FRO­NIUS TXi TWIN User manual

Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0284,EA 004-30062020
Upright console TXi TWIN
Wall-mounted console TXi TWIN
[
Operating Instructions
Torch body changeover system
EN-US

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3
EN-US
Table of contents
Safety Instructions ..................................................................................................................................... 5
Explanation of Safety Instructions......................................................................................................... 5
General ................................................................................................................................................. 5
Intended Use......................................................................................................................................... 6
Environmental Conditions..................................................................................................................... 6
Obligations of the Operating Company................................................................................................. 6
Obligations of Personnel....................................................................................................................... 6
Particular Hazard Areas........................................................................................................................ 6
Personal Protection and Protection of Others....................................................................................... 7
EMC Device Classifications .................................................................................................................. 7
EMC Measures ..................................................................................................................................... 7
EMF measures...................................................................................................................................... 8
Safety Measures at the Setup Location and During Transport............................................................. 8
Safety Measures in Normal Operation.................................................................................................. 8
Maintenance and repair ........................................................................................................................ 9
Safety Inspection .................................................................................................................................. 9
Disposal ................................................................................................................................................ 9
Safety symbols...................................................................................................................................... 9
Data backup.......................................................................................................................................... 9
Copyright............................................................................................................................................... 9
General ...................................................................................................................................................... 11
Device concept ..................................................................................................................................... 11
Intended Use......................................................................................................................................... 11
Required system components .............................................................................................................. 12
Application Example ............................................................................................................................. 12
Scope of Supply......................................................................................................................................... 14
Upright Console Scope of Supply......................................................................................................... 14
Wall-mounted Console Scope of Supply .............................................................................................. 14
Tools Scope of Supply.......................................................................................................................... 14
Warning notices affixed to the device ........................................................................................................ 15
Warning notices on the device (upright console).................................................................................. 15
Warning notices on the device (wall-mounted console)........................................................................ 16
Transport.................................................................................................................................................... 17
Transport Equipment ............................................................................................................................ 17
Transport Instructions on the Packaging .............................................................................................. 17
Operating controls, connections and mechanical components.................................................................. 18
Safety.................................................................................................................................................... 18
Operating controls, connections, and mechanical components of the upright console ........................ 18
Operating controls, connections and mechanical components of the wall-mounted console............... 19
Tactile sensor (option) ............................................................................................................................... 21
General ................................................................................................................................................. 21
Function ................................................................................................................................................ 21
Connector pin assignments and signal descriptions.................................................................................. 22
Safety.................................................................................................................................................... 22
Pin assignment of standard I/O connection for robot controller............................................................ 22
Assignment of fieldbus connection for robot control ............................................................................. 24
Signal descriptions................................................................................................................................ 26
Assignment of I/O connection for add-on devices ................................................................................ 28
Before installation and initial operation ...................................................................................................... 29
Safety.................................................................................................................................................... 29
Operating Personnel, Maintenance Personnel ..................................................................................... 30
Setup Regulations................................................................................................................................. 30
Specifications for the Compressed Air Supply...................................................................................... 30
Installing the Torch Body Change Station.................................................................................................. 31
Fastening the upright console TXi TWIN to the surface (foundation) ................................................... 31
Mounting the wall-mounted console TXi TWIN..................................................................................... 32
Supply the torch body change station with compressed air.................................................................. 33
Installing the Torch Body Coupling ............................................................................................................ 34
Safety.................................................................................................................................................... 34
Install the torch body coupling .............................................................................................................. 34

4
Checking the function of the torch body coupling ................................................................................. 34
Setting up the robot.................................................................................................................................... 37
General ................................................................................................................................................. 37
Functions of the robot programming aid ............................................................................................... 37
Setting up the robot............................................................................................................................... 37
Measuring the torch-body racks using the tactile sensor........................................................................... 41
Measuring the torch-body racks using the tactile sensor...................................................................... 41
Commissioning .......................................................................................................................................... 43
Requirements for Commissioning......................................................................................................... 43
Start-up ................................................................................................................................................. 43
Important information regarding operation............................................................................................ 43
Program sequence..................................................................................................................................... 44
Safety.................................................................................................................................................... 44
Speed Specifications for the Program Sequence ................................................................................. 44
Program Sequence............................................................................................................................... 45
Installing Optional Equipment .................................................................................................................... 51
Safety.................................................................................................................................................... 51
Installing the Torch-body Rack ............................................................................................................. 52
Installing the Wire Cutter....................................................................................................................... 54
Installing the Robacta Reamer V Twin.................................................................................................. 54
Installing the coding ring ....................................................................................................................... 55
Troubleshooting ......................................................................................................................................... 58
Safety.................................................................................................................................................... 58
Troubleshooting .................................................................................................................................... 59
Service, maintenance and disposal ........................................................................................................... 61
Safety.................................................................................................................................................... 61
Maintenance activities........................................................................................................................... 62
Changing the O-rings in the Torch Body Coupling ............................................................................... 62
Disposal ................................................................................................................................................ 63
Technical data............................................................................................................................................ 64
Upright console TXi TWIN .................................................................................................................... 64
Wall-mounted console TXi TWIN.......................................................................................................... 64
Torch body coupling.............................................................................................................................. 64
Declaration of Incorporation....................................................................................................................... 65

5
EN-US
Safety Instructions
Explanation of
Safety Instruc-
tions
DANGER!
Indicates an immediate danger.
► Death or serious injury may result if appropriate precautions are not taken.
WARNING!
Indicates a possibly dangerous situation.
► Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Indicates a situation where damage or injury could occur.
► Minor injury or damage to property may result if appropriate precautions are not taken.
NOTE!
Indicates the possibility of flawed results and damage to the equipment.
General The device has been manufactured using state-of-the-art technology and according to rec-
ognized safety standards. If used incorrectly or misused, however, it can cause
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operating company,
- inefficient operation of the device.
All persons involved in the commissioning, operation, maintenance, and servicing of the
device must
- be suitably qualified,
- have knowledge of automated welding and
- have read these Operating Instructions and any system component operating instruc-
tions in full and follow them carefully.
The Operating Instructions must always be at hand wherever the device is being used. In
addition to the Operating Instructions, all applicable local rules and regulations regarding
accident prevention and environmental protection must also be followed.
All safety and danger notices on the device must
- must be kept in a legible state
- not be damaged/marked
- not be removed
- not be covered, pasted, or painted over
For the location of the safety and danger notices on the device, refer to the section headed
"General" in the Operating Instructions for the device.
Before switching on the device, remove any faults that could compromise safety.
Your personal safety is at stake!

6
Intended Use The device must only be used for its intended purpose.
Utilization for any other purpose, or in any other manner, shall be deemed to be not in ac-
cordance with the intended purpose. The manufacturer accepts no liability for any damage
resulting from improper use.
Intended use also means:
- Reading and adhering to all instructions in the Operating Instructions
- Reading and adhering to all safety instructions and danger notices
- Carrying out all the specified inspection and maintenance work
The device is designed for operation in industry and business. The manufacturer shall not
be liable for any damage resulting from use in a living area.
The manufacturer shall also not be liable for faulty or incorrect work results.
Environmental
Conditions
Operation or storage of the device outside the stipulated area will be deemed as not in ac-
cordance with the intended purpose. The manufacturer accepts no liability for any damage
resulting from improper use.
Temperature range of the ambient air:
- During operation: -10°C to +40°C (14°F to 104°F)
- During transport and storage: -20°C to +55°C (-4°F to 131°F)
Relative humidity:
- Up to 50% at 40°C (104°F)
- Up to 90% at 20°C (68°F)
Ambient air: free of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)
Obligations of the
Operating Com-
pany
The operating company must only allow persons to work with the device if they
- Are familiar with the basic occupational safety and accident prevention regulations
and are trained in handling the device
- Have read and understood these Operating Instructions, especially the section "Safe-
ty Rules," and have confirmed this with their signature
- Are trained according to the requirements for the work results
The safety-conscious work of the personnel must be checked regularly.
Obligations of
Personnel
All persons who are assigned to work with the device must do the following before begin-
ning the work:
- Follow the basic regulations for occupational safety and accident prevention
- Read these Operating Instructions, especially the section "Safety Rules," and confirm
that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property damage can occur
in one's absence.
Particular Hazard
Areas Do not linger in the operating area of the robot.
Always integrate the device into a higher-level safety system in a secured area.

7
EN-US
If this area has to be accessed for preparatory or maintenance work, ensure that
- the entire system is shut down for the duration of access to this area
- and remains shut down to prevent unintended operation, e.g., as a result of a control
error
In addition to these Operating Instructions, the operating instructions and safety rules of
the robot manufacturer must be followed.
Covers must only be opened/removed during maintenance, installation and repair work.
During operation:
- Ensure that all covers are closed and all side parts have been mounted properly
- Keep all covers closed
Personal Protec-
tion and Protec-
tion of Others
You are exposed to numerous hazards while welding. In addition to these Operating In-
structions, the safety rules of the manufacturer of the entire welding system must be fol-
lowed.
Keep persons, especially children, away during the operation of the devices and during the
welding process. However, if persons are in the vicinity:
- Inform them about all hazards (crush hazard posed by moving mechanical parts, flying
chips or similar, escaping compressed air, injury hazard due to flying sparks, blinding
hazard due to arcs, welding fumes that are hazardous to health, noise exposure, pos-
sible hazard due to mains current or welding current, etc.)
- Provide suitable protective equipment, or
- Construct suitable protective walls and curtains.
EMC Device Clas-
sifications
Devices in emission class A:
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:
- Satisfy the emissions criteria for residential and industrial areas. This is also true for
residential areas in which the energy is supplied from the public low-voltage grid.
EMC device classification as per the rating plate or technical data.
EMC Measures In certain cases, even though a device complies with the standard limit values for emis-
sions, it may affect the application area for which it was designed (e.g., when there is sen-
sitive equipment at the same location, or if the site where the device is installed is close to
either radio or television receivers).
If this is the case, then the operating company is obliged to take appropriate action to rectify
the situation.
Check and evaluate possible problems and the interference immunity of equipment in the
vicinity according to national and international regulations:
- Safety devices
- Grid power lines, signal lines, and data transfer lines
- EMC and telecommunications equipment
- Devices for measuring and calibrating

8
Supporting measures to avoid EMC problems:
1. Grid power supply
- If electromagnetic interference occurs despite a grid connection that complies
with regulations, take additional measures (e.g., use a suitable grid filter).
2. Control lines
- Keep them as short as possible
- Route them close together (also to avoid EMF problems)
- Route them far from other lines
3. Equipotential bonding
4. Shield, if necessary
- Shield other devices in the vicinity
- Shield the entire welding installation
EMF measures Electromagnetic fields may cause health problems that are not yet known:
- Effects on the health of persons close by, e.g., those with pacemakers and hearing
aids
- Persons with pacemakers must seek advice from their doctor before staying in the im-
mediate vicinity of the device and the welding process
- Keep distances between welding cables and the head/torso of the welder as large as
possible for safety reasons
- Do not carry welding cables and hosepacks over one's shoulder or wrap them around
one's body or body parts
Safety Measures
at the Setup Loca-
tion and During
Transport
A toppling device can be deadly! Set up the device securely on an even, solid surface
- The maximum permitted tilt angle is 10°.
Special regulations apply in areas at risk of fire or explosion
- Follow the appropriate national and international regulations.
Use instructions and checks within the company to ensure that the vicinity of the workplace
is always clean and organized.
Only set up and operate the device in accordance with the protection class shown on the
rating plate.
Take care to ensure that the applicable national and regional guidelines and accident pre-
vention regulations are observed when transporting the device, especially guidelines con-
cerning hazards during transport and shipment.
It is essential to conduct a visual inspection of the device to check for damage after it has
been transported but before commissioning. Have any damage repaired by trained service
technicians before commissioning the device.
Safety Measures
in Normal Opera-
tion
Only operate the device when all safety devices are fully functional. If the safety devices
are not fully functional, there is a danger of:
- Serious or fatal injury to the operator or a third party
- Damage to the device and other material assets belonging to the operating company
- Inefficient operation of the device
Safety devices that are not fully functional must be repaired before the device is switched
on.
Never bypass or disable safety devices.
Before starting up the device, ensure that no one can be put in danger.

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EN-US
The device must be examined at least once a week for externally detectable damage and
functionality of the safety devices.
Maintenance and
repair
It is impossible to guarantee that bought-in parts are designed and manufactured to meet
the demands made of them, or that they satisfy safety requirements.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without the manufac-
turer's consent.
- Components that are not in perfect condition must be replaced immediately.
- When ordering, please give the exact designation and part number as shown in the
spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the housing
parts.
Only use original housing screws in the correct number and tightened to the specified
torque.
Safety Inspection The manufacturer recommends that a safety inspection of the device be performed at least
every 12 months.
A safety inspection by a certified electrician is recommended:
- after changes
- after alterations
- after repair, care, and maintenance
- at least every 12 months.
For the safety inspection, follow the appropriate national and international standards and
guidelines.
You can obtain more information about the safety inspection and calibration from your ser-
vice center. The service center will provide the necessary documents upon request.
Disposal Do not dispose of this device with normal domestic waste! To comply with the European
Directive on Waste Electrical and Electronic Equipment and its implementation as national
law, electrical equipment that has reached the end of its life must be collected separately
and returned to an approved recycling facility. Any device that you no longer require must
be returned to your dealer, or you must locate the approved collection and recycling facil-
ities in your area. Ignoring this European Directive may have potentially adverse affects on
the environment and your health!
Safety symbols Devices marked with the CSA test mark satisfy the requirements of the relevant standards
for Canada and the USA.
Data backup The user is responsible for backing up any changes made to the factory settings. The man-
ufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these Operating Instructions remains with the manufacturer.

10
Text and illustrations were accurate at the time of printing. Fronius reserves the right to
make changes. The contents of the Operating Instructions shall not provide the basis for
any claims whatsoever on the part of the purchaser. If you have any suggestions for im-
provement, or can point out any mistakes that you have found in the Operating Instruc-
tions, we will be most grateful for your comments.

11
EN-US
General
Device concept The TXi TWIN is a torch body change station for twin welding systems. Two versions are
available:
- Upright console TXi TWIN
- Wall-mounted console TXi TWIN
Upright console Wall-mounted console
The torch body change station is used:
- to store up to 8 torch bodies
- to hold a welding torch cleaning device
- to hold a wire cutter
- to hold a TCP measuring system
Worn torch bodies are placed on the torch body change station by the robot and replaced
with new torch bodies.
Even switching between different torch body geometries can be carried out easily.
In conjunction with a welding torch cleaning device, the upright console TXi TWIN be-
comes a completely autonomous torch body maintenance station that increases the sys-
tem availability and considerably reduces retooling costs.
Intended Use The device is intended exclusively for changing Fronius torch bodies.
The device is intended only for use in conjunction with Fronius system components. This
applies especially to cooling units and coolant – the device must only be used with Fronius
cooling units and Fronius coolant.
Utilization for any other purpose, or in any other manner, shall be deemed to be not in ac-
cordance with the intended purpose. The manufacturer shall not be liable for damage re-
sulting from this nor for faulty or incorrect work results.
Intended use also means:
- Reading and obeying in full the Operating Instructions and all safety instructions and
danger notices
- Carrying out all the specified inspection and maintenance work
The device is designed for operation in industry and business. The manufacturer shall not
be liable for any damage resulting from use in a living area.

12
Required system
components
The OPT/i WF Twin Torch Change (4,101,171,IK) option must be installed in the twin wire-
feeder.
- Twin welding system with conventional robot
- TXi TWIN torch body change station
Upright console 4,044,030
Wall-mounted console 4,044,038
- Fieldbus connection (optional)
ProfiNet 4,100,707
ProfiBus 4,100,127
DeviceNet 4,100,331
EtherCAT 4,100,539
- Torch body coupling 44,0350,3985
- Twin - Single adapter MTB TPSi 44,0350,4117 (optional)
- Wire cutter V 44,0450,1027
- Twin torch body MTB 2x500i
44,0350,5500,636 MTB 2x500i PA/30°/L328/11°/TX
44,0350,5504,636 MTB 2x500i PA/30°/L328/8°/TX
44,0350,5501,636 MTB 2x500i PB 30°/L328/11°/TX
44,0350,5505,636 MTB 2x500i PB 30°/L328/8°/TX
44,0350,5503,636 MTB 2x500i PA 45°/L328/11°/TX
44,0350,5506,636 MTB 2x500i PA 45°/L328/8°/TX
44,0350,5502,636 MTB 2x500i PB 45°/L328/11°/TX
44,0350,5507,636 MTB 2x500i PB 45°/L328/8°/TX
Application Ex-
ample
(1) (1) (2) (3)
(4) (4) (5) (6) (7) (8)(8) (9) (10) (11)

13
EN-US
NOTE!
Regardless of the setup of the entire welding system
► Adhere to the compressed air specifications
► Implement the compressed air supply of the torch body change station as shown
(1) Wirefeeding hose
(2) Wirefeeder WF 30i Twin
(3) Torch hosepack with torch body coupling and torch body MTB 2x500i W
(4) Wire drum
(5) Robot controller
(6) Data cable
(7) Data cable
(8) Power source with cooling unit
(9) Interconnecting hosepack
(10) Torch body change station
(11) Compressed air supply line for torch body change station 6.00 bar (87.02 psi) -
used to supply the add-on devices

14
Scope of Supply
Upright Console
Scope of Supply (1) Torch body change station
incl.
(2) 3 torch-body racks
(3) 2 wire cutter holders
(4) Base plate for add-on devices
(5) Compressed air maintenance unit
(on the rear of the device)
(6) 4 adjusting shims, 1 mm (0.04 inch)
(7) 4 adjusting shims, 1.5 mm (0.06
inches)
Not shown:
these Operating Instructions
Wall-mounted
Console Scope of
Supply
(1) Torch body change station
incl.
(2) 3 torch-body racks
(3) 2 wire cutter holders
(4) Compressed air maintenance unit
(5) Mounting bracket
Not shown:
these Operating Instructions
Tools Scope of
Supply
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(1)
(2)
(3)
(4) (5)
BY2,0201,4862
BY2,0201,4863
44,0350,4076

15
EN-US
Warning notices affixed to the device
Warning notices
on the device (up-
right console)
The device has safety symbols and a rating plate fitted. These safety symbols and the rat-
ing plate must not be removed or painted over. The symbols warn against operating the
equipment incorrectly, as this may result in serious injury and damage to property.
WARNING! Danger of serious injuries due to mechanically moving parts. During mainte-
nance and servicing, keep the device de-energized and depressurized.
Do not use the functions described here until you have fully read and understood the fol-
lowing documents:
- These Operating Instructions
- All system component Operating Instructions, especially the safety rules
For indoor use only
24 VDC
Ser.No.
Model No.
Art.No.
U
I
max
1,5 A
P max
6 bar
IP23
www.fronius.com

16
Warning notices
on the device
(wall-mounted
console)
The device has safety symbols and a rating plate fitted. These safety symbols and the rat-
ing plate must not be removed or painted over. The symbols warn against operating the
equipment incorrectly, as this may result in serious injury and damage to property.
WARNING! Danger of serious injuries due to mechanically moving parts. During mainte-
nance and servicing, keep the device de-energized and depressurized.
Do not use the functions described here until you have fully read and understood the fol-
lowing documents:
- These Operating Instructions
- All system component Operating Instructions, especially the safety rules
For indoor use only
24 VDC
Ser.No.
Model No.
Art.No.
U
Imax 1,5 A
Pmax 6 bar
IP23
www.fronius.com

17
EN-US
Transport
Transport Equip-
ment
Transport the device using the following transport equipment:
- On a pallet using a counterbalanced lift truck
- On a pallet using a lift truck
WARNING!
Falling or toppling devices can be deadly.
► When transporting the device by counterbalanced lift truck or lift truck, secure the de-
vice to prevent it from falling
► Do not turn, brake, or accelerate in a sudden, jerking manner
Transport In-
structions on the
Packaging
CAUTION!
Danger due to improper transport.
This can result in damage to property.
► Follow the transport instructions on the device packaging.

18
Operating controls, connections and mechanical
components
Safety WARNING!
Operating the device incorrectly can cause serious injury and damage to property.
► All functions described may only be used by trained personnel.
► Do not use the functions described here until you have fully read and understood the
Operating Instructions.
► Do not use the functions described here until you have fully read and understood all of
the Operating Instructions of the system components, especially the safety rules.
Operating con-
trols, connec-
tions, and
mechanical com-
ponents of the
upright console
(1) Robacta TX pneumatic cover
(2) Torch-body racks
(3) Dummy cover
In preparation for the installation of an optional interface to connect to the robot
controller
(4) Standard I/O connection for robot controller
To connect the robot controller to the torch body change station
(5) Dummy cover
In preparation for the installation of an optional interface to connect to the robot
controller
(6) Dummy cover
In preparation for the installation of an optional interface to connect to the robot
controller
(7) Compressed air maintenance unit
(8) Compressed air connection "A", size: 3/8" (0.375 inch)
Connection for supplying the torch body change station with 6.00 bar (87.02 psi) of
dry and oil-free compressed air
(11)
(10)
(12)
(13)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)

19
EN-US
(9) Locking pin
To manually open the pneumatic cover:
- Pull out the pin - the pneumatic cover can be opened
- To lock the cover in place, rotate the pin 90°
- When closing the cover, make sure the pin is back in its original position.
(10) Holder retainer
To hold up to 8 torch-body racks
(11) Fixing bracket
For mounting add-on devices
(12) Compressed air connection "B"
Connection used for supplying the Fronius add-on devices with compressed air
(wire cutter, welding torch cleaning devices)
(13) I/O connection for add-on devices
To connect the Fronius add-on devices to the torch body change station
Operating con-
trols, connec-
tions and
mechanical com-
ponents of the
wall-mounted
console
(1) Torch-body racks
(2) Front cover
(3) Robacta TX pneumatic cover
(4) Ring bolt for transporting by crane
(5) Compressed air maintenance unit
In preparation for the installation of an optional interface to connect to the robot
controller
(6) Compressed air connection for wire cutter
(7) Compressed air connection "A"
Size: 3/8" (0.375 inch)
Connection for supplying the torch body change station with 6.00 bar (87.02 psi) of
dry and oil-free compressed air
(1) (2)
(3)
(4) (5) (6) (7) (8)
(9)

20
(8) Fixing bracket
For mounting add-on devices
(9) Locking pin
To manually open the pneumatic cover:
- Pull out the pin - the pneumatic cover can be opened
- To lock the cover in place, rotate the pin 90°
- When closing the cover, make sure the pin is back in its original position.