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 electric current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all the devices and components involved and disconnect them from the grid.
Secure all the devices and components involved to prevent unintentional restarting.
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!
Danger due to emerging wire electrode.
This can result in serious personal injuries.
Hold the welding torch so that the tip of the welding torch points away from the face and body.
Wear suitable protective goggles.
Do not point the welding torch at people.
Ensure that the wire electrode does not touch any electrically conductive objects.
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 electric current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all the devices and components involved and disconnect them from the grid.
Secure all the devices and components involved to prevent unintentional restarting.
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!
Danger due to emerging wire electrode.
This can result in serious personal injuries.
Hold the welding torch so that the tip of the welding torch points away from the face and body.
Wear suitable protective goggles.
Do not point the welding torch at people.
Ensure that the wire electrode does not touch any electrically conductive objects.
Installation and commissioning
Device concept
The gas-cooled robot hose pack Robacta features small dimensions ensuring optimum access, low weight, high serviceability and lossfree gas flow control. The components have been designed especially for application in the lower and medium performance range. Therefore, all components are perfectly suitable for light gauge sheet metal applications.
The robot torch necks MTG 2500/3200/4000 are provided with a revolutionary coupling system as well as mechanical lock of the gas jet. This mechanical lock prevents any loosening of the gas jets during welding.
Device concept
The gas-cooled robot hose pack Robacta features small dimensions ensuring optimum access, low weight, high serviceability and lossfree gas flow control. The components have been designed especially for application in the lower and medium performance range. Therefore, all components are perfectly suitable for light gauge sheet metal applications.
The robot torch necks MTG 2500/3200/4000 are provided with a revolutionary coupling system as well as mechanical lock of the gas jet. This mechanical lock prevents any loosening of the gas jets during welding.
Fitting the holding clip and torch neck
CAUTION!
Danger from tightening the torch neck with excessive torque.
Destruction of coupling point can be the result.
Fasten the torch neck at the specified torque to prevent charring of the coupling point.
NOTE!
Before fitting the torch neck make sure that the coupling point is not contaminated. The torch neck can only be fitted and removed when the fitting wrench is removed.
IMPORTANT! Do not turn the fitting wrench any more than 1 - 1.5 turns when undoing the torch neck fastening screw. Do not turn it any further than it will go.
NOTE!
To avoid a damage of the Robacta G, tighten the fastening screws of the torch neck not without the torch neck.
* Connector switch-off unit
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Fitting the mounting bracket (standard)
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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 be driven in to secure it.
Fitting the mounting bracket (individually)
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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.
Fitting the wire guide core (Fronius)
IMPORTANT! When cutting the wire guide core, ensure that
- no burr juts out into the wire guide core on cutting
- place the side cutter slightly at an angle (burr is pulled outward)
- grind the burr off
* Use only clamping nuts suitable for the relevant wire size. |
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Fitting the wire guide core (Euro)
IMPORTANT! When cutting the wire guide core, ensure that
- no burr juts out into the wire guide core on cutting
- place the side cutter slightly at an angle (burr is pulled outward)
- grind the burr off
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Replacing the torch neck
CAUTION!
Danger of burning because of extremely hot torch.
This can result in serious personal injury and damage to property.
For replacing of components as well as cleaning and checking of components make sure that the torch has cooled down.
CAUTION!
Danger from tightening the torch neck with excessive torque.
Destruction of coupling point can be the result.
Fasten the torch neck at the specified torque to prevent charring of the coupling point.
To avoid a damage of the Robacta coupling point do not fastening the torch neck fixing screws without the torch neck.
** IMPORTANT! The torch neck can only be fitted and removed when the fitting wrench is removed. |
* IMPORTANT! Do not turn the fitting wrench any more than 1 - 1.5 turns when undoing the torch neck fastening screw. Do not turn it any further than it will go. |
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Connecting the robot hose pack
IMPORTANT! Make sure to seal the hose end by means of the enclosed plug, if the port for the torch blow-out unit is not used. Otherwise the inert gas will get mixed with outside air, which may adversely affect the welding results.
* Port for torch blow-out unit (depending on the variant)
MTG 2500 - Replacing the components
CAUTION!
Danger of burning because of extremely hot torch.
This can result in serious injury.
For replacing of components as well as cleaning and checking of components make sure that the torch has cooled down.
* gas nozzle plugged
** gas nozzle screwed
*** Key for bayonet (optional). This tool facilitates loosening and tightening of the gas jet locking mechanism.
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MTG 3200 / 4000 - Replacing the components
CAUTION!
Danger of burning because of extremely hot torch.
This can result in serious injury.
For replacing of components as well as cleaning and checking of components make sure that the torch has cooled down.
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MTG 4000
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Care, maintenance and disposal
Generai informations
Regular preventive maintenance of the welding torch is essential if troublefree operation is to be ensured. The welding torch is subjected to high temperatures and heavy soiling. For this reason, the torch needs more frequent maintenance than other components of the welding system.
IMPORTANT! When removing welding spatter, avoid making any drag-lines and scratches. Future welding spatter could get lodged firmly in these.
- Do NOT bend the torch neck
Generai informations
Regular preventive maintenance of the welding torch is essential if troublefree operation is to be ensured. The welding torch is subjected to high temperatures and heavy soiling. For this reason, the torch needs more frequent maintenance than other components of the welding system.
IMPORTANT! When removing welding spatter, avoid making any drag-lines and scratches. Future welding spatter could get lodged firmly in these.
- Do NOT bend the torch neck
Every time before starting up
- Check the contact tube
- If the contact tube is worn out, exchange it for a new one
- Clean welding spatter out of the gas nozzle
- If the plug-on zone is so badly soiled that the soiling cannot be removed, exchange the gas nozzle for a new one
* Check the spatter-guard and all insulation pieces for damage |
Every time the wirespool is exchanged
- Recommended: Exchange the inner liner
- Clean the wirefeed hose with reduced-blow compressed air
- Clean all wearing parts before fitting them
Disposal
Waste electrical and electronic equipment must be collected separately and recycled in an environmentally-friendly way, in accordance with the European Directive and national legislation. Used equipment must be returned to the distributor or disposed of via an approved local collection and disposal facility. Correct disposal of used equipment promotes the sustainable recycling of material resources. Failing to dispose of used equipment correctly can lead to adverse health and/or environmental impacts.
Packaging materials
Separate collection according to material. Check your local authority regulations. Crush containers to reduce size.
Troubleshooting
Troubleshooting
Troubleshooting
No welding current
Mains switch ON, indicators on the power source are lit up, shielding gas flows
| Cause: | Faulty 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: | Change the torch |
No protective gas shield
All other functions are OK
| Cause: | Gas cylinder is empty |
| Remedy: | Change the gas cylinder |
| Cause: | The gas pressure regulator is faulty |
| Remedy: | Replace the gas pressure regulator |
| Cause: | Gas hose is not fitted or is damaged |
| Remedy: | Fit or change the gas hose |
| Cause: | Welding torch is faulty |
| Remedy: | Change the welding torch |
| Cause: | Gas solenoid valve is faulty |
| Remedy: | Contact After-Sales Service |
Poor weld properties
| Cause: | Incorrect welding parameters |
| Remedy: | Correct settings |
| Cause: | Poor grounding (earthing) connection |
| Remedy: | Ensure good contact to workpiece |
| Cause: | Inadequate or no protective gas shield |
| Remedy: | Check the pressure regulator, gas hose, gas solenoid valve and welding torch shielding gas connection. On gas-cooled welding torches, inspect the gas seals, use a suitable inner liner |
| Cause: | Welding torch is leaking |
| Remedy: | Replace welding torch |
| Cause: | Contact tip is too large or worn out |
| Remedy: | Replace the contact tip |
| Cause: | Wrong wire alloy or wrong wire diameter |
| Remedy: | Check wirespool/basket-type spool in use |
| 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 shield (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 |
| Cause: | Turbulence caused by too high a rate of shielding gas flow |
| Remedy: | Reduce shielding gas flow rate, recommended: shielding gas flow rate (l/min) = wire diameter (mm) x 10 (e.g. 16 l/min for 1.6 mm wire electrode) |
| Cause: | Too large a distance between the welding torch and the workpiece |
| Remedy: | Reduce the distance between the welding torch and the workpiece (approx. 10 - 15 mm / 0.39 - 0.59 in.) |
| Cause: | Tilt angle of the welding torch is too great |
| Remedy: | Reduce the tilt angle of the welding torch |
| Cause: | Wirefeed components do not match the diameter of the wire electrode / the wire electrode material |
| Remedy: | Use the correct wirefeed components |
| Cause: | Loss of gas or extraneous air |
| Remedy: | Check leak-tightness of blow-through line and blow-through valve. Check closure seal of blowthrough line (push-on nipple) |
Poor wirefeed
| Cause: | Braking force set too high |
| Remedy: | Set the brake to a looser setting |
| Cause: | Hole in contact tube is dislocated |
| Remedy: | Exchange the contact tube |
| Cause: | The wire feed inner liner or wire feed insert in the welding torch is defective |
| Remedy: | Check the wire fee inner liner and wire feed insert for kinks, dirt etc. |
| Cause: | The wirefeed rollers are not suitable for the wire electrode being used |
| Remedy: | Use suitable wirefeed rollers |
| Cause: | The wirefeed rollers are exerting the wrong contact pressure |
| Remedy: | Optimise 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 or wire feed insert dislocated or kinked |
| Remedy: | Exchange the inner liner or wire feed insert |
| Cause: | The inner liner, the wire feed insert or wire inlet nozzle are of the wrong dimension |
| Remedy: | Ensure that the inner liner, wire feed insert or wire inlet nozzle are correctly dimensioned |
| Cause: | The inner liner was kinked while being inserted |
| Remedy: | When inserting the inner liner, only touch and hold it near the infeed tube |
| Cause: | After being cut to length, the inner liner is too short |
| Remedy: | Exchange the inner liner and shorten it to the correct length |
| Cause: | The wire is being abraded due to excessive contact pressure on the wirefeed rollers |
| Remedy: | Reduce the contact pressure on the wirefeed rollers |
| Cause: | Welding wire is dirty / slightly rusty |
| Remedy: | Use only high-quality wires that are free of contaminants |
The welding torch becomes very hot
| Cause: | The torch has been operated beyond its maximum amperage rating. |
| Remedy: | Lower the welding power or use a higher-capacity torch |
| Cause: | The design dimensions of the torch are not sufficient for this task |
| Remedy: | Respect the duty cycle and loading limits |
Contact tip has a short service life
| Cause: | Incorrect wirefeeder rollers |
| Remedy: | Use correct wirefeeder rollers |
| Cause: | Wire electrode worn due to excessive contact pressure on the wirefeeder rollers |
| Remedy: | Reduce contact pressure on the wirefeeder rollers |
| Cause: | Wire electrode contains impurities/is corroded |
| Remedy: | Use high-quality wire electrode with no impurities |
| Cause: | Uncoated wire electrode |
| Remedy: | Use wire electrode with suitable coating |
| Cause: | Wrong dimension of contact tip |
| Remedy: | Use a contact tip of the correct dimension |
| Cause: | Duty cycle of welding torch has been exceeded |
| Remedy: | Shorten the duty cycle or use a more powerful welding torch |
| Cause: | Contact tip has overheated. No thermal dissipation as the contact tip is too loose |
| Remedy: | Tighten the contact tip |
NOTE!When using CrNi, the contact tip may be subject to a higher degree of wear due to the nature of the surface of the CrNi wire electrode. | |
Weld-seam porosity
| Cause: | Torch blow-out unit not connected and/or not sealed |
| Remedy: | Connect hose and/or seal hose end by means of supplied plug |
| Cause: | Spatter accumulating in the gas nozzle, causing inadequate gas-shielding of the weld-seam |
| Remedy: | Remove the welding spatter |
| Cause: | Either the shielding-gas hose has holes in it, or it is not connected up properly |
| Remedy: | Change the shielding gas-hose |
| Cause: | The O-ring seals on the connection points are cut or defective |
| Remedy: | Change the O-ring seals |
| Cause: | Moisture / condensate in the shielding-gas hose |
| Remedy: | Dry the shielding-gas hose |
| Cause: | Shielding-gas flow is either too high or too low |
| Remedy: | Correct the shielding-gas flow |
| Cause: | Insufficient shielding-gas flow at the beginning or end of welding |
| Remedy: | Increase the gas pre-flow or post-flow |
| Cause: | The welding wire is rusty or of poor quality |
| Remedy: | Use only high-quality wires that are free of contaminants |
| Cause: | Applies to gas-cooled welding torches: Shielding-gas leakage from non-insulated inner liners |
| Remedy: | On gas-cooled welding torches, use only insulated inner liners. |
| Cause: | Too much parting agent applied |
| Remedy: | Wipe off excess parting agent / apply less parting agent |
Technical data
Robacta G
Explanation of symbols
Gas cooling | |
Length of the hosepack | |
X | Duty cycle in % |
Imax | max. welding current in A |
Electrode diameter |
Voltage measurement (V-Peak):
for mechanically driven welding torches: 141 V
This product conforms to the requirements of IEC 60974-7.
|
| MTG 2500 | MTG 3200 | MTG 4000 | |
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 - 1,6 |
|
| Robacta Drive G | Robacta Drive CMT G / PAP | ||
X / I max (10 min / 40°C) | [%] / [A] | - | - | ||
X / I max (10 min / 40°C) | [%] / [A] | - | - | ||
[mm] | 0,8 - 1,6 | 0,8 - 1,2 (Alu 1,6) | |||
| [m] | 1,5 / 1,75 / 2,0 / 2,5 / 3,5 / | 4,25 / 6,25 / 8,25 | ||
[V] DC | 42 | 55 | |||
[A] | 2,15 | 2,5 | |||
[min] | 0,5 - 22 | 0,5 - 22 | |||
|
| Robacta G | Robacta G / 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 | |||
| [m] | 1,2 / 1,5 / 1,7 | 1,19 / 1,30 / 1,33 / 1,38 / 1,39 | ||
[V] DC | - | - | |||
[A] | - | - | |||
[min] | - | - | |||
Robacta G
Explanation of symbols
Gas cooling | |
Length of the hosepack | |
X | Duty cycle in % |
Imax | max. welding current in A |
Electrode diameter |
Voltage measurement (V-Peak):
for mechanically driven welding torches: 141 V
This product conforms to the requirements of IEC 60974-7.
|
| MTG 2500 | MTG 3200 | MTG 4000 | |
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 - 1,6 |
|
| Robacta Drive G | Robacta Drive CMT G / PAP | ||
X / I max (10 min / 40°C) | [%] / [A] | - | - | ||
X / I max (10 min / 40°C) | [%] / [A] | - | - | ||
[mm] | 0,8 - 1,6 | 0,8 - 1,2 (Alu 1,6) | |||
| [m] | 1,5 / 1,75 / 2,0 / 2,5 / 3,5 / | 4,25 / 6,25 / 8,25 | ||
[V] DC | 42 | 55 | |||
[A] | 2,15 | 2,5 | |||
[min] | 0,5 - 22 | 0,5 - 22 | |||
|
| Robacta G | Robacta G / 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 | |||
| [m] | 1,2 / 1,5 / 1,7 | 1,19 / 1,30 / 1,33 / 1,38 / 1,39 | ||
[V] DC | - | - | |||
[A] | - | - | |||
[min] | - | - | |||