WIG AUTOMATION 03. Torch heads TIG Torch brackets Shock sensors Torch sets TIG separable versions

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1 WIG AUTOMATION 0 Torch heads TIG Torch brackets Shock sensors Torch sets TIG separable versions

2 CONTENTS TIG system definition for conventional robots 2 Torch heads 24 DIX TAZ DIX TETZ DIX TETZ 400 L 0 Shock sensors DIX SAS 100 DIX SAS Torch brackets 5 DIX PHF DIX MEP 200 EW (TW) 6 Torch sets fixed applications 7 DIX TAZ 400 ZAW 7 Torch sets separable applications 9 DIX METZ 600 ZAW 9 Torch sets double separate applications 40 DIX METTZ 600 ZAW 40 DIX MEPWTTZ 600 SAZ/T PUSH-PUSH Tacho 4 DIX MEPWTTZ 600 SAZ/EC PUSH-PULL Encoder 44 22

3 TIG system definition for conventional robots Spool holder Remote control TIG welding power source Cooling module Torch set Torch bracket Wire feeder Shock sensor Adapter flange Cold wire sets Torch head 2

4 Torch heads DIX TAZ 400 Fixed version torch sets TAZ 400 ZAW (up to 400A) Technical data (DIN EN ): Torch type TAZ 400 Cold wire sets KD 400 KDZ 400 (with liquid cooling) Duty cycle: 400A/100% AC/DC Electrode diameter: mm Wire diameter: mm TIG torch set TAZ 400 ZAW with torch type TAZ 400 Properties Adjusting of the electrode with adjusting gauge Notice: Supply hose without control wires for the shock sensor SAS, due to feedback at high frequency applications Application Non- and low alloyed steels High alloyed steels Aluminium-, magnesium-, copper-and nickel alloys Small to large material thicknesses TIG Torch and cold wire set KD 400 Application sample Adjusting gauge DIX EL 400 (optional) Information to the appropriate torch sets you will find in Chapter TIG AUTOMATION Torch sets. TIG torch in the bracket (swivelling) Application sample 24

5 Spare parts and wear parts Torch type TAZ ø 27.4 Description Dimension Part name Part number 1 Gas nozzle ø 8.5 mm DIX GD 405 L Gas nozzle ø 9.5 mm DIX GD Gas nozzle ø 12.5 mm DIX GD Gas nozzle ø 19.5 mm DIX GD Gas lens DIX GL Sealing washer DIX DIS Torch neck DIX AZ Electrode collet DIX SZ Clamping sleeve DIX SH Retaining bracket DIX HK Electrode collet housing DIX SZA Standard electrode diameter: 2.4 mm and.2 mm. Other electrode diameters on request. Standard equipment for electrode diameter.2 mm with gas nozzle diameter 12.5 mm, DIX GD

6 Accessories Torch type TAZ 400 Cold wire sets Description Dimension Part name Part number 1 Cold wire set DIX KD Standard equipment for wire diameter 1.0 mm and gas nozzles DIX GD 406/408/412 2 Cold wire set, liquid cooled DIX KDZ Standard equipment for wire diameter 1.0 mm and gas nozzles DIX GD 406/408/412, water hoses 5.0 m Cold wire set DIX KD 400/ Standard equipment for wire diameter 1.0 mm and gas nozzle DIX GD 405 L 4 Cold wire set, liquid cooled DIX KDZ 400/ Standard equipment for wire diameter 1.0 mm and gas nozzle DIX GD 405 L, water hoses 5.0 m 5 Cold wire connecting adapter DIX KA Wire conduit hose DIX VLM Liner ø 2.2 mm /.5 m DIX DS 4/ For wire feeding use wire feeder DIX WD 500 (Part number: ). Cooling units on request. Information to the appropriate wire feeders you will find in Chapter 4 SYSTEM COMPONENTS Wire feeders. Variants deviating of the accessories on request. 26

7 Spare parts and wear parts Torch type TAZ 400 / Torch head TETZ 400 (L) Cold wire sets KD(Z) 400, KDZ 400/001 (400/002) Description Part name Part number 1 Guide tip DIX FS Guide pipe DIX KD Water set (Water hoses: 5.0 m) DIX KDZ Guide pipe DIX KD 404/ Guide pipe, liquid cooled DIX KDZ 401/ Guide pipe, liquid cooled DIX KDZ Bracket DIX KD Clamp nut DIX KD Retaining nut DIX KD Clamping sleeve DIX KD Standard wire diameter: 0.8 mm, 1.0 mm and 1.2 mm. Other wire diameters on request. 27

8 Torch heads DIX TETZ 400 Separable version torch sets ME(P)T(T)Z 600 ZAW (up to 400A) Technical data (DIN EN ): Torch head TETZ 400 Duty cycle: 400A/100% AC/DC Electrode diameter: mm Torch head TETZ 400 Properties Adjusting of the electrode with adjusting gauge Tool changer with storage station Adjusting gauge EL 400 (optional) Application Non- and low alloyed steels High alloyed steels Aluminium-, magnesium-, copper-and nickel alloys Small to large material thicknesses TIG separable version Application sample Information to the appropriate torch sets you will find in Chapter TIG AUTOMATION Torch sets. TIG double separable version Application sample Application sample TIG double separable version for PUSH-PUSH tacho and PUSH-PULL encoder 28

9 Spare parts and wear parts Torch head TETZ 400 (L) ø Description Dimension Part name Part number 1 Gas nozzle ø 8.5 mm DIX GD 405 L Gas nozzle ø 9.5 mm DIX GD Gas nozzle ø 12.5 mm DIX GD Gas nozzle ø 19.5 mm DIX GD Gas lens DIX GL Sealing washer DIX DIS Protective cap DIX SK Torch neck DIX TETZ Torch neck DIX TETZ L Electrode collet DIX SZ Clamping sleeve DIX SH Retaining bracket DIX HK Electrode collet housing DIX SZA Connecting piece, TETZ DIX TES For torch sets MET(T)Z 600 ZAW, Servo torch adapter STA 100 T 15 Connecting piece, TEPTZ DIX TEPS For torch bracket MEP Intake nozzle DIX MEP Standard electrode diameter: 2.4 mm and.2 mm. Other electrode diameters on request. 29

10 Torch heads DIX TETZ 400 L Separable version torch sets ME(P)T(T)Z 600 ZAW (up to 400A) Technical data (DIN EN ): Torch head TETZ 400 Cold wire sets KD 400 KDZ 400 (with liquid cooling) Duty cycle: 400A/100% AC/DC Electrode diameter: mm Wire diameter: mm Application sample Description Part name Part number 1 Torch head, left DIX TETZ 400 L Version turned by 180 Version 0, TCP: 410 mm to robotic flange - offset, vertical: 58 mm Version 60, TCP: 42 mm to robotic flange - offset, vertical: -100 mm Electrode stand out: 5 mm Standard equipment for electrode diameter.2 mm with gas nozzle diameter 12.5 mm, DIX GD 408. Use the special spanner DIX SLAT 4 to tighten torch heads. Variants deviating of the accessories on request. 0

11 Accessories Torch head TETZ 400 (L) Cold wire sets 1 2 Description Part name Part number 1 Cold wire set, liquid cooled Standard equipment for wire diameter 1.0 mm and gas nozzle DIX GD 405 L, water hoses 5.0 m 2 Cold wire set Standard equipment for wire diameter 1.0 mm and gas nozzle DIX GD 405 L Cold wire set, liquid cooled Standard equipment for wire diameter 1.0 mm and gas nozzles DIX GD 406/408/412, water hoses 5.0 m DIX KDZ 400/ DIX KD 400/ DIX KDZ For liquid cooling use cooling unit DIX UK 500 (Part number: ). Cooling units on request. For more informations to the cooling unit see the standard fittings. Variants deviating of the accessories on request. 1

12 UPGRADE FOR YOUR ROBOT SYSTEM RETROFIT Rejuvenation for your robot system Easy retrofitting without prolonged downtime Boost in productivity Increase in system efficiency Retrofit packages tailored to the application Perfectly matched components Complete retrofit system from a single source SCHWEIS SEN W E LD I N G SCHWEIS SEN W E LD I N G SCHWEIS SEN

13 Shock sensors DIX SAS 100 For robotic and automatic applications Properties Crash-protection of robot, welding torch and welding fixture at collision in set up and automatic mode Quick shut down of the robot through program stop or emergency stop Precise reset after deflection Low weight Application sample - TIG separable - separable version with torch bracket, fixed Application Technical data (DIN EN ): For DINSE torch systems gas cooled DIX MET / METT 10 liquid cooled DIX METZ / METTZ 600 For DINSE torch brackets DIX PHF 100, PHW 100, PHF 110, DIX PHF 10, PHW Reset accuracy: ± 0.0 mm 400 mm to robotic flange Deflection range: 20 Cut-out torque: 14.5 Nm Switch class: Normally closed Switching capacity: 0V DC/0.5A Dimension (D/H): ø 78.5 / 65 mm Weight: 660 g Cable length: mm Adapter flange DIX ADF 6xxx Bore pattern dependent of robot type Information to the appropriate adapter flanges ADF you will find in Chapter 5 TOOLS and ACCESSORIES. A Description Dimension Part name Part number A Shock sensor ø 78.5 / 65 mm DIX SAS Spare parts and wear parts 1 Dust boot DIX SAS Switch set DIX SAS Service tools you will find in Chapter 5 Tools and Accessories.

14 Shock sensors DIX SAS 200 For robotic and automatic applications Properties Crash-protection of robot, welding torch and welding fixture at collision in set up and automatic mode Quick shut down of the robot through program stop or emergency stop Precise reset after deflection Low weight Application sample - WIG - double separable version with torch bracket, PUSH-PUSH tacho / PUSH-PULL encoder Application Technical data (DIN EN ): For DINSE torch systems liquid cooled DIX MEPWTTZ 600 SAZ/T (EC) For DINSE torch brackets DIX MEP 200 EW (TW) 1 2 Reset accuracy: ± 0.0 mm 400 mm to robotic flange Deflection range: 20 Cut-out torque: 18.0 Nm Switch class: Normally closed Switching capacity: 0V DC/0,5A Dimension (D/H): ø 78.5 / 65 mm Weight: 660 g Cable length: mm Adapter flange DIX ADF 6xxx Bore pattern dependent of robot type Information to the appropriate adapter flanges ADF you will find in Chapter 5 TOOLS and ACCESSORIES. A Description Dimension Part name Part number A Shock sensor ø 78.5 / 65 mm DIX SAS Spare parts and wear parts 1 Dust boot DIX SAS Switch set DIX SAS Service tools you will find in Chapter 5 Tools and Accessories. 4

15 Torch brackets DIX PHF 110 For robotic and automatic applications TIG Properties All common TCP s (different lengths and angles) with adapter flanges and further retainers attainable Torch brackets made of aluminium cast alloy High mechanical strength High dimension accuracy Low weight Very good corrosion resistance Insulation by insulating sleeve Application For DINSE torch systems liquid cooled DIX METZ / METTZ 600 Technical data: Torch bracket, fixed PHF 110 Angle, horizontal: 0 TCP for torch heads, with shock sensor DIX SAS 100: 47 mm to robotic flange (electrode stand out: 5 mm) 1 2 Torch bracket, fixed PHF 110 Separable and double separable version, with shock sensor DIX SAS 100 (application sample) A Description Part name Part number A Torch bracket, fixed DIX PHF Spare parts and wear parts 1 Retainer DIX HA 110/011 (0 ) Fixed bracket DIX FH Service tools you will find in Chapter 5 Tools and Accessories. 5

16 Torch brackets DIX MEP 200 EW (TW) For PUSH-PULL and PUSH-PUSH applications Application For DINSE torch systems liquid cooled DIX MEPWTTZ 600 SAZ/T (EC) Torch bracket with integrated wire feeder (Delivery without drive rolls) A 5 B Description Part name Part number A Torch bracket, Encoder DIX MEP 200 EW B Torch bracket, Tacho DIX MEP 200 TW Spare parts and wear parts 1 Pressure system, with pos. 2 and DIX MEP Pressure housing, without pressure roll DIX MEP Pressure roll DIX MEP Screw axle DIX MEP Drive roll, for aluminium alloy DIX MEP 21- A Drive roll, for steel DIX MEP 22- S Stirrup lock DIX MEP Pivot bearing, for stirrup lock, not shown DIX MEP Flange screw Threaded pin Control wire DIX MEP Enter the required wire diameter, e.g.: 08 = 0.8 mm, 12 = 1.2 mm, or 16 = 1.6 mm Standard diameter: 0.8 mm, 1.0 mm, 1.2 mm and 1.6 mm. Other wire diameters on request. Service tools you will find in Chapter 5 Tools and Accessories.

17 Torch sets fixed applications DIX TAZ 400 ZAW Application For DINSE Torch type liquide cooled DIX TAZ 400 Properties Adjusting of the electrode with adjusting gauge Notice: Supply hose without control wires for the shock sensor SAS, due to feedback at high frequency applications TIG Torch in the bracket (swivelling) Application sample Information to the appropriate cold wire set you will find in Chapter TIG AUTOMATION TIG torch heads Description Dimension Part name Part number 1 Torch set m DIX TAZ ZAW Torch set m DIX TAZ ZAW Bracket DIX PHAT Adjusting gauge DIX EL Clamping sleeve DIX SH For adjusting of the electrode with the adjusting gauge Standard equipment for electrode diameter.2 mm with gas nozzle diameter 12.5 mm, DIX GD 408. Variants deviating of the standard fittings on request. Liners, capillary liners and service tools you will find in Chapter 5 Tools and Accessories. 7

18 Spare parts and wear parts Torch sets TAZ 400 ZAW Supply hose Torch view A Plug view Description Part name Part number A Supply hose DIX VLTAZ _ 1 Housing sleeve DIX GH Cover hose set DIX VL _ Gas hose DIX VL _ 4 Water hose DIX VL _ 5 Combi cable DIX VL _ 6 Threaded pin Enter the required length of the welding torch set, e.g.: 50 = 5.0 m or 70 = 7.0 m. Standard lengths: 5.0 m and 7.0 m 8

19 Torch sets separable applications DIX METZ 600 ZAW Application For DINSE Torch head liquide cooled DIX TETZ 400 (L) Properties Adjusting of the electrode with adjusting gauge Tool changer with storage station TIG separable version application sample Information to the appropriate cold wire sets you will find in Chapter TIG AUTOMATION - TIG torch heads Description Dimension Part name Part number 1 Torch head, compl. 0 DIX TETZ Connecting piece, TETZ DIX TES Torch set 5.0 m DIX METZ ZAW Torch set 7.0 m DIX METZ ZAW Torch bracket, fixed DIX PHF Shock sensor ø 78.5 / 65 mm DIX SAS Adjusting gauge DIX EL Clamping sleeve DIX SH For adjusting of the electrode with the adjusting gauge 8 Plug set For shock sensor, only assembled available DIX MEX Standard equipment for electrode diameter.2 mm with gas nozzle diameter 12.5 mm, DIX GD 408. TCP (for DIX SAS 100): 47 mm to robotic flange (electrode stand out: 5 mm). The corresponding adapter flange you find in the accessories list! Use the special spanner DIX SLAT 4 to tighten torch heads. Variants deviating of the standard fittings on request. Liners, capillary liners and service tools you will find in Chapter 5 Tools and Accessories. 9

20 Torch sets double separate applications DIX METTZ 600 ZAW Application For DINSE Torch head liquide cooled DIX TETZ 400 (L) Properties Adjusting of the electrode with adjusting gauge Tool changer with storage station TIG double separable version application sample Information to the appropriate cold wire sets you will find in Chapter TIG AUTOMATION - TIG torch heads Description Dimension Part name Part number 1 Torch head, compl. 0 DIX TETZ Connecting piece, TETZ DIX TES Torch body DIX MEK 00/ Torch set 5.0 m DIX METTZ ZAW Torch set 7.0 m DIX METTZ ZAW Torch bracket, fixed DIX PHF Shock sensor ø 78.5 / 65 mm DIX SAS Adjusting gauge DIX EL Clamping sleeve For adjusting of the electrode with adjusting gauge 9 Plug set For shock sensor, only assembled available DIX SH DIX MEX Standard equipment for electrode diameter.2 mm with gas nozzle diameter 12.5 mm, DIX GD 408. TCP (for DIX SAS 100): 47 mm to robotic flange (electrode stand out: 5 mm). The corresponding adapter flange you find in the accessories list! Use the special spanner DIX SLAT 4 to tighten torch heads. Variants deviating of the standard fittings on request. Liners, capillary liners and service tools you will find in Chapter 5 Tools and Accessories.

21 Spare parts and wear parts Connecting set for torch sets METZ Connecting set for torch sets METTZ Description Part name Part number 1 Torch connection, MEZ DIX MEZ Housing, MET 1 DIX MET Push-button set, ME 1 For set-up mode, according to equipment 4 Socket set, ME 1 For shock sensor DIX ME DIX ME Housing - supporting ring, METT DIX METT Housing, METT 1 DIX METT Fitting part, METT DIX METT Supply hose for torch sets MET(T)Z 600 ZAW Torch view A Plug view Description Part name Part number A Supply hose DIX VLEZ 600- ZAW Combi cable DIX VL Control wire set, blue For shock sensor DIX VL Gas hose DIX VL Cover hose set DIX VL Water hose DIX VL Control wire set, black DIX VL Enter the required length of the welding torch set, e.g.: 50 = 5.0 m or 70 = 7.0 m. Standard lengths: 5.0 m and 7.0 m 41

22 Spare parts and wear parts Torch sets TAZ 400 ZAW, MET(T)Z 600 ZAW Plug A Description Part name Part number A Plug DIX KCZ 400 ZAW Connection hose, blue DIX VL 17-2 BLAU Connection hose, red DIX VL 17-2 ROT Hose clamp Hose socket Water plug DIX Fixing ring DIX HR Plug housing DIX SG Holding screw DIX 1-2-Z Plug insert DIX ZAW Center bushing DIX ZAW Other fittings on request. 42

23 Torch sets double separable applications DIX MEPWTTZ 600 SAZ/T PUSH-PUSH Tacho Application For DINSE Torch head liquide cooled DIX TETZ 400 (L) Properties Adjusting of the electrode with adjusting gauge Tool changer with storage station Information to the appropriate cold wire sets you will find in Chapter TIG AUTOMATION - TIG torch heads. Application sample TIG double separable version for PUSH-PUSH Tacho Description Dimension Part name Part number 1 Cold wire set DIX KD Torch head 0 DIX TETZ Connecting piece, TEPTZ DIX TEPS Intake nozzle DIX MEP Torch bracket, tacho DIX MEP 200 TW With integrated wire feeder without drive roll 6 Torch set 5.0 m DIX MEPWTTZ SAZ/T Liner ø 2.2 mm/0.m DIX DS 4/2, Drive roll, not shown, ø 1.0 mm S DIX MEP S for steel 9 Retainer DIX HA 201 (0 ) Shock sensor ø 78.8 / 65 mm DIX SAS Liner ø 2.9 mm/5.5m DIX DS 4/ Adjusting gauge DIX EL Clamping sleeve DIX SH For adjusting of the electrode with the adjusting gauge 14 Plug set For GREEN-line wire feeders, only assembled available DIX MEX Standard equipment for electrode diameter.2 mm with gas nozzle diameter 12.5 mm, DIX GD 408, and wire diameter 1.0 mm steel. TCP: 511 mm to robotic flange (Electrode stand out: 5 mm). The corresponding adapter flange you find in the accessories list! Use the special spanner DIX SLAT 4 to tighten torch heads. Variants deviating of the standard fittings on request. Other liners, capillary liners and service tools you will find in Chapter 5 Tools and Accessories. 4

24 Torch sets double separable applications DIX MEPWTTZ 600 SAZ/EC PUSH-PULL Encoder Application For DINSE Torch head liquide cooled DIX TETZ 400 (L) Properties Adjusting of the electrode with adjusting gauge Tool changer with storage station TIG double separable version for PUSH-PULL Encoder Application sample Information to the appropriate cold wire sets you will find in Chapter TIG AUTOMATION - TIG torch heads Description Dimension Part name Part number 1 Cold wire set DIX KD Torch head 0 DIX TETZ Connecting piece, TEPTZ DIX TEPS Intake nozzle DIX MEP Torch bracket, Encoder DIX MEP 200 EW With integrated wire feeder without drive roll 6 Torch set 5.0 m DIX MEPWTTZ SAZ/EC Liner ø 2.2 mm/0.m DIX DS 4/ Drive roll, not shown, ø 1.0 mm S DIX MEP S for steel 9 Retainer DIX HA 201 (0 ) Shock sensor ø 78.8 / 65 mm DIX SAS Liner ø 2.9 mm/5.5m DIX DS 4/ Adjusting gauge DIX EL Clamping sleeve DIX SH For adjusting of the electrode with adjusting gauge 14 Plug set For GREEN-line wire feeders, only assembled available DIX MEX Standard equipment for electrode diameter.2 mm with gas nozzle diameter 12.5 mm, DIX GD 408, and wire diameter 1.0 mm steel. TCP: 511 mm to robotic flange (Electrode stand out: 5 mm). The corresponding adapter flange you find in the accessories list! Use the special spanner DIX SLAT 4 to tighten torch heads. Variants deviating of the standard fittings on request. 44 Other liners, capillary liners and service tools you will find in Chapter 5 Tools and Accessories. You will find the appropriate for PUSH-PULL controls in Chapter 4 SYSTEM COMPONENTS - controls.

25 Spare parts and wear parts Torch sets MEPWTTZ 600 SAZ/T (EC) Connecting set Description Part name Part number 1 Intake nozzle DIX MEP Connecting piece, MEP DIX MEP Drive connection, MEPZ DIX MEPZ Housing - supporting ring, METT DIX METT Housing, METT 2 DIX METT Fitting part, METT, not shown DIX METT Cover cap DIX MEPW For tacho 8 Mounting socket DIX SCA-E-BU 9POL For encoder 9 Switch cap WIG DIX ECC 600 EC Socket set, ME 1 For shock sensor 11 Socket set, ME 2 For motor and tacho 12 Push-button set, ME 2 For set-up mode DIX ME DIX ME DIX ME

26 Spare parts and wear parts Torch sets MEPWTTZ 600 SAZ/T (EC) Supply hose A Torch view Plug view Description Part name Part number A Supply hose DIX VLEWPZ 600- T B Supply hose, not shown DIX VLEWPZ 600- E Conduit hose DIX VL Water hose DIX VL Gas hose DIX VL Control wire set, black For set-up mode 5 Control wire set, white/brown For Tacho 6 Control wire set, brown/red For motor 7 Control wire set, blue For shock sensor DIX VL DIX VL DIX VL DIX VL Cover hose set WIG DIX VL Silicone hose, black, 50 m Combi cable DIX VL Enter the required length of the welding torch set, e.g.: 12 = 1.2 m or 14 = 1.4 m. Standard length: 5.0 m 46

27 Spare parts and wear parts Torch sets MEPWTTZ 600 SAZ/T (EC) Plug A Description Part name Part number A Plug DIX KCZME 610 SAZ Fixing ring DIX HR Plug housing DIX SG-EC Connection hose, red DIX VL Connection hose, blue DIX VL Cap, red DIX VL Cap, blue DIX VL Water plug DIX Holding screw (10 pcs.) DIX ME 00 HS Plug insert DIX ME 610 SAZ Clamp nut DIX MEZ

28 Wire feeding systems for welding applications The perfect drive package! u precise wire feeding u modern drive concept u fully digitalized process control u detailed monitoring u maximum production reliability DINSE System innovations. 0I48

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