Robacta PTW 500, 1500, 3500 Operating Instructions

The water-cooled plasma robot welding torch is designed for plasma welding and plasma brazing of materials up to a thickness of 1.5 mm (PTW 500), 3 mm (PTW 1500) 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.

Robacta PTW 500 with Robacta Plasma KD Drive and wirefeed options Robacta PTW

Robacta PTW 1500 with Robacta Plasma KD Drive and wirefeed options

Robacta PTW 3500 with Robacta Plasma KD Drive and wirefeed options

The water-cooled plasma robot welding torch is designed for plasma welding and plasma brazing of materials up to a thickness of 1.5 mm (PTW 500), 3 mm (PTW 1500) 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.

Robacta PTW 500 with Robacta Plasma KD Drive and wirefeed options Robacta PTW

Robacta PTW 1500 with Robacta Plasma KD Drive and wirefeed options

Robacta PTW 3500 with Robacta Plasma KD Drive and wirefeed options

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)

(1)	Shielding gas nozzle
(2)	Plasma nozzle 1.2 mm
(3)	Ceramic gas nozzle
(4)	Torch body with stop ring
(5)	Tungsten electrode 1.0 mm
(6)	Clamping sleeve 1.0 mm

(7)	Torch cap
(8)	Hosepack 4 m, Fronius F++ / FG connection
(9)	Adjusting gauge
(10)	Holder
(11)	Connection for cut-out box

(1)	Shielding gas nozzle
(2)	Plasma nozzle 2.5 mm
(3)	Ceramic centring tube
(4)	Torch body with stop ring
(5)	Tungsten electrode WL 15, 2.4 mm
(6)	Clamping sleeve 2.4 mm

(7)	Robacta PTW 1500 torch cap
(8)	Hosepack 4 m, Fronius F++ connection
(9)	Adjusting gauge 2,5 - 3 mm
(10)	Holder
(11)	Connection for cut-out box

(1)	Shielding gas nozzle
(2)	Plasma nozzle 3.2 mm
(3)	Ceramic centring tube
(4)	Torch body with stop ring
(5)	Tungsten electrode WL 15, 4.8 mm
(6)	Clamping sleeve 4.8 mm

(7)	Robacta PTW 3500 torch cap
(8)	Hosepack 4 m, Fronius F++ / FG connection
(9)	Adjusting gauge
(10)	Connection for cut-out box
(11)	Water stopper
(12)	Holder

Hot wire option
Plasma nozzle 0.6 / 0.8 / 1.0 / 1.4 / 1.6 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 / 100 mm

Adjusting gauge ∅ 1.5 - 2 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 1.0 / 1.5 / 2 / 3 mm; 2.0 x 29 mm long
Ceramic centring tube 1.6 / 3.2 mm
Clamping sleeve 1.6 / 3.2 mm
Adapter for the non-digital PlasmaModul
Drag gas nozzle 50 / 100 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 2.0 / 2.5 / 3.5 / 4.0 mm
Plasma nozzle 2.0 / 2.5 / 3.2 / 3.5 / 4.0 mm with 4 x 1 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 / 100 mm
Ceramic gas nozzle + appropriate stop ring

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 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.

1

Insert clamping sleeve

2

Insert tungsten electrode

IMPORTANT! Insert the tungsten electrode so that the tip protrudes approx. 10 mm out of the torch body. Slightly tighten the torch cap so that the tungsten electrode can still move inside the torch body.

3

Assemble centring tube, plasma nozzle and shielding gas nozzle

IMPORTANT! Check that the tungsten electrode is adjusted correctly (see „Adjusting the tungsten electrode.

1

Fit holder, insert clamping sleeve

2

Insert tungsten electrode

IMPORTANT! Insert the tungsten electrode so that the tip protrudes approx. 10 mm out of the torch body. Slightly tighten the torch cap so that the tungsten electrode can still move inside the torch body.

3

Assemble centring tube, plasma nozzle and shielding gas nozzle

IMPORTANT! Check that the tungsten electrode is adjusted correctly (see „Adjusting the tungsten electrode“)

1

Fit holder, insert clamping sleeve

2

Insert tungsten electrode

IMPORTANT! Insert the tungsten electrode so that the tip protrudes approx. 10 mm out of the torch body. Slightly tighten the torch cap so that the tungsten electrode can still move inside the torch body.

3

Assemble centring tube, plasma nozzle and shielding gas nozzle

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“)

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 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.

Apart from 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

The supplied setting gage makes it easier to position the tungsten electrode.

1

*) Loosen the torch cap - caution, the tungsten electrode may fall out of the plasma torch if the torch is in a particular position.

2

3

... and adjust tungsten electrode

4

5

6

Setting the adjusting gauge to measurement „x“

IMPORTANT! 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“:

∅ Plasma-nozzle	„x“	Adjusting gauge
1.0 mm	-	-
1.5 mm	1.5 mm	∅1.5 - 2 mm
2.0 mm	2.0 mm	∅1.5 - 2 mm
2.5 mm	2.5 mm	∅2.5 - 3 mm
3.0 mm	2.5 mm	∅2.5 - 3 mm

1

Loosen the torch cap - caution, the tungsten electrode may fall out of the plasma torch if the torch is in a particular position.

2

Place adjusting gauge onto plasma nozzle ...

3

... and adjust tungsten electrode

4

Fix the tungsten electrode in place using the torch cap

1

Loosen the torch cap - caution, the tungsten electrode may fall out of the plasma torch if the torch is in a particular position.

2

Place adjusting gauge onto plasma nozzle ...

3

... and adjust tungsten electrode

4

Fix the tungsten electrode in place using the torch cap

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 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.

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“.

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

1Mount plasma torch onto robot

2Check 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.

3Adjust the tungsten electrode using the adjusting gauge

4Connect 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

Plasma torch hosepack: connections

5When starting up for the first time, make sure the gas flow is correct

6Position plasma torch (adjust robot)

7Purge shielding gas and plasma gas for at least 30 seconds

NOTE!

The plasma torch must be cooled constantly during operation.

8Check 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)

NOTE!

Igniting the pilot arc without presetting the plasma gas can damage the plasma nozzle, ceramic centring tube and tungsten electrode (all wearing parts).

9Specify the plasma gas value (according to the diameter of the plasma nozzle and the application)

10Ignite pilot arc

IMPORTANT! To reduce wear, the pilot arc should burn throughout the operation.

11Start welding (depending on the application)

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 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“).

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 1 l/min

This table is only valid for the PTW 500 (electrode diameter 1.0 mm; d.c. 60%):

ø Plasma nozzle	Plasma gas flow rate	Max. welding current
0.6 mm	Min. 0.30 l/min	15 A
0.8 mm	Min. 0.30 l/min	20 A
1 mm	Min. 0.30 l/min	28 A
1.2 mm	Min. 0.30 l/min	35 A
1.4 mm	Min. 0.30 l/min	45 A
1.6 mm	Min. 0.30 l/min	50 A
1.8 mm	Min. 0.30 l/min	50 A

This table is only valid for the PTW 1500:

ø Plasma nozzle	Plasma gas flow rate	Max. welding current
1.5 mm	Min. 0.30 l/min Max. 0.80 l/min	60 A 100 A
2.0 mm	Min. 0.35 l/min Max. 1.00 l/min	80 A 120 A
2.5 mm	Min. 0.45 l/min Max. 1.20 l/min	110 A 145 A
3.0 mm	Min. 0.55 l/min Max. 1.30 l/min	130 A 150 A

This table is only valid for the PTW 3500 in conjunction with a FK9000 cooling unit:

ø Plasma nozzle	Plasma gas flow rate	Max. welding current
2.0 mm	Min. 1.0 l/min	170 A
2.5 mm	Min. 1.0 l/min	190 A
3.2 mm	Min. 1.0 l/min	210 A
3.5 mm	Min. 1.0 l/min	225 A
4.0 mm	Min. 1.0 l/min	250 A

Table is only valid for the PTW 3500 in conjunction with a CHILLY 15 cooling unit:

ø Plasma nozzle	Plasma gas flow rate	Max. welding current
2.0 mm	Min. 1.0 l/min	225 A
2.5 mm	Min. 1.0 l/min	250 A
3.2 mm	Min. 1.0 l/min	275 A
3.5 mm	Min. 2.0 l/min	300 A
4.0 mm	Min. 2.0 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.

In the case of a plasma nozzle with a diameter of 2.0 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.

WARNING!

An electric shock can be fatal.

Before carrying out any work on the welding torch:

Turn the mains switches of the power source and plasma device to the "0" position

Disconnect the power source and plasma device from the mains

Put up an easy-to-understand warning sign to stop anybody inadvertently switching them back on again

WARNING!

An electric shock can be fatal.

Before carrying out any work on the welding torch:

Turn the mains switches of the power source and plasma device to the "0" position

Disconnect the power source and plasma device from the mains

Put up an easy-to-understand warning sign to stop anybody inadvertently switching them back on again

Pilot arc not igniting

Cause:	Tungsten electrode missing
Remedy:	Insert tungsten electrode
Cause:	Plasma nozzle and tungsten electrode too far apart
Remedy:	Position tungsten electrode correctly
Cause:	Plasma nozzle and tungsten electrode touching or too close (short circuit between plasma nozzle and tungsten electrode)
Remedy:	Position tungsten electrode correctly

Copper droplets on the plasma nozzle after a short welding time

The formation of droplets on the plasma nozzle is a sign that the plasma nozzle is badly damaged. If the temperature is too high, the plasma nozzle melts and leaks out.

Cause:	Excessive load values
Remedy:	Check current and plasma gas flow rate, change plasma nozzle, reduce load

Excessive plasma nozzle wear

Cause:	Insufficient cooling
Remedy:	Check the current and plasma gas flow rate, check the cooling circuit, increase the plasma gas flow rate, check for wear on the nozzle connection

WARNING!

An electric shock can be fatal.

Before carrying out any work on the welding torch:

Turn the mains switches of the power source and plasma device to the "0" position

Disconnect the power source and plasma device from the mains

Put up an easy-to-understand warning sign to stop anybody inadvertently switching them back on again

WARNING!

An electric shock can be fatal.

Before carrying out any work on the welding torch:

Turn the mains switches of the power source and plasma device to the "0" position

Disconnect the power source and plasma device from the mains

Put up an easy-to-understand warning sign to stop anybody inadvertently switching them back on again

Regular and preventive maintenance of the plasma welding torch are important factors in achieving problem-free operation. The plasma welding torch is subjected to high temperatures. This is why the plasma welding torch needs more frequent maintenance than other components of a welding system.

Check plasma welding torch, torch hosepack, and power connections for damage
Check gas and water connections for leaks
Check that the cooling unit for the plasma torch is functioning correctly, monitor the water return flow quantity in the coolant container, vent the cooling unit if necessary
Check that plasma torch wear parts are in good condition, clean wear parts before installing them
Check secure fit of the plasma welding torch on the hosepack:
the plasma welding torch must be engaged; the locking button must be fully visible

If applicable, check the 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

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

	PTW 1500
Power range	0.5 - 50 A
Maximum value at 60 % d.c.	50 A
Maximum value at 100 % d.c.	35 A
Pilot arc current	5 A
Voltage measurement (V-Peak)	113 V
Striking voltage (Up)	1o kV
Plasma gas/shielding gas (EN ISO 14175)	Argon
Hosepack length	4 m
Electrode diameter	1 mm
Cooling system Coolant	) *)
Cooling power ***)	500 W
Min. coolant pressure	3.0 bar 43.50 psi.
Max. coolant pressure	5.5 bar 79.74 psi.
Minimum coolant flowrate	1.0 l/min

d.c. = duty cycle
*) Liquid cooling
**) Original Fronius coolant
***) Minimum cooling power in accordance with standard IEC 60974-2

The product complies with standard IEC 60974-7

	PTW 1500
Power range	0.5 - 50 A
Maximum value at 60 % d.c.	50 A
Maximum value at 100 % d.c.	35 A
Pilot arc current	5 A
Voltage measurement (V-Peak)	113 V
Striking voltage (Up)	1o kV
Plasma gas/shielding gas (EN ISO 14175)	Argon
Hosepack length	4 m
Electrode diameter	1 mm
Cooling system Coolant	) *)
Cooling power ***)	500 W
Min. coolant pressure	3.0 bar 43.50 psi.
Max. coolant pressure	5.5 bar 79.74 psi.
Minimum coolant flowrate	1.0 l/min

d.c. = duty cycle
*) Liquid cooling
**) Original Fronius coolant
***) Minimum cooling power in accordance with standard IEC 60974-2

The product complies with standard IEC 60974-7

	PTW 1500	PTW 3500
Power range	3 - 150 A	3 - 350 A
Maximum value at 60 % d.c.	-	-
Maximum value at 100 % d.c.	150 A	350 A
Pilot arc current	10 A	30 A
Voltage measurement (V-Peak)	113 V	113 V
Striking voltage (Up)	1o kV	1o kV
Plasma gas/shielding gas (EN ISO 14175)	Argon	Argon
Hosepack length	4 / 6 / 8 m	4 / 6 m
Electrode diameter	1.6 - 3.2 mm	4.8 - 6.4 mm
Cooling system Coolant	) *)	) *)
Cooling power ***)	700 / 1000 / 1300 W	1700 / 1900 W
Min. coolant pressure	3.0 bar 43.50 psi.	3.0 bar 43.50 psi.
Max. coolant pressure	5.5 bar 79.74 psi.	5.5 bar 79.74 psi.
Minimum coolant flowrate	1.0 l/min	1.0 l/min

d.c. = duty cycle
*) Liquid cooling
**) Original Fronius coolant
***) Minimum cooling power in accordance with standard IEC 60974-2

The product complies with standard IEC 60974-7

Robacta PTW 500, 1500, 3500

General

Machine concept

Machine concept

Applications

Scope of supply - Robacta PTW 500

Scope of supply - Robacta PTW 1500

Scope of supply - Robacta PTW 3500

PTW 500 options

PTW 1500 options

PTW 3500 options

Assembling the Robacta PTW 500, 1500, 3500

Safety

WARNING!

Safety

WARNING!

Assembling the Robacta PTW 500

Assembling the Robacta PTW 1500

Assembling the Robacta PTW 3500

Adjusting the tungsten electrode

Safety

WARNING!

Safety

WARNING!

General

Adjusting the PTW 500 tungsten electrode

Calibrating the PTW 1500 adjusting gauge

Adjusting the PTW 1500 tungsten electrode

Adjusting the PTW 3500 tungsten electrode

Start-up

Safety

WARNING!

Safety

WARNING!

Proper use

Start-up

NOTE!

NOTE!

NOTE!

Loading limits dependent on the plasma gas flow rate

General

General

Loading limits dependent on the plasma gas flow rate

This table is only valid for the PTW 500 (electrode diameter 1.0 mm; d.c. 60%):

This table is only valid for the PTW 1500:

This table is only valid for the PTW 3500 in conjunction with a FK9000 cooling unit:

Table is only valid for the PTW 3500 in conjunction with a CHILLY 15 cooling unit:

Loading limit example (PTW 1500)

Troubleshooting

Safety

WARNING!

Safety

WARNING!

Troubleshooting

Care, maintenance and disposal

Safety

WARNING!

Safety

WARNING!

Plasma welding torch maintenance

Maintenance activities with each start-up of the plasma welding torch

Monthly

NOTE!

Disposal

Technical data

PTW 500

PTW 500

PTW 1500, PTW 3500