TÄYDELLISTÄ HITSAUSTA ROBACTA PTW 500/500/3500 / Operating Instructions / Spare Parts List v.0/0 ENG
Dear Reader Introduction Thank you for choosing Fronius - and congratulations on your new, technically highgrade Fronius product! This instruction manual will help you get to know your new machine. Read the manual carefully and you will soon be familiar with all the many great features of your new Fronius product. This really is the best way to get the most out of all the advantages that your machine has to offer. EN Please also take special note of the safety rules - and observe them! In this way, you will help to ensure more safety at your product location. And of course, if you treat your product carefully, this definitely helps to prolong its enduring quality and reliability - things which are both essential prerequisites for getting outstanding results. ud_fr_st_et_00493 0/0
Table of contents General... Machine concept... Applications... 3 Scope of supply... 3 PTW 500 options... 5 PTW 500 options... 5 PTW 3500 options... 5 Assembling the Robacta PTW 500, 500, 3500... 6 Safety... 6 Assembling the Robacta PTW 500... 6 Assembling the Robacta PTW 500... 7 Assembling the Robacta PTW 3500... 7 Assembling the Robacta PTW 3500... 8 Adjusting the tungsten electrode... 9 General... 9 Adjusting the PTW 500 tungsten electrode... 9 Calibrating the PTW 500 adjusting gauge... 0 Adjusting the PTW 500 tungsten electrode... 0 Adjusting the PTW 3500 tungsten electrode... Start-up... General... Proper use... Start-up... Loading limits dependent on the plasma gas flow rate... 4 General... 4 Loading limits dependent on the plasma gas flow rate... 4 Loading limit example (PTW 500)... 5 Troubleshooting... 6 Safety... 6 Troubleshooting... 6 Care, maintenance and disposal... 7 General... 7 At every start-up... 7 Monthly... 7 Disposal... 7 Technical data... 8 PTW 500, PTW 500, PTW 3500... 8 EN
General Machine concept (Cold) wire feeder Robacta Plasma KD Drive Robacta PTW 500 Robacta PTW 500 with Robacta Plasma KD Drive and wirefeed options (Cold) wire feeder Robacta Plasma KD Drive Robacta PTW 500 Robacta PTW 500 with Robacta Plasma KD Drive and wirefeed options (Cold) wire feeder Robacta Plasma KD Drive Robacta PTW 3500 Robacta PTW 3500 with Robacta Plasma KD Drive and wirefeed options
Machine concept (continued) The water-cooled plasma robot welding torch is designed for plasma welding and plasma brazing of materials up to a thickness of.5 mm (PTW 500), 3 mm (PTW 500) and 8 mm (PTW 3500). The welding torches have a Fronius F++ connection as standard. Various adapters are available to enable the torches to be operated with any standard plasma device. Each torch can be equipped with KD Drive, a pushed wire-feed unit or a drag gas nozzle. EN Applications The plasma robot welding torch is used in automated applications, e.g.: - Pipeline and equipment construction - Container construction - Applications requiring the highest quality standards - Applications using special materials (e.g. titanium, nickel-based alloys) Scope of supply Adjusting gauge Holder Ceramic gas nozzle Hosepack 4 m, Fronius F++ / FG connection Robacta PTW 500 scope of supply Holder Torch cap Clamping sleeve.0 mm Tungsten electrode.0 mm Torch body with stop ring Plasma nozzle. mm Shielding gas nozzle Connection for cut-out box 3
Scope of supply (continued) Ceramic centring tube Torch body with stop ring Adjusting gauge.5-3 mm Tungsten electrode WL 5,.4 mm Holder Clamping sleeve.4 mm Robacta PTW 500 torch cap Hosepack 4 m, Fronius F++ connection Connection for cut-out box Plasma nozzle.5 mm Shielding gas nozzle Robacta PTW 500 scope of supply Plasma nozzle 3. mm Shielding gas nozzle Adjusting gauge Water stopper Ceramic centring tube Torch body with stop ring Connection for cut-out box Hosepack 4 m, Fronius F++ / FG connection Robacta PTW 3500 torch cap Clamping sleeve 4.8 mm Tungsten electrode WL 5, 4.8 mm Holder Robacta PTW 3500 scope of supply 4
PTW 500 options - Hot wire option - Plasma nozzle 0.6 / 0.8 /.0 /.4 /.6 mm - Adapter for the non-digital PlasmaModul - Cold wire feeder with drive (push-pull system): Robacta Plasma KD Drive - Cold wire feeder (push system): Robacta Plasma KD - Drag gas nozzle 50 / 00 mm EN PTW 500 options - Adjusting gauge.5 - mm - Cold wire feeder with drive (push-pull system): Robacta Plasma KD Drive - Cold wire feeder (push system): Robacta Plasma KD - Hot wire option - Plasma nozzle.0 /.5 / / 3 mm;.0 x 9 mm long - Ceramic centring tube.6 / 3. mm - Clamping sleeve.6 / 3. mm - Adapter for the non-digital PlasmaModul - Drag gas nozzle 50 / 00 mm PTW 3500 options - Cold wire feeder with drive (push-pull system): Robacta Plasma KD Drive - Cold wire feeder (push system): Robacta Plasma KD - Hot wire option - Plasma nozzle.0 /.5 / 3.5 / 4.0 mm - Plasma nozzle.0 /.5 / 3. / 3.5 / 4.0 mm with 4 x mm balance holes - Conical plasma nozzle - Ceramic centring tube 6.4 mm - Clamping sleeve 6.4 mm - Adapter for the non-digital PlasmaModul - Drag gas nozzle 50 / 00 mm - Ceramic gas nozzle + appropriate stop ring 5
Assembling the Robacta PTW 500, 500, 3500 Safety WARNING! Work that is carried out incorrectly can cause serious injury and damage. The following activities must only be carried out by trained and qualified personnel. Follow the safety regulations. Assembling the Robacta PTW 500 3 4 5 x360 3 Insert clamping sleeve Insert tungsten electrode Important! Insert the tungsten electrode so that the tip protrudes approx. 0 mm out of the torch body. Slightly tighten the torch cap so that the tungsten electrode can still move inside the torch body. 3 Important! Check that the tungsten electrode is adjusted correctly (see Adjusting the tungsten electrode ) 3 Assemble centring tube, plasma nozzle and shielding gas nozzle 6
Assembling the Robacta PTW 500 4 EN 3 Fit holder, insert clamping sleeve Insert tungsten electrode Important! Insert the tungsten electrode so that the tip protrudes approx. 0 mm out of the torch body. Slightly tighten the torch cap so that the tungsten electrode can still move inside the torch body. Important! Check that the tungsten electrode is adjusted correctly (see Adjusting the tungsten electrode ) 3 0 mm Assemble centring tube, plasma nozzle and shielding gas nozzle Assembling the Robacta PTW 3500 4 3 Fit holder, insert clamping sleeve Insert tungsten electrode 7
Assembling the Robacta PTW 3500 Important! Insert the tungsten electrode so that the tip protrudes approx. 0 mm out of the torch body. Slightly tighten the torch cap so that the tungsten electrode can still move inside the torch body. 3 0mm Water-cooled protective gas nozzles must be connected to the water connections. Ceramic protective gas nozzles do not need any water cooling. If ceramic protective gas nozzles are being used, the two water connections must be joined together using the water stopper. Important! Check that the tungsten electrode is adjusted correctly (see Adjusting the tungsten electrode ) 3 Assemble centring tube, plasma nozzle and shielding gas nozzle 8
Adjusting the tungsten electrode General Alongside the specified plasma gas flow rate, the position of the tungsten electrode plays a crucial role in determining the loading limits. By loading limits we mean the maximum possible welding current - for a particular plasma nozzle, - for a particular plasma gas flow rate, - for a particular tungsten electrode position. EN The setting process for the tungsten electrode for plasma welding / plasma brazing is described in the following section. WARNING! Work that is carried out incorrectly can cause serious injury and damage. The following activities must only be carried out by trained and qualified personnel. Follow the safety regulations. Adjusting the PTW 500 tungsten electrode 3 x360 * 4 *) Loosen the torch cap - caution, the tungsten electrode may fall out of the plasma torch if the torch is in a particular position. 3 4 0... and adjust tungsten electrode 9
Adjusting the PTW 500 tungsten electrode (continued) 5 6 3 Calibrating the PTW 500 adjusting gauge NOTE! The standard setting for measurement x on the adjusting gauge depends on the diameter of the plasma nozzle. Refer to the following table when adjusting the standard setting for measurement x : Setting the adjusting gauge to measurement x Plasma x Adjusting nozzle gauge.0 mm - -.5 mm.5 mm.5 - mm.0 mm.0 mm.5 - mm.5 mm.5 mm.5-3 mm 3.0 mm.5 mm.5-3 mm Adjusting the PTW 500 tungsten electrode Loosen the torch cap - caution, the tungsten electrode may fall out of the plasma torch if the torch is in a particular position. Place adjusting gauge onto plasma nozzle... 0
Adjusting the PTW 500 tungsten electrode (continued) EN... and adjust tungsten electrode Fix the tungsten electrode in place using the torch cap Adjusting the PTW 3500 tungsten electrode Loosen the torch cap - caution, the tungsten electrode may fall out of the plasma torch if the torch is in a particular position. Place adjusting gauge onto plasma nozzle... 3 4... and adjust tungsten electrode Fix the tungsten electrode in place using the torch cap
Start-up General WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: - these Operating Instructions - all the operating instructions for the system components, especially the safety rules Proper use The plasma torch is intended exclusively for plasma welding and plasma brazing. Utilisation 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 any damage resulting from such improper use. Utilisation in accordance with the intended purpose also comprises - following all the instructions in these operating instructions - carrying out all the specified inspection and servicing work Start-up. Mount plasma torch onto robot. Check plasma torch to see whether: - all parts are present - the parts have been correctly fitted NOTE! An incorrectly adjusted tungsten electrode can damage the plasma nozzle during commissioning. Adjust the tungsten electrode according to the plasma nozzle used and the application. 3. Adjust the tungsten electrode using the adjusting gauge 4. Connect the components of the plasma torch hosepack to the plasma device: - Current/shielding gas connection - Pilot flow cable - Cable for pilot flow mass/plasma gas - Water return hose - Water flow hose Pilot flow plus connection Pilot flow minus / plasma gas connection Cut-out box connections Water return connection Water flow connection Current/shielding gas connection Plasma torch hosepack: connections
Start-up (continued) 5. When starting up for the first time, make sure the gas flow is correct 6. Position plasma torch (adjust robot) 7. Purge shielding gas and plasma gas for at least 30 seconds NOTE! The plasma torch must be cooled constantly during operation. 8. Check that the cooling circuit on the plasma machine is functioning correctly, set the cooling unit to permanent operation (e.g. set-up menu on power source, parameter C-C =ON) EN NOTE! Igniting the pilot arc without presetting the plasma gas can damage the plasma nozzle, ceramic centring tube and tungsten electrode (all wearing parts). 9. Specify the plasma gas value (according to the diameter of the plasma nozzle and the application) 0. Ignite pilot arc Important! To reduce wear, the pilot arc should burn throughout the operation.. Start welding (depending on the application) 3
Loading limits dependent on the plasma gas flow rate General Loading limits for plasma welding/plasma brazing depend on the following factors: - Diameter of the plasma nozzle - Position of the tungsten electrode - Plasma gas flow rate The following loading limits apply to the standard tungsten electrode setting (see also Adjusting the tungsten electrode ). Loading limits dependent on the plasma gas flow rate For plasma welding, the values for the plasma gas flow rate and maximum welding current must lie within the set limits. An upper or lower exceed of these limits can change the plasma properties, e.g.: - Low plasma gas flow rate... soft plasma jet - High plasma gas flow rate... hard plasma jet ( plasma cutting ) Important! Do not exceed the upper or lower limits set for plasma gas values and max. welding current during operation. Important! The minimum coolant flow rate is l/min This table is only valid for the PTW 500 (electrode diameter.0 mm; d.c. 60%): Plasma nozzle Plasma gas flow rate Max. welding current 0.6 mm min.0.30 l/min 5 A 0.8 mm min.0.30 l/min 0 A mm min.0.30 l/min 8 A. mm min.0.30 l/min 35 A.4 mm min.0.30 l/min 45 A.6 mm min.0.30 l/min 50 A.8 mm min.0.30 l/min 50 A This table is only valid for the PTW 500: Plasma nozzle Plasma gas flow rate Max. welding current.5 mm min.0.30 l/min 60 A max.0.80 l/min 00 A.0 mm min.0.35 l/min 80 A max..00 l/min 0 A.5 mm min.0.45 l/min 0 A max..0 l/min 45 A 3.0 mm min.0.55 l/min 30 A max..30 l/min 50 A This table is only valid for the PTW 3500 in conjunction with a FK9000 cooling unit: 4
Loading limits dependent on the plasma gas flow rate (continued) Plasma nozzle Plasma gas flow rate Max. welding current.0 mm min..0 l/min 70 A.5 mm min..0 l/min 90 A 3. mm min..0 l/min 0 A 3.5 mm min..0 l/min 5 A 4.0 mm min..0 l/min 50 A EN Table is only valid for the PTW 3500 in conjunction with a CHILLY 5 cooling unit: Plasma nozzle Plasma gas flow rate Max. welding current.0 mm min..0 l/min 5 A.5 mm min..0 l/min 50 A 3. mm min..0 l/min 75 A 3.5 mm min..0 l/min 300 A 4.0 mm min..0 l/min 350 A Minimum plasma gas flow rate: Amount of gas at which the welding arc still remains stable. Important! Welding using a minimum plasma gas flow places a severe load on the plasma nozzle and should be avoided. Maximum plasma gas flow rate: - Amount of gas that makes working with the maximum welding current possible, depending on the plasma nozzle Maximum welding current: Welding current permitted when using a particular plasma nozzle, standard tungsten electrode setting and minimum or maximum plasma gas flow rate. Important! Use pure argon as plasma gas. The limit values listed above can only be obtained using pure argon. Loading limit example (PTW 500) In the case of a plasma nozzle with a diameter of.0 mm and a selected minimum plasma gas flow rate of 0.35 l/min, a maximum welding current of 80 A is permitted for the standard tungsten electrode setting. 5
Troubleshooting Safety WARNING! An electric shock can be fatal. Before carrying out any work on the plasma torch: - Switch the power source and plasma device mains switch to the O position - Disconnect power source and plasma device from the mains - Put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again Troubleshooting Pilot arc not igniting Cause: Tungsten electrode missing Remedy: Insert tungsten electrode Cause: Remedy: Cause: Remedy: Plasma nozzle and tungsten electrode too far apart Position tungsten electrode correctly Plasma nozzle and tungsten electrode touching or too close (short circuit between plasma nozzle and tungsten electrode) Position tungsten electrode correctly Copper droplets on the plasma nozzle after a brief period of welding Droplet formation on the plasma nozzle is a sign that the plasma nozzle has been badly damaged: due to excessive heat, the copper contained in the plasma nozzle is melting and leaking out. Cause: Loading values too high Remedy: Replace plasma nozzle, reduce load Increased plasma nozzle wear Cause: Insufficient cooling Remedy: Check the cooling circuit, increase the plasma gas flow, check for wear on the nozzle connection 6
Care, maintenance and disposal General Regular and preventive maintenance of the plasma torch is essential for problem-free operation. The plasma torch is subjected to high temperatures. The plasma torch therefore requires more frequent maintenance than other components in a plasma welding system. EN WARNING! An electric shock can be fatal. Before carrying out any work on the plasma torch: - Switch the power source and plasma device mains switch to the O position - Disconnect power source and plasma device from the mains - Put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again At every start-up - Check plasma torch, torch hosepack and current connections for signs of damage - Check gas and water connections for leaks - Check that the cooling unit used for cooling the plasma torch is functioning perfectly, monitor the water return amount in the coolant container, and bleed the cooling unit if necessary - Check that the wearing parts for the plasma torch are in perfect condition, and clean wearing parts before fitting them Monthly - If applicable, check filter in the cooling circuit for contamination - Check that coolant is pure; if there are any impurities, replace the coolant and rinse the plasma torch thoroughly several times by letting coolant flow into it and back out again NOTE! Deposits inside the plasma torch can cause high frequency arc-overs, thereby damaging the plasma torch - Dismantle the plasma torch and check for deposits/contamination Disposal Dispose of in accordance with the applicable national and local regulations. 7
Technical data PTW 500, PTW 500, PTW 3500 PTW 500 PTW 500 PTW 3500 Power range 0.5-50 A 3-50 A 3-350 A Maximum value at 60 % d.c. (duty cycle) 50 A - - Maximum value at 00 % d.c. (duty cycle) 35 A 50 A 350 A Pilot arc current 5 A 0 A 30 A Voltage measurement (V-Peak) 4 V 4 V 4 V Plasma gas/shielding gas (EN 439) Argon Argon Argon Hosepack length 4 m 4 / 6 m 4 / 6 m Electrode diameter mm,6-3, mm 4,8-6,4 mm Cooling system *) *) *) Coolant **) **) **) Cooling power ***) 500 W 700 / 000 W,7/,9 kw Min. coolant pressure 3.0 bar 3.0 bar 3.0 bar 43.50 psi 43.50 psi 43.50 psi Max. coolant pressure 5.5 bar 5.5 bar 5.5 bar 79.74 psi 79.74 psi 79.74 psi Minimum coolant flowrate.0 l/min.0 l/min.0 l/min *) Liquid cooling **) Original Fronius coolant ***) Minimum cooling power in accordance with standard IEC 60974- The product complies with standard IEC 60974-7 8
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