Safety
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 device and all system components.
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.
WARNING!
Danger from electric current due to defective system components and incorrect operation.
This can result in serious personal injury and damage to property.
All cables, leads and hosepacks must always be securely connected, undamaged and correctly insulated.
Only use adequately dimensioned cables, leads and hosepacks.
WARNING!
Risk of coolant escaping.
This can result in serious personal injury and damage to property.
When disconnecting a welding torch from the cooling unit or other system components, always seal the coolant hoses using the plastic seal attached to the torch.
WARNING!
Danger due to hot system components and/or equipment.
Can result in serious burns or scalding.
Before starting work, allow all hot system components and/or equipment to cool to +25°C/+77°F (e.g., coolant, water-cooled system components, wirefeeder drive motor, etc.)
Wear suitable protective equipment (e.g., heat-resistant gloves, safety goggles, etc.) if cooling down is not possible.
WARNING!
Danger from contact with toxic welding fumes.
This can result in serious personal injuries.
Always extract welding fumes.
Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least 20 m³ (169070.1 US gi) per hour at all times.
If in doubt, a safety engineer should be commissioned to check the pollution level in the workplace.
CAUTION!
Danger from operation without coolant.
This can result in damage to property.
Never operate water-cooled welding torches without coolant.
During welding, ensure that the coolant is circulating correctly – this will be the case for Fronius cooling units if a regular return flow of coolant can be seen in the coolant container of the cooling unit.
The manufacturer will not be liable for any damages due to non-observance of the above mentioned points. All claims against the warranty are void.
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 device and all system components.
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.
WARNING!
Danger from electric current due to defective system components and incorrect operation.
This can result in serious personal injury and damage to property.
All cables, leads and hosepacks must always be securely connected, undamaged and correctly insulated.
Only use adequately dimensioned cables, leads and hosepacks.
WARNING!
Risk of coolant escaping.
This can result in serious personal injury and damage to property.
When disconnecting a welding torch from the cooling unit or other system components, always seal the coolant hoses using the plastic seal attached to the torch.
WARNING!
Danger due to hot system components and/or equipment.
Can result in serious burns or scalding.
Before starting work, allow all hot system components and/or equipment to cool to +25°C/+77°F (e.g., coolant, water-cooled system components, wirefeeder drive motor, etc.)
Wear suitable protective equipment (e.g., heat-resistant gloves, safety goggles, etc.) if cooling down is not possible.
WARNING!
Danger from contact with toxic welding fumes.
This can result in serious personal injuries.
Always extract welding fumes.
Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least 20 m³ (169070.1 US gi) per hour at all times.
If in doubt, a safety engineer should be commissioned to check the pollution level in the workplace.
CAUTION!
Danger from operation without coolant.
This can result in damage to property.
Never operate water-cooled welding torches without coolant.
During welding, ensure that the coolant is circulating correctly – this will be the case for Fronius cooling units if a regular return flow of coolant can be seen in the coolant container of the cooling unit.
The manufacturer will not be liable for any damages due to non-observance of the above mentioned points. All claims against the warranty are void.
General
Device concept
The Robacta and Robacta Twin robot hose packs are available in numerous versions, and are used in automated series production. They are particularly suitable for welding steel and CrNi. Connections with external or internal water connections, as well as a large number of torch neck versions are available.
For hose pack lengths up to 6 metres (19 ft. 8.22 in.), the Robacta and Robacta Twin robot hose packs represent a low-cost alternative to the motorised Robacta Drive or Robacta Drive Twin robot hose packs.
Device concept
The Robacta and Robacta Twin robot hose packs are available in numerous versions, and are used in automated series production. They are particularly suitable for welding steel and CrNi. Connections with external or internal water connections, as well as a large number of torch neck versions are available.
For hose pack lengths up to 6 metres (19 ft. 8.22 in.), the Robacta and Robacta Twin robot hose packs represent a low-cost alternative to the motorised Robacta Drive or Robacta Drive Twin robot hose packs.
Control elements and connections
Controls and connections
1
* Collision box cable for connecting the cable to the BNC socket on the collision box. If the welding torch collides with an obstacle, the collision box stops the feeding movement of the robot and also stops the welding process.
** "Feeder inching" button for feeding in the filler wire with no accompanying flow of gas or current. As long as the feeder inching button is held down, the filler wire is fed in. The feeder inching speed depends on the length of time that the feeder inching button is held down (Fig. 2).
2
3
*** Start welding button
Controls and connections
1
* Collision box cable for connecting the cable to the BNC socket on the collision box. If the welding torch collides with an obstacle, the collision box stops the feeding movement of the robot and also stops the welding process.
** "Feeder inching" button for feeding in the filler wire with no accompanying flow of gas or current. As long as the feeder inching button is held down, the filler wire is fed in. The feeder inching speed depends on the length of time that the feeder inching button is held down (Fig. 2).
2
3
*** Start welding button
Installation and commissioning
Fitting the clamp/adjusting clip
IMPORTANT! The Robacta Twin comes with a clamp fitted as standard.
The Robacta clamp and Robacta adjusting clip are for fitting the Robacta hose pack to the robot or to the welding machine.
The adjusting clip supports TCP correction on the robot. The Robacta adjusting clip can be adjusted in such a way that the position of the arc is maintained during a corrective movement by the robot. The robot therefore needs no additional corrective movement in the x or y direction.
1
2
1
2
Fitting the clamp/adjusting clip
IMPORTANT! The Robacta Twin comes with a clamp fitted as standard.
The Robacta clamp and Robacta adjusting clip are for fitting the Robacta hose pack to the robot or to the welding machine.
The adjusting clip supports TCP correction on the robot. The Robacta adjusting clip can be adjusted in such a way that the position of the arc is maintained during a corrective movement by the robot. The robot therefore needs no additional corrective movement in the x or y direction.
1
2
1
2
Fitting the mounting bracket (standard)
WARNING!
Danger due to work that has been carried out incorrectly.
This may result in serious injury and damage to property.
This installation must only be carried out by trained and qualified personnel.
Observe the safety rules in the power source operating instructions.
IMPORTANT! Drill a Ø5.8 mm hole for the mounting bracket and use a reamer to enlarge the hole so it can accommodate the dowel pin (Ø6G7).
IMPORTANT! The mounting bracket must be fitted using an M8 shoulder screw and an M6 screw. After screwing the mounting bracket in place, another dowel pin (Ø6 mm) must bei driven in to secure it.
1
2
3
Fitting the mounting bracket (individually)
WARNING!
Danger due to work that has been carried out incorrectly.
This may result in serious injury and damage to property.
This installation must only be carried out by trained and qualified personnel.
Observe the safety rules in the power source operating instructions.
IMPORTANT! Drill a Ø5.8 mm hole for the mounting bracket and use a reamer to enlarge the hole so it can accommodate the dowel pin (Ø6G7).
IMPORTANT! The mounting bracket must be fitted using an M8 shoulder screw. The required bracket must then be positioned and two dowel pins (Ø6 mm) driven in to secure it.
1
2
3
Robacta torch necks - dismantling and assembling
NOTE!
Risk of coolant escaping through loose union nut.
When fitting the torch neck, ensure that the union nut is securely fastened: Tighten union nut using a flat spanner.
For a defined, reproducible tightening torque, use a flat spanner and torque wrench, ideal tightening torque = 18 ±2 Nm.
1
2
3
4
5
Dismantling and assembling Robacta Twin torch necks
NOTE!
Risk of coolant escaping through loose union nuts.
When fitting the Twin torch neck, ensure that the union nuts are securely fastened: Tighten union nuts using flat spanner and torque wrench, tightening torque = 18 ±2 Nm.
IMPORTANT! When connecting and terminating lines, observe the following sequence:
- Blow-out line x.1
- Water flow x.2 (blue)
- Water return x.3 (red)
1
2
3
4
5
6
Dismantling and assembling Robacta Twin Compact Pro torch necks
Connecting the robot hose pack
NOTE!
Shielding gas mixed with extraneous air has an adverse effect on welding results.
The end of the hose must be sealed off with the stopper supplied if the torch blow-off connection is not in use
Do not connect the hose if no compressed air is connected to the solenoid valve for the blow-off function. Seal hose with stopper.
1
* Connection for torch blow-off option
Correct laying of the robot hose pack
To attain optimum wirefeed, observe the following when laying the hose pack:
- Do not kink the hose pack
- Arrange the hose pack in as straight a line as possible
- Do not overstretch the hose pack, especially in robot mode
- Keep bends in the hose pack as wide as possible
- Use balancers and hose pack holders (e.g.: Universal hose pack holder)
Replacing the gas nozzle Robacta 160 / 300 / 500 Robacta 700 / 700 Time
NOTE!
Risk of damage if the gas nozzle is removed or replaced incorrectly.
Damage to the O-rings may result.
Always open the union nut before removing or replacing the gas nozzle.
IMPORTANT! When replacing the gas nozzle, ensure that the holes on the perforated ring are positioned exactly over the holes in the torch body. Otherwise, sufficient cooling of the gas nozzle cannot be guaranteed.
1
2
* specified direction of rotation
3
* specified direction of rotation
4
Replacing welding torch wearing parts - Robacta
1
Robacta 160
2
Robacta 280
3
Robacta 300 / 500
4
Robacta 400
5
Robacta 700 / 700 TIME
6
Robacta 2500
7
Robacta 5000
Replacing components Robacta Twin Compact Pro
CAUTION!
Danger due to strongly heated welding torch or hot coolant.
This can result in burns.
The exchange of the components as well as the cleaning and check of the components may only occur in the cooled-down state of the welding torch.
NOTE!
Risk of serious physical damage.
It is imperative that the sequence of work steps is complied with and the torques specified adhered to.
1
2
3
4
* A torque wrench and the matching socket wrench are available instead of the tool supplied as standard. This ensures that it is possible to tighten the components with the torque specified. See spare parts list for item number.
Replacing welding torch wearing parts Robacta Twin
IMPORTANT! Always use two identical contact tubes.
NOTE!
Risk of serious damage.
ALWAYS observe the work sequence and the specified torques.
1
2
3
4
* Instead of the standard tool provided, a torque wrench and appropriate box spanner are also available. This ensures that the components can be tightened to the specified torque. For item numbers, see spare parts list.
Standard values for steel liners
IMPORTANT! Inner liners are supplied in overlengths.
Use bare steel liner
* recommended
Fitting the steel liner Robacta 280 / 400 Robacta 2500 / 5000 Robacta Twin
Torch neck with nozzle fitting screwed on
NOTE!
When cutting the liner to length, make sure that
no flash protrudes into the liner
Place the cutting pliers at a slight angle (flash is pulled outwards)
File down any flash
1
2
3
4
* Contact tube with centre hole
** Contact tube without centre hole
** Contact tube without centre hole
5
Fitting the steel liner Robacta 160 / 300 / 500 Robacta 700 / 700 Time
Torch neck with no nozzle fitting screwed on
NOTE!
When cutting the liner to length, make sure that
no flash protrudes into the liner
Place the cutting pliers at a slight angle (flash is pulled outwards)
File down any flash
1
2
3
4
* Contact tube with centre hole
** Contact tube without centre hole
** Contact tube without centre hole
5
6
* Contact tube with centre hole
** Contact tube without centre hole
** Contact tube without centre hole
Standard values for graphite combination liners and Teflon liners
NOTE!
For aluminium applications, choose the next largest contact tube diameter.
IMPORTANT! Inner liners are supplied in overlengths.
Graphite combination liners
Teflon liners
Fitting plastic liners (Fronius connection with no wirefeeding nozzle)
applies to:
Teflon liners
Combination liners
Graphite liners
NOTE!
Feed the inner liner as close to the feed rollers as possible, but do not let them touch.
NOTE!
Before feeding in the filler wire, round off the end of the wire.
1
2
3
4
5
6
Fitting plastic liners (Fronius connection with wirefeeding nozzle)
applies to:
Teflon liners
Combination liners
Graphite liners
NOTE!
Guide the wirefeeding nozzle as close to the feed rollers as possible, but do not let them touch.
NOTE!
Before feeding in the filler wire, round off the end of the wire.
1
* Plastic component - do not overtighten!
2
3
* Plastic component - do not overtighten!
4
5
Fitting plastic liner (Euro connection)
applies to:
Teflon liners
Combination liners
Graphite liners
NOTE!
Feed the inner liner or inlet nozzle as close to the feed rollers as possible, but do not let them touch.
NOTE!
Before feeding in the filler wire, round off the end of the wire.
1
2
3
4
* Inlet nozzle option (42,0001,5621)
5
6
Care, maintenance and disposal
Care, maintenance and disposal
Regular preventive maintenance of the welding torch is essential for problem-free operation. The welding torch is subjected to high temperatures and heavy soiling. The welding torch therefore requires more frequent maintenance than other components in the welding system.
IMPORTANT! When removing welding spatter, avoid scoring or scratching the torch. Future welding spatter may become firmly lodged in score or scratch marks.
- Do NOT bend the torch neck
Care, maintenance and disposal
Regular preventive maintenance of the welding torch is essential for problem-free operation. The welding torch is subjected to high temperatures and heavy soiling. The welding torch therefore requires more frequent maintenance than other components in the welding system.
IMPORTANT! When removing welding spatter, avoid scoring or scratching the torch. Future welding spatter may become firmly lodged in score or scratch marks.
- Do NOT bend the torch neck
Every start-up
- Check the contact tube
- Replace worn out contact tube
- Remove welding spatter from gas nozzle (e.g. manually, by blowing off, or by using a Robacta Reamer or Robacta TC 1000)
- If there is dirt that cannot be removed from around the nozzle join, replace the gas nozzle
- Check the water connections for leaks
- Monitor the water return level in the coolant container and vent the cooling unit if necessary
* Check spatter guard or insulation for damage
Every time the wirespool is changed
- Recommended: replace inner liner
- Clean wirefeeding hose with reduced compressed air
- Clean wearing parts before fitting
- Dispose of in accordance with the applicable national and local regulations.
Recognising faulty wearing parts
- Insulating parts
- Notches
- Burned off or torn middle bar
- Scorched or torn-off shoulders
- Nozzle fittings
- Notches and burns on the front edge
- heavily covered in welding spatter
- Spatter guard
- Burned-off outside edges, notches
- Contact tubes
- Worn out (oval) wire entry and wire exit holes
- Heavily covered in welding spatter
- Burns on the tip of the contact tube
Disposal
Waste electrical and electronic equipment must be collected separately and recycled in an environmentally responsible manner in accordance with the EU Directive and national law. Used equipment must be returned to the distributor or through a local, authorised collection and disposal system. Correct disposal of the used device promotes sustainable recycling of resources and prevents negative effects on health and the environment.
Packaging materials- Collect separately
- Observe locally valid regulations
- Compress the cardboard box to reduce volume
Troubleshooting
Troubleshooting
No welding current
Mains switch is on, indicators on the power source are lit, shielding gas availableNetzschalter eingeschaltet, Anzeigen an der Stromquelle leuchten, Schutzgas vorhanden
| Cause: | Incorrect earth (ground) connection |
| Remedy: | Check the earth (ground) connection and clamp for correct polarity |
| Cause: | There is a break in the current cable in the welding torch |
| Remedy: | Replace the torch |
No shielding gas
All other functions are OK
| Cause: | The gas cylinder is empty |
| Remedy: | Change the gas cylinder |
| Cause: | Gas pressure regulator is faulty |
| Remedy: | Change the gas pressure regulator |
| Cause: | The gas hose is not connected, or is damaged or kinked |
| Remedy: | Connect/replace the gas hose, or straighten out kinks |
| Cause: | The welding torch is defective |
| Remedy: | Replace welding torch |
| Cause: | Gas solenoid valve is defective |
| Remedy: | Replace gas solenoid valve |
Poor welding properties
| Cause: | Incorrect welding parameters |
| Remedy: | Check the settings |
| Cause: | Poor connection to earth (ground) |
| Remedy: | Ensure good contact to workpiece |
| Cause: | Not enough shielding gas, or none at all |
| Remedy: | Check the pressure regulator, gas hose, gas solenoid valve and torch gas connection. |
| Cause: | Welding torch is leaking |
| Remedy: | Replace welding torch |
| Cause: | Contact tube is too large or worn out |
| Remedy: | Change the contact tube |
Poor welding properties
| Cause: | Wrong wire alloy or wrong wire diameter |
| Remedy: | Check the wirespool that has been inserted |
| Cause: | Wrong wire alloy or wrong wire diameter |
| Remedy: | Check weldability of the base material |
| Cause: | The shielding gas is not suitable for this wire alloy |
| Remedy: | Use the correct shielding gas |
| Cause: | Unfavourable welding conditions: shielding gas is contaminated (by moisture, air), inadequate gas shielding (weld pool „boiling“, draughts), contaminants in the workpiece (rust, paint, grease) |
| Remedy: | Optimise the welding conditions |
| Cause: | Welding spatter in the gas nozzle |
| Remedy: | Remove welding spatter |
Poor welding properties
| Cause: | Turbulence caused by too high a rate of shielding gas flow |
| Remedy: | Reduce amount of shielding gas, recommended shielding gas quantity (l/min) = wire diameter (mm) x 10 (e.g. 16 l/min for 1.6 mm filler wire) |
| Cause: | Too large a distance between the welding torch and the workpiece. |
| Remedy: | Reduce the distance between the welding torch and the workpiece (recommended: 10-15 mm) |
| Cause: | Tilt angle of the welding torch is too great |
| Remedy: | Reduce the tilt angle of the welding torch |
| Cause: | Wirefeed components have incorrect diameter |
| Remedy: | Use wirefeed components with correct diameter |
Poor wirefeed
| Cause: | The braking force has been set too high |
| Remedy: | Reduce the braking force |
| Cause: | Hole in the contact tube is displaced |
| Remedy: | Change the contact tube |
| Cause: | Faulty wire feed liner in torch |
| Remedy: | Check the wire feed liner for kinks, dirt, etc. |
| Cause: | The wirefeed rollers are not suitable for the filler wire being used |
| Remedy: | Use suitable wirefeed rollers |
| Cause: | Feed rollers have the wrong contact pressure |
| Remedy: | Adjust the contact pressure |
| Cause: | The wirefeed rollers are soiled or damaged |
| Remedy: | Clean the wirefeed rollers or exchange them for new ones |
| Cause: | Inner liner wrongly laid or kinked |
| Remedy: | Replace inner liner |
| Cause: | Inner liner or wire inlet nozzle wrongly dimensioned |
| Remedy: | Ensure inner liner or wire inlet nozzle are correctly dimensioned |
| Cause: | Inner liner was kinked while being inserted |
| Remedy: | When inserting the inner liner, only handle it around the infeed tub |
| Cause: | AlSi filler wire: Filler wire damaged by the bronze insert |
| Remedy: | Teflon liner must reach the contact tube |
| Cause: | The inner liner has been cut too short |
| Remedy: | Replace the inner liner and cut it to the correct length |
| Cause: | Welding wire worn due to overly heavy contact pressure at the feed rollers |
| Remedy: | Reduce contact pressure at the feed rollers |
| Cause: | Filler wire contains impurities / corroded |
| Remedy: | Use high-quality filler wire with no impurities |
The welding torch becomes very hot
| Cause: | Loose union nut on central connector |
| Remedy: | Tighten the union nut |
| Cause: | The welding torch has been operated beyond its maximum number of amps. |
| Remedy: | Reduce welding power or use a higher capacity torch |
| Cause: | The design dimensions of the torch are not sufficient for this task |
| Remedy: | Observe the duty cycle and loading limits |
| Cause: | Only on water-cooled machines: Water flow rate is insufficient |
| Remedy: | Check water level, water flow rate and cleanliness, and arrangement of hose pack, etc. |
Contact tube only has a short service life
| Cause: | Wrong feed rollers |
| Remedy: | Use correct feed rollers |
| Cause: | Welding wire worn due to overly heavy contact pressure at the feed rollers |
| Remedy: | Reduce contact pressure at the feed rollers |
| Cause: | Filler wire contains impurities / corroded |
| Remedy: | Use high-quality filler wire with no impurities |
| Cause: | Uncoated filler wire |
| Remedy: | Use filler wire with suitable coating |
| Cause: | Wrong dimension of contact tube |
| Remedy: | Use a contact tube of the correct dimension |
| Cause: | Duty cycle of welding torch has been exceeded |
| Remedy: | Shorten the ON times or use a higher capacity torch |
| Cause: | Contact tube has overheated. No thermal dissipation, as the contact tube is loose |
| Remedy: | Tighten the contact tube |
NOTE!When using CrNi, the contact tube may be subject to a higher degree of wear due to the nature of the surface of CrNi welding wire. | |
Feeder inching button malfunction
| Cause: | Plug-in connections of „feeder inching button/control line/power source“ faulty |
| Remedy: | Check plug-in connection / have power source or welding torch serviced |
| Cause: | Control line is faulty |
| Remedy: | Replace control line / have welding torch repaired |
Weld seam porosity
| Cause: | Spattering in the gas nozzle, causing inadequate gas-shielding of the weld seam |
| Remedy: | Remove welding spatter |
| Cause: | Either the shielding gas hose has holes in it, or the hose is not connected properly |
| Remedy: | Replace shielding gas hose |
| Cause: | The O-ring seals on the connection points have been cut through or are faulty |
| Remedy: | Change the O-ring seals |
| Cause: | Moisture/condensation in the shielding gas line |
| Remedy: | Dry shielding gas line |
| Cause: | Shielding gas flow is either too high or too low |
| Remedy: | Correct the shielding gas flow |
| Cause: | Insufficient shielding gas flow when welding starts or finishes |
| Remedy: | Increase gas pre-flow or gas post-flow |
| Cause: | Rusty or poor quality filler wire |
| Remedy: | Use high-quality filler wire with no impurities |
| Cause: | Too much parting agent applied |
| Remedy: | Remove superfluous parting agent / apply less parting agent |
Troubleshooting
No welding current
Mains switch is on, indicators on the power source are lit, shielding gas availableNetzschalter eingeschaltet, Anzeigen an der Stromquelle leuchten, Schutzgas vorhanden
| Cause: | Incorrect earth (ground) connection |
| Remedy: | Check the earth (ground) connection and clamp for correct polarity |
| Cause: | There is a break in the current cable in the welding torch |
| Remedy: | Replace the torch |
No shielding gas
All other functions are OK
| Cause: | The gas cylinder is empty |
| Remedy: | Change the gas cylinder |
| Cause: | Gas pressure regulator is faulty |
| Remedy: | Change the gas pressure regulator |
| Cause: | The gas hose is not connected, or is damaged or kinked |
| Remedy: | Connect/replace the gas hose, or straighten out kinks |
| Cause: | The welding torch is defective |
| Remedy: | Replace welding torch |
| Cause: | Gas solenoid valve is defective |
| Remedy: | Replace gas solenoid valve |
Poor welding properties
| Cause: | Incorrect welding parameters |
| Remedy: | Check the settings |
| Cause: | Poor connection to earth (ground) |
| Remedy: | Ensure good contact to workpiece |
| Cause: | Not enough shielding gas, or none at all |
| Remedy: | Check the pressure regulator, gas hose, gas solenoid valve and torch gas connection. |
| Cause: | Welding torch is leaking |
| Remedy: | Replace welding torch |
| Cause: | Contact tube is too large or worn out |
| Remedy: | Change the contact tube |
Poor welding properties
| Cause: | Wrong wire alloy or wrong wire diameter |
| Remedy: | Check the wirespool that has been inserted |
| Cause: | Wrong wire alloy or wrong wire diameter |
| Remedy: | Check weldability of the base material |
| Cause: | The shielding gas is not suitable for this wire alloy |
| Remedy: | Use the correct shielding gas |
| Cause: | Unfavourable welding conditions: shielding gas is contaminated (by moisture, air), inadequate gas shielding (weld pool „boiling“, draughts), contaminants in the workpiece (rust, paint, grease) |
| Remedy: | Optimise the welding conditions |
| Cause: | Welding spatter in the gas nozzle |
| Remedy: | Remove welding spatter |
Poor welding properties
| Cause: | Turbulence caused by too high a rate of shielding gas flow |
| Remedy: | Reduce amount of shielding gas, recommended shielding gas quantity (l/min) = wire diameter (mm) x 10 (e.g. 16 l/min for 1.6 mm filler wire) |
| Cause: | Too large a distance between the welding torch and the workpiece. |
| Remedy: | Reduce the distance between the welding torch and the workpiece (recommended: 10-15 mm) |
| Cause: | Tilt angle of the welding torch is too great |
| Remedy: | Reduce the tilt angle of the welding torch |
| Cause: | Wirefeed components have incorrect diameter |
| Remedy: | Use wirefeed components with correct diameter |
Poor wirefeed
| Cause: | The braking force has been set too high |
| Remedy: | Reduce the braking force |
| Cause: | Hole in the contact tube is displaced |
| Remedy: | Change the contact tube |
| Cause: | Faulty wire feed liner in torch |
| Remedy: | Check the wire feed liner for kinks, dirt, etc. |
| Cause: | The wirefeed rollers are not suitable for the filler wire being used |
| Remedy: | Use suitable wirefeed rollers |
| Cause: | Feed rollers have the wrong contact pressure |
| Remedy: | Adjust the contact pressure |
| Cause: | The wirefeed rollers are soiled or damaged |
| Remedy: | Clean the wirefeed rollers or exchange them for new ones |
| Cause: | Inner liner wrongly laid or kinked |
| Remedy: | Replace inner liner |
| Cause: | Inner liner or wire inlet nozzle wrongly dimensioned |
| Remedy: | Ensure inner liner or wire inlet nozzle are correctly dimensioned |
| Cause: | Inner liner was kinked while being inserted |
| Remedy: | When inserting the inner liner, only handle it around the infeed tub |
| Cause: | AlSi filler wire: Filler wire damaged by the bronze insert |
| Remedy: | Teflon liner must reach the contact tube |
| Cause: | The inner liner has been cut too short |
| Remedy: | Replace the inner liner and cut it to the correct length |
| Cause: | Welding wire worn due to overly heavy contact pressure at the feed rollers |
| Remedy: | Reduce contact pressure at the feed rollers |
| Cause: | Filler wire contains impurities / corroded |
| Remedy: | Use high-quality filler wire with no impurities |
The welding torch becomes very hot
| Cause: | Loose union nut on central connector |
| Remedy: | Tighten the union nut |
| Cause: | The welding torch has been operated beyond its maximum number of amps. |
| Remedy: | Reduce welding power or use a higher capacity torch |
| Cause: | The design dimensions of the torch are not sufficient for this task |
| Remedy: | Observe the duty cycle and loading limits |
| Cause: | Only on water-cooled machines: Water flow rate is insufficient |
| Remedy: | Check water level, water flow rate and cleanliness, and arrangement of hose pack, etc. |
Contact tube only has a short service life
| Cause: | Wrong feed rollers |
| Remedy: | Use correct feed rollers |
| Cause: | Welding wire worn due to overly heavy contact pressure at the feed rollers |
| Remedy: | Reduce contact pressure at the feed rollers |
| Cause: | Filler wire contains impurities / corroded |
| Remedy: | Use high-quality filler wire with no impurities |
| Cause: | Uncoated filler wire |
| Remedy: | Use filler wire with suitable coating |
| Cause: | Wrong dimension of contact tube |
| Remedy: | Use a contact tube of the correct dimension |
| Cause: | Duty cycle of welding torch has been exceeded |
| Remedy: | Shorten the ON times or use a higher capacity torch |
| Cause: | Contact tube has overheated. No thermal dissipation, as the contact tube is loose |
| Remedy: | Tighten the contact tube |
NOTE!When using CrNi, the contact tube may be subject to a higher degree of wear due to the nature of the surface of CrNi welding wire. | |
Feeder inching button malfunction
| Cause: | Plug-in connections of „feeder inching button/control line/power source“ faulty |
| Remedy: | Check plug-in connection / have power source or welding torch serviced |
| Cause: | Control line is faulty |
| Remedy: | Replace control line / have welding torch repaired |
Weld seam porosity
| Cause: | Spattering in the gas nozzle, causing inadequate gas-shielding of the weld seam |
| Remedy: | Remove welding spatter |
| Cause: | Either the shielding gas hose has holes in it, or the hose is not connected properly |
| Remedy: | Replace shielding gas hose |
| Cause: | The O-ring seals on the connection points have been cut through or are faulty |
| Remedy: | Change the O-ring seals |
| Cause: | Moisture/condensation in the shielding gas line |
| Remedy: | Dry shielding gas line |
| Cause: | Shielding gas flow is either too high or too low |
| Remedy: | Correct the shielding gas flow |
| Cause: | Insufficient shielding gas flow when welding starts or finishes |
| Remedy: | Increase gas pre-flow or gas post-flow |
| Cause: | Rusty or poor quality filler wire |
| Remedy: | Use high-quality filler wire with no impurities |
| Cause: | Too much parting agent applied |
| Remedy: | Remove superfluous parting agent / apply less parting agent |
Technical data
Torch necks
Explanation of symbols:
 | water-cooled torch neck |
X | Duty cycle in % |
ED* | Duty cycle |
Imax | max. welding current in A |
(M6) | with contact tube M6 |
(M8) | with contact tube M8 |
 | Electrode diameter |
- for mechanically driven welding torches: 141 V
This product conforms to the requirements of IEC 60974-7.
| |
| Robacta 160 | Robacta 280 | Robacta 300 | Robacta 400 |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | - | |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | - | |
| [mm] | 0,8 - 1,2 | 0,8 - 1,2 | 0,8 - 1,2 | 0,8 - 1,2 |
| |
| Robacta 500 | Robacta 700 | Robacta 700 TIME | Robacta 2500 |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | - | |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | - | |
| [mm] | 0,8 - 1,6 | 1,0 - 1,6 | 1,0 - 1,6 | 0,8 - 1,2 |
| |
| Robacta 5000 | Robacta 7000 | MTW 500-M | Laser HD/W |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | - | |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | - | |
| [mm] | 0,8 - 1,6 | 1,0 - 1,6 | 0,8 - 1,6 | 1,0 - 1,6 |
| |
| Robacta Twin Single 300 | Robacta Twin 500 | Robacta Twin | Robacta Twin |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | - | |
| [mm] | 0,8 - 1,2 | 0,8 - 1,6 | 0,8 - 1,2 | 1,0 - 1,6 |
| |
| Robacta Twin 900 Compact | Robacta Twin Compact PRO | ||
X / I max (10 min / 40°C) | [%] / [A] | - | - | |||
| [mm] | 1,0 - 1,6 | 1,0 - 1,6 |
| |
| MTB 500d W/R | MTB 350d W/R | MTB 330d W/R | |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | ||
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | ||
| [mm] | 1,0 - 1,6 | 0,8 - 1,6 | 0,8 - 1,6 |
| |
| MTB 400d G/R | MTB 350d G/R | MTB 330d G/R | |
X / I max (10 min / 40°C) | [%] / [A] | 40 / ED* 400 | 40 / ED* 350 | 40 / ED* 330 | ||
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | ||
| [mm] | 0,8 - 1,6 | 0,8 - 1,6 | 0,8 - 1,6 |
Torch necks
Explanation of symbols:
| water-cooled torch neck |
X | Duty cycle in % |
ED* | Duty cycle |
Imax | max. welding current in A |
(M6) | with contact tube M6 |
(M8) | with contact tube M8 |
| Electrode diameter |
- for mechanically driven welding torches: 141 V
This product conforms to the requirements of IEC 60974-7.
| |
| Robacta 160 | Robacta 280 | Robacta 300 | Robacta 400 |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | - | |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | - | |
| [mm] | 0,8 - 1,2 | 0,8 - 1,2 | 0,8 - 1,2 | 0,8 - 1,2 |
| |
| Robacta 500 | Robacta 700 | Robacta 700 TIME | Robacta 2500 |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | - | |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | - | |
| [mm] | 0,8 - 1,6 | 1,0 - 1,6 | 1,0 - 1,6 | 0,8 - 1,2 |
| |
| Robacta 5000 | Robacta 7000 | MTW 500-M | Laser HD/W |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | - | |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | - | |
| [mm] | 0,8 - 1,6 | 1,0 - 1,6 | 0,8 - 1,6 | 1,0 - 1,6 |
| |
| Robacta Twin Single 300 | Robacta Twin 500 | Robacta Twin | Robacta Twin |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | - | |
| [mm] | 0,8 - 1,2 | 0,8 - 1,6 | 0,8 - 1,2 | 1,0 - 1,6 |
| |
| Robacta Twin 900 Compact | Robacta Twin Compact PRO | ||
X / I max (10 min / 40°C) | [%] / [A] | - | - | |||
| [mm] | 1,0 - 1,6 | 1,0 - 1,6 |
| |
| MTB 500d W/R | MTB 350d W/R | MTB 330d W/R | |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | ||
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | ||
| [mm] | 1,0 - 1,6 | 0,8 - 1,6 | 0,8 - 1,6 |
| |
| MTB 400d G/R | MTB 350d G/R | MTB 330d G/R | |
X / I max (10 min / 40°C) | [%] / [A] | 40 / ED* 400 | 40 / ED* 350 | 40 / ED* 330 | ||
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | ||
| [mm] | 0,8 - 1,6 | 0,8 - 1,6 | 0,8 - 1,6 |
Hosepacks
Explanation of symbols:
| Water cooling |
 | Length of the hosepack |
X | Duty cycle in % |
Imax | max. welding current in A |
| Electrode diameter |
* | Lowest cooling power as per IEC 60974-2, depends on the length of the hosepack |
- for mechanically driven welding torches: 141 V
This product conforms to the requirements of IEC 60974-7.
| |
| Robacta | Robacta W/CB-PAP | |
X / I max (10 min / 40°C) | [%] / [A] | - | - | ||
X / I max (10 min / 40°C) | [%] / [A] | - | - | ||
| [mm] | 0,8 - 1,6 | 0,8 - 1,6 | ||
Pmin* |
 | [m] ([W]) | 1,2 (1100) / 1,5 (1300) /1,75 (1400) / 2,5 (1400) / 3,5 (1700) / 4,5 (2100) | 1,19 (550) / 1,30 (550) / 1,33 (550) / 1,38 (550) / 1,39 (600) / 1,41 (600) / 1,43 (600) / 1,44 (600) / 1,46 (600) / 1,48 (600) / 1,51 (600) / 1,59 (650) / 1,60 (650) / 1,65 (650) / 1,67 (650) / 1,68 (650) / 1,72 (650) / 1,80 (700) | |
Qmin | | [L/min] | 1 | 1 | |
Pmin | | [bar] | 3 | 3 | |
Qmin | | [bar] | 5,5 | 5,5 | |
| | Robacta Twin | Robacta Twin | Robacta Twin | ||
 | ||||||
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | ||
| [mm] | 0,8 - 1,2 | 0,8 - 1,2 | 0,8 - 1,6 | ||
Pmin* |
| [m] ([W]) | 1,6 (1400) / | 4,5 (2000) | 1,6 (1400) / 2,6 (1900) | |
Qmin | | [L/min] | 1 | 1 | 1 | |
Pmin | | [bar] | 3 | 3 | 3 | |
Pmax | | [bar] | 5,5 | 5,5 | 5,5 | |