FRONIUS ROBACTA TX W (01) PDF Document

The FRONIUS ROBACTA TX W is intended solely for changing Fronius torch bodies. It is designed for use in conjunction with Fronius system components, including cooling units and coolant. Proper use includes:

– Carefully reading and following all instructions 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. Any use above and beyond this purpose is deemed improper.

Operation or storage of the device outside the stipulated area is not in accordance with its intended purpose.

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. The device can be used at altitudes of up to 2000 m (6561 ft).

Control elements and connections:

– Wire sensor: Checks whether the wire electrode is protruding from the welding torch.

– I/O connection for accessory equipment: To connect Fronius accessory equipment to the torch body changeover station.

– Compressed air connection “C”

– Unlock/Lock button: For manual operation of the torch body coupling.

– Compressed air connection “A”: To supply the torch body coupling with compressed air.

– External power supply connection “A”: Supplied with 24 V DC.

– Robot control connection compartment: For optionally connecting the torch body changeover station to the robot control via standard I/O connection or field bus coupler.

– Compressed air connection “B”: Connection to supply the torch body changeover station with 5.50 – 6.00 bar of dry and oil-free compressed air. Size: 3/8″ (0.375 in.).

– External power supply connection “B”, optional only: Supplied with 24 V DC.

Mechanical components:

– Rack holder: For holding the torch body racks.

– Mounting bracket: For attaching accessory equipment.

– Torch body rack: For holding a torch body.

To ensure the torch body changeover system functions correctly, the following compressed air supply specifications must be met:

– Compressed air is free of oil.

– Compressed air is free of dust (no dirt particles larger than 5 µm).

– Compressed air is free of water.

– Compressed air supply at 5.50 – 6.00 bar (79.77 – 87.02 psi).

– Minimum inner diameter of compressed air lines 5.5 mm (0.22 in.).

NOTE: Different fixings may be required depending on the type of underlying surface (foundation). The installer is responsible for selecting the right type of fixing.

Step 1. Set up the torch body changeover station in a suitable location.

Step 2. If necessary, align the torch body changeover station horizontally and vertically using adjustment plates.

Step 3. Bolt the torch body changeover station bases to the underlying surface (foundation).

Step 4. Once bolted down, check whether the torch body changeover station is horizontally and vertically aligned with the underlying surface.

Preparation:

Step 1. Place the junction valve on the fitting panel as shown.

Step 2. Secure the junction valve using the provided screws, washers, and nuts.

Step 3. Undo the screw (3) and disconnect the compressed air line from the gas purging option connection (4) on the wire-feed unit.

Step 4. Fit the mounting plate and junction valve onto the wire-feed unit and secure using the provided TX 25 screw.

Step 5. Insert the supplied compressed air line (outer diameter 6 mm) into the connection on the junction valve and into the gas purging option connection.

Installation:

Step 1. Insert the compressed air line into compressed air connection “A” on the torch body changeover station and into the corresponding connection on the junction valve.

Step 2. Insert the gas purging line from the hosepack into its connection on the junction valve.

Checking the torch body sensor:

Step 1. Establish a connection with the robot control (either using the standard I/O connecting plug or a field bus coupler).

Step 2. Insert a torch body as far as it will go into the torch body rack. The LED should come on, and a signal should be sent to the robot control.

Step 3. If the LED does not come on, check if the torch body sensor is connected to the torch body changeover station PC board.

Setting the wire sensor:

Step 1. Rotate the wire electrode in the opening of the wire sensor during the entire setting process. The LED will come on if the sensor detects the wire.

Step 2. Turn the adjusting screw in the reverse direction until the LED goes off. The wire sensor is now deactivated.

Step 3. Turn the adjusting screw just until the LED comes on again. The wire sensor is now set at the lowest sensitivity level to prevent accidental triggering.

Step 1. Insert the inner liner from the original equipment kit of the hosepack as far as it will go into the torch body.

Step 2. Push the cutting aid as far as it will go onto the inner liner.

Step 3. Tighten the locking screw of the cutting aid.

Step 4. Pull the inner liner and cutting aid out of the torch body without changing the position of the cutting aid.

Step 5. Cut off the inner liner at the end of the cutting aid using cutting pliers.

Step 6. Deburr the inner liner at both ends.

Step 7. Insert the prepared inner liner into the torch body.

Step 8. Insert the TX inlet/outlet nozzle fully into the torch body. Press it down until you hear a click.

Step 1. Insert the inner liner from the original equipment kit of the hosepack as far as it will go into the torch body.

Step 2. Push the cutting aid as far as it will go onto the inner liner.

Step 3. Tighten the locking screw of the cutting aid.

Step 4. Pull the inner liner and cutting aid out of the torch body without changing the position of the cutting aid.

Step 5. Cut off the inner liner at the end of the cutting aid using a knife.

Step 6. Deburr the inner liner at both ends.

Step 7. Insert the prepared inner liner into the torch body.

Step 8. Insert the TX inlet/outlet nozzle fully into the torch body. Press it down until you hear a click.

Step 1. Press the centre bolt out of the torch body coupling.

Step 2. Unscrew the run-off plate from the centre bolt using a 6 mm socket wrench insert.

Step 3. Remove the grub screw from the centre bolt using a 1.5mm Allen key.

Step 4. Screw the run-off plate back into the centre bolt.

Step 5. Push the centre bolt into the torch body coupling.

Step 1. Insert the inner liner from the original equipment kit of the hosepack as far as it will go into the torch body coupling.

Step 2. Insert the cutting pipe (item number: 42,0001,5910) of the hosepack onto the inner liner.

Step 3. Cut off the inner liner at the end of the cutting pipe using cutting pliers (for steel liners) or a knife (for plastic liners).

Step 4. Remove the cutting pipe.

Step 5. Remove the inner liner from the torch body coupling.

Step 6. Deburr the inner liner at both ends.

Step 7. Insert the deburred inner liner as far as it will go into the torch body coupling.

NOTE: When fitting the torch body coupling, the TCP moves by 50 mm (1.97 in.).

For Robacta Drive and Robacta Drive CMT drive units:

Step 1. Push the centre bolt approx. 5 mm (0.2 in.) out of the torch body coupling.

Step 2. Position the torch body coupling and inner liner onto the drive unit.

Step 3. Screw the torch body coupling as far as possible onto the drive unit by hand.

Step 4. Tighten the torch body coupling using the installation tool (Tightening torque = 20 Nm).

For Robacta hosepacks:

Step 1. Push the centre bolt approx. 5 mm out of the torch body coupling.

Step 2. Fit the torch body coupling without the inner liner onto the drive unit (the inner liner must have been prepared in the hosepack beforehand).

Step 3. Screw the torch body coupling as far as possible onto the drive unit by hand.

Step 4. Tighten the torch body coupling using the installation tool (Tightening torque = 20 Nm).

The torch body can be turned in 90° steps within the torch body insulation to change its alignment. If the alignment is changed, the robot programming aid must also be realigned.

Step 1. Undo the four screws on the torch body insulation.

Step 2. Push the torch body insulation down approx. 50 mm (1.97 in.).

Step 3. Turn the torch body as required.

Step 4. Push the torch body insulation as far as it will go back onto the torch body, ensuring the pin on the insulation fits into one of the three corresponding holes.

Step 5. Secure the torch body insulation by tightening the four screws using an Allen key (Tightening torque = 1 Nm). Always tighten opposite screws.

Connecting:

Step 1. Screw a suitable compressed air connection into connection “B” on the torch body changeover station, using thread sealing tape.

Step 2. Depressurise the compressed air supply line.

Step 3. Connect the supply line to connection “B”.

Step 4. Supply the line with compressed air.

Step 5. Undo the 8 screws and remove the lid of the changeover station.

Adjusting:

Step 1. Pull the control dial to unlock it.

Step 2. Turn the control dial until the pressure gauge shows 1.3 MPa (13 bar / 188.55 psi). If necessary for long hosepacks, set the pressure to a max. of 1.6 MPa (16 bar / 232.06 psi).

Step 3. Press the control dial to lock it.

Step 4. Place the lid back on the changeover station and tighten the 8 screws and washers.

Step 1. Position the robot arm so the Unlock/Lock button can be pressed with one hand, and the torch body can be handled with the other.

Step 2. Hold the torch body on the robot arm with one hand.

Step 3. Press and hold the Unlock/Lock button on the changeover station. The torch body coupling lock will open.

Step 4. Remove the torch body from the torch body coupling.

Step 5. Place a new torch body back onto the coupling, press it against the coupling, and hold it in position.

Step 6. Release the Unlock/Lock button. The lock will close, and the torch body will be fixed after approx. 5 seconds.

Step 7. Check that the gap between the torch body and the coupling is the same around the entire perimeter.

Step 8. Shake and pull the torch body to ensure it is securely connected.

Determining TCP and Station Axes:

Step 1. Screw 3 TCP tips into the holes of the rack holder.

Step 2. Measure the TCP of the welding torch being used.

Step 3. Determine the X-axis and Y-axis of the torch body changeover station using the TCP tips and record them in the robot’s coordinate system.

Fitting the Robot Programming Aid:

Step 1. Hold the torch body on the robot arm.

Step 2. Press and hold the Unlock/Lock button on the station to open the coupling lock.

Step 3. Remove the torch body from the coupling.

Step 4. Place both parts of the robot programming aid onto the torch body coupling on the robot and hold in place.

Step 5. Release the Unlock/Lock button to fix the top part of the programming aid.

Step 6. Place the bottom part of the programming aid into the first torch body rack on the station.

Setting Robot Positions:

Step 1. Measure the TCP of the robot programming aid.

Step 2. Move the robot so the two parts of the programming aid are aligned with a gap of approx. 15 mm (0.59 in.). Save this as position H.

Step 3. Move the robot closer, leaving a gap of approx. 1.5 mm (0.06 in.).

Step 4. Move the robot until both parts of the aid are on top of each other (end position). Save this as position G.

Step 5. Create the robot program for this torch body rack position and repeat for all other positions.

Step 6. Remove and safely store the TCP tips.

The following prerequisites must be fulfilled for start-up:

– Torch body changeover station is bolted to the underlying surface.

– Torch body changeover station is installed.

– All torch body sensors are checked, and the wire sensor is set.

– All torch bodies have been prepared.

– System components for Robacta hosepack are prepared (if applicable).

– Torch body coupling is prepared for Robacta Drive or Robacta Drive CMT hosepack (if applicable).

– Power source has been prepared.

– Torch body coupling is mounted onto the robot.

– Torch bodies are aligned for special rack positions (if necessary).

– Compressed-air booster unit is connected and adjusted.

– Torch body has been changed manually to confirm function.

– Robot is set up using the robot programming aid.

Torch body unexpectedly loses contact with coupling during gas purging.

– Cause: Gas purging pressure too high.

– Remedy: Adjust gas purging pressure.

– Cause: Gas hole in centre bolt is dirty.

– Remedy: Clean gas hole in centre bolt.

Residual coolant on torch body after change.

– Cause: Coolant hoses incorrectly connected to the cooling unit.

– Remedy: Connect the coolant hoses in the right direction for the coolant flow.

– Cause: Torch body coupling is worn.

– Remedy: Send the torch body coupling to the manufacturer’s service department.

– Cause: Robot speed is too fast when picking up and setting down the torch body.

– Remedy: Reduce robot speed.

– Cause: Compressed air escaping from the coupling is blowing coolant out of the set-down torch body.

– Remedy: Lock the torch body coupling next to the torch body changeover station.

Coolant sprays out of the torch body after being set down.

– Cause: Torch body is very hot.

– Remedy: Use a water-cooled gas nozzle.

RCU 5000i or power source shows “No coolant flow” / “no | H2O” error.

– Cause: Cooling unit flow watchdog has been triggered.

– Remedy: Set filter time for flow watchdog to 25 seconds using RCU 5000i.

Torch body coupling does not open.

– Cause: Compressed air supply to station is briefly too low.

– Remedy: Change torch body manually.

– Cause: Very long hosepacks.

– Remedy: Increase pressure to max. 1.6 MPa (16 bar) for the compressed air amplifier.

– Cause: Compressed air supply of station is too low.

– Remedy: Ensure compressed air supply is as per specifications.

– Cause: Incorrect output pressure set on the compressed air amplifier.

– Remedy: Adjust the compressed air amplifier as per specifications.

– Cause: Torch body coupling is faulty.

– Remedy: Press the emergency release button and service the centre bolt. If this does not solve the problem, send the coupling to the manufacturer’s service department.

Preparation:

Step 1. Position the robot arm to access the Unlock/Lock button and handle the torch body.

Step 2. Feed out the wire electrode from the hosepack.

Step 3. Hold the torch body, press the Unlock/Lock button, and remove the torch body from the coupling.

Step 4. Depressurise and disconnect the compressed air line from connection “A”.

Step 5. Press and hold the Unlock/Lock button until compressed air no longer emerges from connection “A”.

Step 6. De-energise the torch body changeover station.

Maintenance Checks:

1. Check the torch body for damage and wear:

– Inspect wire guide pin, coolant pins, and gas pin for damage.

– Check the TX inlet/outlet nozzle for wear.

– Check O-rings on the wire guide pin and gas pin for damage.

– Ensure the four screws are securely seated (tightening torque = 1 Nm).

2. Check the torch body coupling:

– Check the marked surface area for dirt or damage.

– Check for coolant residue; if found, replace the coolant stops.

– For Robacta Drive/CMT hosepacks, check the inner liner of the core bolt for wear.

3. Change the inner liner in the torch body if necessary (see separate procedures for steel and plastic liners).

Final Steps:

Step 1. Thread the wire electrode into the hosepack.

Step 2. Reconnect the compressed air line to connection “A”.

Step 3. Re-establish the compressed air and power supply.

Step 4. Place the torch body correctly onto the torch body coupling.

Removing old coolant stops:

Step 1. Place the bit insert for coolant stops onto the manual torque wrench.

Step 2. Push the bit insert as far as it will go into the coolant stops.

Step 3. Unscrew the coolant stops from the torch body coupling using the manual torque wrench.

Preparing new coolant stops:

Step 1. Insert the 6 x 1.5 mm O-ring into the groove on the inside of the coupling crown.

Step 2. Insert the 7 x 1 mm O-ring into the groove on the outside of the coupling crown.

Step 3. Insert the 2 x 1 mm O-ring into the groove on the coupling plunger.

Step 4. Insert the coupling valve into the coupling crown.

Step 5. Insert the spring into the coupling crown.

Step 6. Insert the coupling plunger into the coupling crown. This completes one coolant stop.

Step 7. Repeat for the second coolant stop.

Fitting new coolant stops:

Step 1. Lightly lubricate the O-ring on the coolant stop.

Step 2. Fit the ready-made coolant stop onto the bit insert on the manual torque wrench.

Step 3. Insert the coolant stop into a hole in the coupling with a rotary movement to avoid damaging the O-ring.

Step 4. Tighten the coolant stop (Tightening torque = 3 Nm).

Step 5. Repeat the steps for the second coolant stop.

Preparation:

Perform the preparation steps for maintenance, including removing the torch body, depressurizing the system, and de-energizing the station. Then, unscrew the torch body coupling from the robot arm using the installation tool and press the core bolt out of the torch body coupling.

Cleaning:

Step 1. Unscrew the gas pin from the core bolt using a 5.5 mm socket wrench.

Step 2. Take the control slide and the spring under it off the core bolt.

Step 3. Clean the control slide and spring. Do not lubricate them.

Step 4. Clean the hole in the core bolt.

Step 5. Re-fit the spring and control slide into the hole. They must drop in without any resistance.

Step 6. Screw the gas pin back into the core bolt using a 5.5 mm socket wrench.

And finally:

Reassemble the system by inserting the core bolt and inner liner, screwing the coupling back onto the drive unit, threading the wire, and reconnecting air and power.

Only press the emergency release button if the torch body does not come off the coupling after a robot command or if it cannot be changed manually.

Step 1. Perform the preparation steps for maintenance (position robot, feed out wire, depressurize, disconnect air line “A”).

Step 2. Remove the plastic placeholder from the plastic sleeve on the torch body coupling.

Step 3. Unscrew the grub screw from the torch body coupling using a 1.5 mm Allen key.

Step 4. Ensure the opening in the plastic sleeve is directly above the exposed hole in the torch body coupling.

Step 5. Press a compressed air pistol firmly into the plastic sleeve.

Step 6. Actuate the compressed air pistol and simultaneously pull the torch body off the coupling.

Step 7. Send the torch body coupling and centre bolt to the manufacturer for service.

Removing the old sensor:

Step 1. Perform the preparation steps for maintenance, including de-energizing the station and depressurizing the air lines.

Step 2. Undo the 8 screws and remove the lid of the changeover station.

Step 3. Undo the cable tie holding the sensor cable.

Step 4. Unplug the sensor from the PC board corresponding to its rack position (e.g., ‘X3 sensor 2’ for position 2).

Step 5. Remove the cable tie on the torch body rack.

Step 6. Undo the screw holding the sensor using a 4 mm Allen key.

Step 7. Feed the sensor cable out from the torch body changeover station.

Step 8. Unscrew the torch body sensor from the torch body rack.

Fitting the new sensor:

Step 1. Screw the new torch body sensor into the torch body rack until it reaches a dimension of 8 mm (0.31 in.) from the rack surface to the sensor face.

Step 2. Tighten the securing screw using a 4 mm Allen key.

Step 3. Fix the sensor cable to the torch body rack using a new cable tie.

Step 4. Plug the sensor into the correct position on the PC board.

Step 5. Fix the sensor cable inside the station using a new cable tie.

Step 6. Place the lid back on the changeover station and secure it with the 8 screws and washers.

Step 7. Reconnect the compressed air and power supply.