compressed air free of water

Compressed air supply of 6.00 bar (87.02 psi)

Internal diameter of the compressed air lines at least 5.5 mm (0.22 in.)

Installing the Torch Body Change Station

Fastening the upright console TXi TWIN to the surface (foundation)

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 in-

▶

volved 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 in-

▶

volved from the power supply and ensure that the power supply remains disconnected until the work is completed.

WARNING!

Danger from machines toppling over or falling.

This can result in serious personal injury and damage to property.

Set up the device securely on an even, solid surface.

▶

Check all screw connections are tightly fastened after installation.

▶

IMPORTANT! Before positioning and setting up the device, there must be sufficient ﬂoor load-bearing capacity per m² for the weight of the device.

NOTE!

Depending on the surface (foundation), different mounting materials may be required to mount the device.

These mounting materials are not part of the scope of supply for the device. The installer is responsible for selecting the proper mounting materials.

When mounting the device ensure that no mechanical deformations can oc-

▶

cur on the torch body change station as a result of the change cycle. Mount the torch body change station on the same base as the robot.

▶

In the case of gantry or linear travel, the torch body change station should

▶

travel with the robot; If assembly is not possible, observe the necessary tolerances.

1 2

* Only use the adjusting shims when necessary

Ground the upright console TXi TWIN

The ground connection is located on the rear of the device.

Mounting the

20 Nm

4x 20 Nm / 14.75 lb·ft

20 Nm

4x 20 Nm / 14.75 lb·ft

wall-mounted console TXi TWIN

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 in-

▶

volved from the power supply and ensure that the power supply remains disconnected until the work is completed.

WARNING!

Danger from devices falling or toppling over.

This can result in serious personal injury and damage to property.

Only secure devices to vertical walls or suitable mounting fixtures.

▶

At least 2 people are needed to install the device.

▶

IMPORTANT! Before positioning and mounting the device, there must be sufficient wall load-bearing capacity per m² for the weight of the device.

NOTE!

EN-US

Depending on the surface, different mounting materials may be required to mount the device.

These mounting materials are not part of the scope of supply for the device. The installer is responsible for selecting the proper mounting materials.

When mounting the device ensure that no mechanical deformations can oc-

▶

cur on the torch body change station as a result of the change cycle. In the case of gantry or linear travel, the torch body change station should

▶

travel with the robot; If assembly is not possible, observe the necessary tolerances.

The mounting bracket can either be fitted to the rear of the device or the righthand side of the device:

Installation on the rear of the device

Remove the mounting bracket from pallet and wall-mounted console

Select a mounting option

Installation on the right-hand side of the device

Drill the correct hole pattern into the wall using the mounting bracket that

6,0 bar

87.02 psi

6,0 bar

87.02 psi

corresponds to the mounting method that you have selected

Mount the mounting bracket on the wall-mounted console

Tightening torque between the mounting bracket and the wall-mounted console: 20 Nm / 14.75 lb ft per screw

Fit the wall-mounted console with mounting bracket to the wall

Ground the wall-mounted console TXi TWIN

The ground connection is located on the rear of the device.

Supply the torch body change station with compressed air

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 in-

▶

volved from the power supply and ensure that the power supply remains disconnected until the work is completed.

Upright console

Wall-mounted console

Installing the Torch Body Coupling

BY2,0201,4863

20Nm

42,0411,1315

EN-US

Safety

Installing 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 in-

▶

volved from the power supply and ensure that the power supply remains disconnected until the work is completed.

NOTE!

The coupling areas between the torch body coupling and torch body must

▶

always be free of oil, grease, and dust, and be dry. To prevent small parts from falling out or being lost, do not clean the area

▶

marked [ * ] on the torch hosepack with compressed air!

Checking the

BY2,0201,4862

function of the torch body coupling

NOTE!

Flawless operation of the interchangeable coupling can only be guaranteed with a vertical alignment facing down.

Actuate the torch body coupling five times using a robot signal and check

whether the torch body coupling opens and closes

If the torch body coupling opens and closes correctly, check the manual locking of a torch body in the torch body coupling.

Checking manual locking

Torch body coupling closed

Torch body coupling open

Torch body coupling closed Torch body coupling open

NOTE!

The locking balls of the torch body coupling are intended for dry operation.

Do not lubricate the locking balls.

▶

NOTE!

Always insert the torch body into the torch body coupling so that it is straight and until it reaches the stop.

EN-US

If the torch body can be correctly locked in the torch body coupling by hand, then the torch body coupling is ready for use.

Setting up the robot

TCP

General Before starting automatic mode, set

up the robot using the robot programming aid included in the scope of supply.

The notch on the programming aid indicates the direction in which the gas nozzle of a torch body locked in the torch body coupling points.

Once setup is complete, the notch must always point forward, away from the change station.

Setting up the robot

NOTE!

In order to make setting up the robot easier, we recommend setting up a dedicated coordinate system for the torch body change station in the robot controller.

Install the programming aid

Measure the TCP of the programming aid

0.0 - 0.5 mm

0° - ±0.5°

0.0

0° - ±0.5°

0.0

0.0 - 0.5 mm

0° - ±0.5°

> ±0.5°

> 0.5 mm

> 0.0 mm

> 0.5 mm

> ±0.5°

> 0.5 mm

> ±0.5°

Position programming aid

Supporting tools:

Feeler gauge

Flashlight

* Notch pointing forward

Position the programming aid according to the following illustrations.

EN-US

NOTE!

The following positions are not permissible.

Permissible deviations: max. 0.5 mm / 0.02 inch, max. ± 0.5°

If additional robots are present, set up the robots for all remaining torch-body racks.

Measuring the torch-body racks using the tactile

sensor

Measuring the torch-body racks using the tactile sensor

WARNING!

Danger from electrical current. During the TouchSensing process, the tactile sensor has an open-circuit voltage of up to 70 V (max. 3 A).

This can result in serious personal injury and damage to property.

Do not touch the tactile sensor, the torch-body racks and the torch body

▶

change system during the TouchSensing process. Observe the safety rules of the robot cell.

▶

Requirements:

The torch-body racks to be measured must be free.

Each torch-body rack must be measured separately.

Process:

Replace tactile sensor (manual or automated)

Position the tactile sensor approximately in the center of the torch-body rack

Rotate clockwise until the small measuring probe touches the inside right of

the torch-body rack

Perform straight horizontal movement backwards until the small measuring

probe touches the rear surface

Perform straight horizontal movement forwards

Rotate approx. 90° counter-clockwise

Perform straight horizontal movement backwards until the small measuring

probe touches the rear surface

EN-US

With min. 3 vertical movements, determine the horizontal plane of the torch-

body rack until the large measuring probe touches the surface

Perform straight horizontal movement to the left until the large measuring

probe touches the left inside of the torch-body rack

Perform straight horizontal movement backwards until the large measuring

probe touches the rear surface

Perform straight horizontal movement to the right until the large measuring

probe touches the inside right of the torch-body rack

Commissioning

EN-US

Requirements for commissioning

Start-up Torch body change station start-up is initiated by an active signal from the robot

Important information regarding operation

The following requirements must be fulfilled for commissioning:

Torch body change station bolted to the surface and supplied with com-

pressed air All torch body sensors tested, wire sensor set up

All torch bodies prepared

Torch body coupling installed

Function of the torch body coupling checked

Robot has been set up using the robot programming aid

WF 30i TWIN installed in the welding system

OPT/i WF Twin Torch Change option built into the WF 30i TWIN

controller.

WARNING!

Danger from falling objects! For example, objects may fall due to unintended or unintentional decoupling or coupling errors.

This can result in serious personal injury and damage to property.

Wear a protective helmet suitable for industrial applications in the operating

▶

area of the robot and torch body change station! Do not remain underneath the robot arm!

▶

CAUTION!

Danger from impermissible force!

This can result in damage to property.

Except for the Fronius components, there must be no other parts on or

▶

mounted on the torch body change station! During operation, observe the max. permissible forces in accordance with the

▶

figures below!

max. 100 N

Max. permissible force exerted by the robot on

max. 100 N

the upright console

Max. permissible force exerted by the robot on the wall-mounted console - regardless of whether the wall-mounted console is mounted on the rear of the device or on the right-hand side of the device

Program sequence

EN-US

Safety

Speed Specifications for the Program Sequence

CAUTION!

Danger from incomplete installations.

This can result in serious damage to property.

Only start automatic mode once the torch body change system has been in-

▶

stalled and commissioned correctly.

List of all speeds specified in the programming sequence, in the respective units:

cm/min m/s ipm

1,000 = 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

Program Sequence

- Unwind wire electrodes 1 and 2 signal until the

wire electrode protrudes 50 mm (1.97 inch) out of

Cutting the wire electrode

Start

Move to pos. A

- approx. 25 mm (0.98 in.) adjacent to the wire cutter

- Speed: High speed mode

Query

Power source ready

Set

the gas nozzle

Move to pos. B

- Move into wire cutter

- Speed: High speed mode

Set

- Cut wire electrode signal

- 10 mm (0.39 inch) above the wire cutter

Start robot movement in the direction of pos. D

- Signal valve first Robacta TX cover

Winding the wire electrode

Wait 0.5 seconds

Move to pos. C

- Speed: High speed mode

Reset

- Cut wire electrode signal

Set

Query

Sensor first

Robacta TX cover

'True'

'False'

Stop program

- Robacta TX cover error

Set

- Wind wire electrodes 1 and 2 for approx. 500 mm

Winding the

- Wire retraction speed: 600 cm/min (236.22 ipm)

wire electrode

- Move up 60 mm (2.36 in.) in front of the

(19.69 inch) signal

Query

Power source ready

Query

torch body sensor

(torch-body rack free)

'False'

Move to pos. D

middle of the torch-body rack

- Speed: High speed mode

'True'

EN-US

Stop program

- Torch body changeover error

- Speed: max. 50 cm/min (19.69 ipm)

Depositing the torch body

Wait 5 seconds without torch deflate

Move to pos. E

- Move into torch-body rack

Wait 0.5 seconds

Query

torch body sensor

(torch body moved into

torch-body rack)

Wait 0.5 seconds

'True'

Set

- Change torch body signal

Wait 1 seconds with torch deflate

'False'

Stop movement into

torch-body rack

Stop program

- Torch body changeover error

Move to pos. F

- Move up 30 mm (1.18 in.) above the center of the torch-body rack

- Speed: max. 30 cm/min (11.81 ipm)

Move to pos. G

Depositing the torch body

- Move up 60 mm (2.36 in.) above the center of the torch-body rack

- Speed: High speed mode

Move up Z 60 mm (2.36 in.) above the center

Move up Z 30 mm (1.18 in.) above the center

Picking up the torch body

- Speed: max. 30 cm/min (11.81 ipm)

Move to pos. J (-0,5 mm / -0.019 in.)

- Pick up torch body so that it sits flush

- Speed: max. 10 cm/min (3.94 ipm)

Query

Torch body sensor (new torch

body present)

'True'

Move to pos. H

of the torch body to be picked up

- Speed: High speed mode

Query

Power source ready

Move to pos. I

of the torch body to be picked up

'False'

Stop program

- Torch body changeover error

Reset

- Change torch body signal

Wait 1 second

Picking up the torch bodyTesting the wire electrode

Query

Torch body sensor (new

torch body present)

‘False‘

Reset

- Change torch body signal

Wait 1 second

Query

Torch body sensor

(torch body is picked up

successfully)

‘True‘

Move to pos. J

(+0,5mm / +0.019 in. upwords)

EN-US

‘True‘

‘False‘

Error: Torch neck not

recognized

Move to pos. K

- X 60 mm (2.36 in.) in front of the middle of the torch-body rack

- Speed: max. 50 cm/min (19.69 ipm)

Set

- Unwind wire electrodes 1 and 2 signal for 500 mm (19.69 inch)

- Feeder inching speed: 600 cm/min (236.)

Move to pos. L

- approx. 50 mm (1.97 in.) adjacent to the wire sensor

- Speed: 100 cm/min (39.37 ipm)

Move to pos. M

- Wire electrode 1 directly in front of the wire sensor

- Speed: 50 cm/min (19.69 ipm)

Query

Wire electrode 1

present

‘True‘

Move to pos. N

- approx. 50 mm (1.97 in.) adjacent to the wire sensor

- Speed: 100 cm/min (39.37 ipm)

Move to pos. O

- Wire electrode 2 directly in front of the wire sensor

- Speed: 50 cm/min (19.69 ipm)

Testing the wire electrode

‘False‘

Stop program

- Wire electrode error

Cutting the wire electrode

Query

Wire electrode 2

present

‘True‘

Move to pos. A

- approx. 25 mm (0.98 in.) adjacent to

the wire cutter

- Speed: High speed mode

Move to pos. B

- Move into wire cutter

- Speed: High speed mode

Set

- Cut wire electrode signal

Wait 0.5 seconds

‘False‘

Stop program

- Wire electrode error

EN-US

Cutting the wire electrode

elctrode

Testing the wire

Query

Sensor first Robacta TX

‘True‘

cover

‘False‘

Move to pos. C

- 10 mm (0.39 inch) above the wire cutter

- Speed: High speed mode

Reset

- Cut wire electrode signal

End

Stop program

- Robacta TX cover error

Installing Optional Equipment

Safety Follow the safety rules below when carrying out all tasks described in the "Op-

tions" chapter.

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 equip-

▶

ment and all system components.

WARNING!

Danger from machines that start automatically.

This can result in serious personal injury and damage to property.

In addition to these Operating Instructions, observe the safety rules of the

▶

robot manufacturer and welding system manufacturer! For your personal safety, make sure that all protective measures have been

▶

taken in the robot's operating area and remain in effect while you are in this area.

WARNING!

Danger caused by the robot arm.

This can result in serious personal injury and damage to property.

Ensure that no third parties are located in the operating area of the robot

▶

while any work is taking place.

WARNING!

Danger due to mechanically moving 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 "Gas purging 16 bar" option on the wirefeeder from the com-

▶

pressed air supply Ensure that all of these measures remain in place until all work is complete.

▶

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

▶

electrically charged components (such as capacitors) have been discharged.

WARNING!

Installing the Torch-body Rack

Danger due to hot system components and/or equipment.

This 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 debris, and sharp components!

This can result in serious personal injury and damage to property.

Always wear the following protective equipment when carrying out the work

▶

described below: Safety glasses with side guards, Gloves - electrically insulating and heat protective, Protective helmet.

The installation procedure for the torch-body rack is described using the upright console as an example. The installation procedure on the wall-mounted console is the same.

EN-US

2 3

30 Nm

22.12 lb·ft

4 Nm

2.95 lb·ft

6 7

NOTE!

Connect the torch-body rack to the torch body change station as per the Circuit Diagram.

30 Nm

22.12 lb·ft

10 Nm

7.37 lb·ft

4 Nm

2.95 lb·ft

EN-US

Installing the

Wire Cutter

The installation procedure for the wire cutter is described using the upright console as an example. The installation procedure on the wall-mounted console is the same.

Installing the Robacta Reamer V Twin

3 4

Installing the

coding ring

With the aid of the coding ring (optionally available), up to 7 different torch bodies can be defined mechanically.

Position the coding ring on the torch body using the 3 position markers

Using the lower threaded pin, secure the coding ring tangentially

Hexagon socket size 1.5 mm

EN-US

Cross-section X - X

Screw in the second threaded pin

until the coding ring is fixed as shown Hexagon socket size 1.5 mm

Screw in the third threaded pin un-

til the coding ring is fixed as shown Hexagon socket size 1.5 mm

Tighten the second and third

threaded pins Tightening torque = 1 Nm / 0.73 lb·ft

A B C

(1)

(2)

(3)

(4)

(5)

(6)

(7)

The torch bodies are defined by screw-

ing in the cylinder head screws A, B, and C differently (Hexagon socket size 2.5 mm).

Symbols:

Cylinder head screw is screwed in

(Cylinder head screw present)

IMPORTANT!

Combination without screwed-in

cylinder head screws is not permitted. During operation, data must always

be retrieved from all 3 sensors. For example, if data is only retrieved from one sensor, a torch body with 2 or 3 screws may also be located in the rack.

NOTE!

When using the coding ring:

The sensor fitted as standard on the torch-body rack must be readjusted,

▶

otherwise a collision will occur. 2 additional torch body sensors (42,0002,0444) are required per rack.

▶

Adjusting the sensor fitted as standard:

Remove the torch body from the torch-body rack

Loosen the front jam nut – counter the rear jam nut Size 19 mm

Move sensor back

Insert the torch body into the torch-body rack

Position the sensor in relation to the cylinder head screw so that the sensor

detects the screw, but not the coding ring (without screw).

IMPORTANT! The sensor must not touch the cylinder head screw!

Tighten the front jam nut – counter the rear jam nut

Size 19 mm, tightening torque = 5 Nm / 3.68 lb·ft

The same procedure applies to the 2 other torch body sensors.

EN-US

Troubleshooting

Safety Follow the safety rules below when carrying out all the tasks described in the

"Troubleshooting" chapter.

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 equip-

▶

ment and all system components.

WARNING!

Danger from machines that start automatically.

This can result in serious personal injury and damage to property.

In addition to these Operating Instructions, observe the safety rules of the

▶

robot manufacturer and welding system manufacturer. For your personal safety, make sure that all protective measures have been

▶

taken in the robot's operating area and remain in effect while you are in this area.

WARNING!

Danger caused by the robot arm.

This can result in serious personal injury and damage to property.

Ensure that no third parties are located in the operating area of the robot

▶

while any work is taking place.

WARNING!

Danger due to mechanically moving 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 "Gas purging 16 bar" option on the wirefeeder from the com-

▶

pressed air supply Ensure that all of these measures remain in place until all work is complete.

▶

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

▶

electrically charged components (such as capacitors) have been discharged.

WARNING!

Troubleshooting

Danger due to hot system components and/or equipment.

This 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.

CAUTION!

Danger from compressed air escaping from the torch body coupling, ﬂying debris, and sharp components.

This can result in serious personal injury and damage to property.

Always wear the following protective equipment when carrying out the work

▶

described below: Safety glasses with side guards, Gloves - electrically insulating and heat protective, Protective helmet.

There is coolant residue on the torch body after a torch body changeover

Cause: Remedy:

The hosepack coolant stop is worn Change the hosepack coolant stop

EN-US

Cause:

Remedy:

Cause: Remedy:

Cause:

Remedy:

Cause:

Remedy:

Cause: Remedy:

Water column in the hosepack too high (for example, if the cooling unit is positioned higher than the change station)

Position the cooling unit at the same level as the change station

Water/current plug on welding torch leaking or damaged Notify service team

The speed of the robot while picking up and depositing the torch body is too high

Reduce the speed of the robot while picking up and depositing the torch body

O-rings defective or worn (for example due to inaccurate positioning of the robot when changing the torch body)

Change O-rings, program robot according to the Operating Instructions or set it up again

Pressure in the cooling circuit when changing the torch body Ensure that the cooling circuit is depressurized when changing the

torch body

Torch body coupling does not open

Cause: Remedy:

Compressed air supply of the torch body coupling is too low Ensure compressed air supply according to the specifications in the

Operating Instructions

Cause: Remedy:

Torch body coupling not locked correctly

Cause:

Remedy:

Cause:

Remedy:

Solenoid valve defective Replace solenoid valve

Pneumatic or electrical control lines faulty Replace faulty control lines

Torch body coupling faulty/damaged Unlock the torch body coupling by hand and send it to the manufac-

turer for servicing

The coupling areas of the torch body coupling and torch neck are covered with grease/dirty/damaged

Ensure that the coupling areas are free of grease, clean, and undamaged

Incorrect torch body change station/torch-body rack installation position

Torch body change station/torch-body rack must only be installed horizontally (the gas nozzle of stored torch bodies must point downwards)

Cause: Remedy:

Pneumatic cover does not close

Cause: Remedy:

Pneumatic cover closes too slowly / too quickly

Cause: Remedy:

Pneumatic or electrical control lines faulty Replace faulty control lines

Torch body coupling faulty/damaged Unlock the torch body coupling by hand and send it to the manufac-

turer for servicing

Robot in incorrect position when changing the torch body Program the robot as per the Operating Instructions

The locking pin is locked Release the locking pin lock

Operating pressure deviates from 6 bar Adjust pneumatic cover

see page 63

Service, maintenance and disposal

Safety Follow the safety rules below when carrying out all the tasks described in the

"Service, Maintenance, and Disposal" chapter.

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 equip-

▶

ment and all system components.

WARNING!

Danger from machines that start automatically.

This can result in serious personal injury and damage to property.

In addition to these Operating Instructions, observe the safety rules of the

▶

robot manufacturer and welding system manufacturer. For your personal safety, make sure that all protective measures have been

▶

taken in the robot's operating area and remain in effect while you are in this area.

EN-US

WARNING!

Danger caused by the robot arm.

This can result in serious personal injury and damage to property.

Ensure that no third parties are located in the operating area of the robot

▶

while any work is taking place.

WARNING!

Danger due to mechanically moving 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 "Gas purging 16 bar" option on the wirefeeder from the com-

▶

pressed air supply Ensure that all of these measures remain in place until all work is complete.

▶

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

▶

electrically charged components (such as capacitors) have been discharged.

WARNING!

Danger due to hot system components and/or equipment.

This 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 debris, and sharp components.

This can result in serious personal injury and damage to property.

Always wear the following protective equipment when carrying out the work

▶

described below: Safety glasses with side guards, Gloves - electrically insulating and heat protective, Protective helmet.

Maintenance activities

NOTE!

Perform daily visual inspection!

Daily visual inspection is mandatory.

The interface between the torch body and the torch hosepack must be clean,

▶

dry, and free from grease and mechanical damage such as scratches or scoring.

If coolant leaks:

Check all coolant-carrying components

If necessary, change the water stops on the torch hosepack

Check that O-rings are intact and greased;

if necessary, replace and grease the O-rings. Check the position of the robot in relation to the torch-body rack according

to the program sequence.

Changing the O-

rings in the torch body coupling

Remove the torch body from the torch body coupling

Unscrew the torch body coupling from the drive unit/the hosepack

NOTE!

When inserting new O-rings, make sure that they are properly greased.

Fit the torch body coupling to the hosepack/drive unit correctly

EN-US

Adjusting the pneumatic cover

The pneumatic cover is set as follows on delivery:

Operating pressure of 6 bar

Opening angle max. 90°

No postoscillation when opening

No loud closing noise

If the operating pressure differs, the pneumatic cover can be adjusted as follows.

Set opening speed:

Set closing speed:

Turning the adjusting screw to the left causes the cover to close more quickly.

Disposal Materials should be disposed of according to valid local and national regulations.

Technical data

EN-US

Upright console TXi TWIN

Wall-mounted console TXi TWIN

Supply voltage + 24 V DC

Nominal pressure 6 bar/87.02 psi

Standard I/O Input: + 24 V DC/ max. 1.5 A

Degree of protection IP 23

EMC device class O

Dimensions l x w x h 662.5 x 348.2 x 835.5 mm

26.08 x 13.71 x 32.89 in.

Weight 43.5 kg / 95.90 lbs.

Supply voltage + 24 V DC

Nominal pressure 6 bar/87.02 psi

Standard I/O Input: + 24 V DC/ max. 1.5 A

Protection class IP 23

EMC emission class A

Dimensions l x w x h 607.5 x 428.2 x 506.0 mm

23.92 x 16.86 x 19.92 in.

Torch body coupling

Weight 32.5 kg / 71.65 lbs.

Weight 0.91 kg / 2.01 lb.

Nominal pressure 6 bar/87.02 psi

Declaration of Incorporation

DE German Deutsch EN English English FR French Française

EU-EINBAUERKLÄRUNG 2016 EU DECLARATION OF INCORPORATION 2016 DECLARATION D’ INCORPORATION DE U.E., 2016

Wels-Thalheim, 2016-07-07

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FRONIUS INTERNATIONAL GMBH

Fronius International GmbH

Hiermit erklären wir, dass folgendes Produkt:

Robacta TX

Schweißzubehör

den unten angeführten, grundlegenden Anforderungen einer „unvollständigen Maschine“ im Sinne der Maschinenrichtlinie 2006/42/EG entspricht. Das Produkt ist ausschließlich zum Einbau in eine Maschine oder unvollständige Maschine vorgesehen und entspricht daher noch nicht sämtlichen Anforderungen der Maschinenrichtlinie. Die Inbetriebnahme des Produkts ist solange untersagt, bis festgestellt wurde, dass die Maschine, in die das o. g. Produkt eingebaut wird, allen grundlegenden Anforderungen der Maschinenrichtlinie 2006/42/EG entspricht. Die speziellen technischen Unterlagen gemäß Anhang VII Teil B wurden erstellt.

Anhang I: EN ISO 12100:2010 EN 61000-6-2:2005+AC:2005 EN 61000-6-4:2007+A1:2011

Dokumentationsverantwortlicher: (technische Dokumentation)

Ing. Josef Feichtinger Günter Fronius Straße 1 A - 4600 Wels-Thalheim

We hereby declare that the following product:

Robacta TX

Arc welding equipment

conforms to the essential requirements listed below of "partly completed machinery" within the meaning of the Machinery Directive, 2006/42/EU. The product is intended exclusively for installation in machinery or partly completed machinery. It therefore does not yet fully conform to all the requirements of the Machinery Directive. It is not permitted to commission the product until it is has been established that the machinery in which the above product is installed conforms to all the requirements of the Machinery Directive, 2006/42/EU. The special technical documents according to Annex VII Part B have been created.

Annex I: EN ISO 12100:2010 EN 61000-6-2:2005+AC:2005 EN 61000-6-4:2007+A1:2011

person responsible for documents: (technical documents)

Ing. Josef Feichtinger Günter Fronius Straße 1 A - 4600 Wels-Thalheim

Nous déclarons par la présente que le produit suivant:

Robacta TX

Accessoires de soudage

répond aux exigences essentielles indiquées ci-dessous, relatives à celles d'une « quasi-machine » au sens de la directive machines 2006/42/CE. Le produit est exclusivement prévu pour un montage dans une machine ou une quasi-machine et ne répond donc pas encore à toutes les exigences de la directive machines. La mise en service du produit est interdite jusqu'à ce qu'il soit constaté que la machine dans laquelle le produit précité a été monté, est en conformité avec toutes les exigences de la directive machines 2006/42/CE. Les documents techniques spéciaux, conformément à l'annexe VII Partie B, ont été élaborés.

Annexe I: EN ISO 12100:2010 EN 61000-6-2:2005+AC:2005 EN 61000-6-4:2007+A1:2011

responsable documentation: (technique documentation)

Ing. Josef Feichtinger Günter Fronius Straße 1 A - 4600 Wels-Thalheim

2016 ppa. Mag.Ing.H.Hackl

Member of Board Chief Technology Officer

EN-US

Fronius TX/i TWIN Operating Instruction [EN]

Specifications and Main Features

Frequently Asked Questions

User Manual