FRO­NIUS TTW 4500 User manual

Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Perfect Charging / Perfect Welding / Solar Energy
TTW 4500 / 5500 PAP
EN
Operating instructions
TIG robot welding torch
PL
Instrukcja obsługi
Palnik spawalniczy dla robota TIG
ZH
操作说明书
WIG 机器人焊炬
42,0410,1949 014-27082021

Contents
General 4
Device concept 4
Application areas 4
Scope of supply 4
TTW 4500 PAP options 5
TTW 5500 PAP options 5
Fitting the welding torch 6
Safety 6
Fitting the TTW 4500 6
Fitting the TTW 5500 7
Fitting the narrow-gap gas nozzle (option) 7
Troubleshooting 9
Safety 9
Troubleshooting 9
Care, maintenance and disposal 10
Safety 10
General 10
At every start-up 10
Monthly 10
Disposal 10
Technical data 11
TTW 4500, TTW 5500 11
3
EN

General
Device concept
TTW 4500 / 5500 PAP device concept
The TTW 4500 and TTW 5500 water-
cooled TIG robot welding torches are used
for TIG welding.
The welding torches have a Fronius F++
connection as standard. Various adapters
are available to enable the torches to be
operated with any standard TIG welding
machine. Each torch can be equipped with
a pushed wire-feed unit and a drag gas
nozzle. The hosepack can also be used
for certain plasma torches.
Application areas The robot welding torches are used in, e.g.:
- Pipeline and equipment construction
- Container construction
- Applications requiring the highest quality standards
- Applications using special materials (e.g. titanium, nickel-based alloys)
- The automobile and the automotive component supply industries
Scope of supply
(1) (2) (3) (4) (5) (6) (7)
(8)
TTW 4500 PAP scope of supply
(1) Ceramic protective gas nozzle
(2) Gas lens
(3) TTW torch body
(4) Clamping sleeve 3.2 mm
(5) Tungsten electrode 3.2 mm
(6) Torch cap, medium
4

(7) Hosepack with integrated wire-feed hose
(8) Adjusting gauge
(1) (3) (5) (6) (7) (8) (9)
(2) (4)
TTW 5500 PAP scope of supply
(1) Ceramic protective gas nozzle
(2) Gas lens
(3) Gas shroud
(4) Insulating ring
(5) TTW torch body
(6) Tungsten electrode 4.8 mm
(7) Clamping sleeve 4.8 mm
(8) Torch cap, short (TTW 5500)
(9) Hosepack with integrated wire-feed hose
TTW 4500 PAP
options
- Cold wire feeder (push system): Robacta Plasma / TIG KD
- Clamping sleeve (see spare parts list)
- Gas nozzle M 18 x 1.5
- Adapter for Fronius Z central connector
- Drag gas nozzle 50 / 100 mm
- Clamp holder
- Torch caps
TTW 5500 PAP
options
- Cold wire feeder (push system): Robacta KD Plasma / TIG PAP
- Clamping sleeve 3.2 / 4 / 6.4 mm
- Drag gas nozzle 50 / 100 mm
- Gas nozzle 3/4
- Clamp holder
- Torch caps
- Adapter for Fronius Z central connector
5
EN

Fitting the welding torch
Safety WARNING!
Danger due to work that has been carried out incorrectly.
This can result in severe personal injury and damage to property.
▶All connections must be made by trained and qualified personnel in compliance with
the relevant safety regulations.
▶Note the safety rules in the operating instructions.
WARNING!
Danger from electric current.
An electric shock can be fatal.
▶Before carrying out any work on the welding torch:
▶Turn the power source mains switch to the "O" position
▶Unplug the power source from the mains
▶Put up an easy-to-understand warning sign to stop anybody inadvertently switching
it back on again
Fitting the TTW
4500
1
2
1
1
2
2
1
32
4
3 4
6

Fitting the TTW
5500
2
3
1
㪉
1
2
1
2
1
2
3 4
Fitting the nar-
row-gap gas
nozzle (option)
You will also need the following items to fit the narrow-gap gas nozzle:
- Insulation ring D 35.5 mm - 42,0100,0010
- Gas shield M18 x 1.5 mm - 42,0001,6781
- Narrow-gap gas nozzle - 42,0300,3210
1
23
4
5
5
1
1
*
2
*
* Screw on as far as it will go
2
7
EN

2
1
3
~ 15 mm
3
1
**
** Push on as far as it will go
4
1
2
5
8

Troubleshooting
Safety WARNING!
Danger from electric current.
An electric shock can be fatal.
▶Before carrying out any work on the welding torch:
▶Turn the power source mains switch to the "O" position
▶Unplug the power source from the mains
▶Put up an easy-to-understand warning sign to stop anybody inadvertently switching
it back on again
Troubleshooting Arc not igniting
Tungsten electrode dirty
Clean tungsten electrode
Tungsten electrode positioned incorrectly
Position tungsten electrode correctly
Cause:
Remedy:
Cause:
Remedy:
Insufficient shielding gas cover
No gas lens in welding torch
Fit gas lens
Cause:
Remedy:
HF is conducted to robot
Electrically-conductive robot flange fitted
Fit plastic robot flange
Cause:
Remedy:
HF does not ignite on workpiece
No pilot arc
Fit pilot arc and connect pilot arc adapter
Cause:
Remedy:
9
EN

Care, maintenance and disposal
Safety WARNING!
Danger from electric current.
An electric shock can be fatal.
▶Before carrying out any work on the welding torch:
▶Turn the power source mains switch to the "O" position
▶Unplug the power source from the mains
▶Put up an easy-to-understand warning sign to stop anybody inadvertently switching
it back on again
General Regular preventive maintenance of the welding torch is essential for problem-free opera-
tion. The welding torch is subjected to high temperatures. It therefore requires more fre-
quent maintenance than other components in the welding system.
At every start-up - Check welding torch, hosepack and power connections for signs of damage
- Check gas and water connections for leaks
- Check that the cooling unit is working properly, monitor the water return level in the
coolant container, vent the cooling unit if necessary
- Check that the wearing parts are in perfect condition, clean wearing parts before fit-
ting them
Monthly - 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 welding torch thoroughly several times by letting coolant flow into it and back out
again
- Dismantle the welding torch and check for deposits/contamination
Disposal Dispose of in accordance with the applicable national and local regulations.
10