Fronius LaserHybrid WF 25i Operating Instructions Manual
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Fronius LaserHybrid WF 25i Operating Instructions Manual

Fronius LaserHybrid WF 25i Operating Instructions Manual

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/ Perfect Charging /
Perfect Welding
WF 25i LaserHybrid 10 kW
SB 360i LaserHybrid
42,0426,0279,EN 004-03102018
/ Solar Energy
Operating Instructions
LaserHybrid

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Summary of Contents for Fronius LaserHybrid WF 25i

  • Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating Instructions WF 25i LaserHybrid 10 kW SB 360i LaserHybrid LaserHybrid 42,0426,0279,EN 004-03102018...
  • Page 3 Fronius product. These instructions will help you familiarize yourself with the product. Reading the instructions carefully will enable you to learn about the many different features your Fronius product has to offer. This will allow you to make full use of its advan- tages.

  • Page 5: Table Of Contents

    Contents Safety Instructions ............................. Explanation of Safety Instructions......................General ..............................Intended Use............................Environmental Conditions ........................Obligations of the Operating Company....................Obligations of Personnel........................Personal Protective Equipment......................Danger from Toxic Gases and Vapors....................Danger Posed by Shielding Gas Leak ....................Danger from Flying Sparks ........................Hazards from welding current .......................
  • Page 6 Commissioning General ..............................Safety..............................Setup Regulations..........................Grid Connection ............................ Set Up LaserHybrid Welding System....................Installing the Laser Welding Head on the Robot..................Connection Options on the Robot......................Installing the Laser Welding Head on the Robot................... Installing and Connecting SplitBox SB 360i LaserHybrid ................Installing SplitBox SB 360i LaserHybrid on Robot ................
  • Page 7 Inserting the Laser Optics ........................Checking/Adjusting Laser Optics Focus ....................Fixing the Laser Optics ......................... Final Tasks............................Laser Optics – Overview........................Checking Position of the Wire Electrode in relation to the Laser Focus ............ Safety..............................General ..............................Checking Position of the Wire Electrode in relation to the Laser Focus ..........Example: Reference Program Application after Welding Torch Change ..........

  • Page 9: Safety Instructions

    Safety Instructions Explanation of DANGER! Indicates an immediate danger. Death or serious injury may result if Safety Instruc- appropriate precautions are not taken. tions 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.

  • Page 10: Intended Use

    Intended Use The LaserHybrid head is to be used exclusively for its intended purpose. The LaserHybrid head is intended exclusively for LaserHybrid welding of aluminum, CrNi and steel materials. Any other use does not constitute proper use. The manufacturer is not responsible for any damage resulting from improper use. Proper use also means: Completely reading and obeying all instructions in the Operating Instructions Completely reading and obeying all safety instructions and danger notices...

  • Page 11: Danger From Toxic Gases And Vapors

    Persons present in the sealed cell for the LaserHybrid process must wear rigid, wet-insulating footwear protect hands with appropriate gloves (featuring electrical insulation and thermal pro- tection) protect their eyes from laser beams by wearing regulation-compliant safety glasses for lasers. To protect their face and eyes against UV beams, further protection in the form of a protective shield with regulation-compliant filter insert for laser protection class 4 must also be used in front of the safety glasses for lasers and the person's face.

  • Page 12: Danger From Flying Sparks

    Danger from Fly- Flying sparks can cause fires and explosions. ing Sparks Never undertake welding near flammable materials. Flammable materials must be kept at least 11 meters (35 ft.) from the LaserHybrid welding process or protected with a certified cover. Keep suitable, tested fire extinguishers on hand.

  • Page 13: Particular Hazard Areas

    Supporting measures to avoid EMC problems: 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). Welding power-leads Keep them as short as possible Route them close together (also to avoid EMC problems) Route them far from other lines Equipotential bonding Workpiece grounding...

  • Page 14: Informal Safety Measures

    When handling coolants, observe the specifications on the safety data sheet. The coolant safety data sheet is available from your service center or from the manufacturer's homep- age. Only use suitable load-carrying equipment from the manufacturer for transporting devices by crane. Attach chains or ropes to all designated suspension points on suitable load-carrying equipment.

  • Page 15: Safety Measures In Normal Operation

    Before transporting the device, always completely drain the coolant and dismantle the fol- lowing components: Wirefeeder Wirespool Shielding gas cylinder It is essential to conduct a visual inspection of the device to check for damage after it has been transported but before it is commissioned. Have any damage repaired by trained ser- vice technicians before commissioning the device.

  • Page 16: Calibrating Power Sources

    Calibrating Power Regular calibration of power sources is required in accordance with international stan- Sources dards. The manufacturer recommends a calibration interval of 12 months. Please contact your service center if you require further details. The CE label The LaserHybrid head meets the basic requirements of the Low Voltage and Electromag- netic Compatibility Directives and therefore has CE sign.

  • Page 17: General Information

    General Information...

  • Page 19: General

    Intended Use The WF 25i LaserHybrid 10 kW is designed exclusively for automated MIG/MAG welding in connection with Fronius system components. Any other use does not constitute proper use. The manufacturer is not responsible for any damage resulting from improper use.

  • Page 20: Scope Of Supply

    Scope of Supply The following components are included as standard with the laser welding head: 1 x WF 25i LaserHybrid 10 kW laser welding head (complete) 1 x LaserHybrid hosepack 1 x stick out gauge 1 x flow volume meter (max. 25 l/min) 1 x Operating Instructions Tool and wirefeed end accessories, depending on the configuration Tool and Wirefeeder Accessories:...

  • Page 21: Gas Nozzle Cross Jet

    Gas nozzle cross During welding, depending on the energy density and material, the laser triggers a plasma flare of a varying height which absorbs the laser light. At constant laser output a penetration of different depths is created. To ensure constant penetration despite the plasma flare, it is possible to use the gas nozzle cross jet.

  • Page 22: Requirements

    Requirements Mechanical Re- The following mechanical requirements must be met in order to ensure a stable and re- quirements peatable LaserHybrid process: Accurate welding torch guidance for robots or single-purpose machines (e.g. longitu- dinal chassis) Precise weld seam preparation Low component tolerances Precise and very fast weld seam management systems with little deviation Robot Require- The laser welding head weighs around 19 kg.

  • Page 23: Alignment

    Alignment Always avoid 90° angles to the workpiece surface when aligning the LaserHybrid head. NOTE! Failure to do so will cause serious damage to the optical fi- ber, because the laser radiation will be reflected directly on to the laser optics. 5°...

  • Page 24: System Overview

    System Overview System Overview LaserHybrid System with SplitBox SB 360i LaserHybrid Mounted on the Robot (10) (11) (12) Welding wire drum * Wirefeeding hose Wirefeeder reel: Interconnecting hosepack WF 25i REEL 4R Robot + OPT/i WF Wire straightening SplitBox SB 360i LaserHybrid path (4,100,880,CK) (10) Hosepack LaserHybrid...

  • Page 25: Other Laserhybrid Systems

    Other LaserHy- LaserHybrid System with SplitBox SB 360i LaserHybrid Mounted on the Wall brid Systems (10) (11) (12) Welding wire drum Wirefeeding hose Wirefeeder reel: Interconnecting hosepack WF 25i REEL 4R Robot + OPT/i WF Wire straightening SplitBox SB 360i LaserHybrid path (4,100,880,CK) (10) Hosepack LaserHybrid...
  • Page 26 LaserHybrid System with SplitBox SB 360i LaserHybrid Mounted on the Power Source (10) (11) Remote control Wirefeeder reel: WF 25i REEL 4R Control line for wirefeeder reel + OPT/i WF reel carriage D300 Power source TPS 500i Hosepack LaserHybrid + Robot interface + Cooling unit CU 1400i Pro MC or Wirefeeding hose CU 2000i MC Single...

  • Page 27: Setup Variants

    Setup Variants Power Source Located in Welding Cell (I) TPS 500i – power source HP 95i CON W / 1.2 m / 95 mm² – interconnecting hosepack SB 360i LaserHybrid – SplitBox, mounted on the power source MHP 360i LH/W/FSC/FW 7.5m – LaserHybrid hosepack Welding wire drum WF 25i REEL 4R –...
  • Page 28 Power Source Not Located in Welding Cell (II) TPS 500i – power source HP 95i CON W / 10 m / 95 mm² – interconnecting hosepack SB 360i LaserHybrid – SplitBox, wall mounting MHP 360i LH/W/FSC/FW 7.5m – LaserHybrid hosepack Welding wire drum WF 25i REEL 4R –...

  • Page 29: Operating Controls And Connections

    Operating controls and connections...

  • Page 31: Product Description

    Product description Device Descrip- tion WF 25i Laser- Hybrid 10 kW (15) (16) (17) (18) (10) (19) (20) (11) (21) (12) (13) (14) Item Description Exhaust for crossjet (must be connected to an extraction unit) Supply to crossjet Connection for optional pressure monitoring A LaserHybrid hosepack with extra data line is needed for optional pressure mon- itoring.

  • Page 32: Device Description, Sb 360I Laserhybrid

    Item Description (10) Gas-test button Wire-return button* Wire-threading button* * The wire-return and wire-threading buttons are located on the opposite side of the laser welding head. (11) Mounting plate Thickness 21 mm or 17.5 mm, depending on application (12) LaserHybrid welding torch (13) Gas nozzle crossjet (optional) (14)

  • Page 33: Pressure Monitoring In The Splitbox Sb 360I Laserhybrid

    Item Description Connection for welding torch cooling – coolant supply line (blue) for connecting the coolant supply line hose from the interconnecting hosepack SplitBox SB 360i LaserHybrid mount Welding torch connection (FSC) for connecting the LaserHybrid hosepack (10) Connection crossjet OUT (11) (12) Connection crossjet IN...

  • Page 34: Collision Protection

    Collision Protection General The laser welding head is fitted with collision protection to protect the LaserHybrid welding torch and the entire laser welding head. The collision protection works on the floating contact principle. Displacing the welding torch a certain amount will open the circuit (ring line) between the two inputs for the robot control. The ring line runs from the laser welding head, via the LaserHybrid hosepack, on to the SplitBox SB 360i LaserHybrid, and from there on to the connection for the robot interface used on the power source.

  • Page 35: Connection Specifications

    Connection Specifications Connection Spec- ifications (10) Item Description Crossjet extraction connection for connecting a hose in accordance with the following data: Internal diameter Di = 51 mm External diameter Da = 57 mm Max. length = 10 m Crossjet supply for connecting a hose in accordance with the following data: Internal diameter Di = 12 mm External diameter Da = 14 mm...
  • Page 36 Item Description Crossjet gas nozzle supply for connecting a hose in accordance with the following data External diameter Da = 4 mm The hose connects the crossjet gas nozzle supply (4) to the crossjet gas nozzle (7). Fiber optic cable for laser bending radius >...

  • Page 37: Compressed Air Diagram

    Compressed Air MPH LH = LaserHybrid hosepack Diagram MHP LH SB 360i LaserHybrid WF 25i LaserHybrid 10 kW Item Description Compressed air supply (min. 6 bar) Solenoid valve Internal pressure measurement Pressure measurement option Radial air stream branching Gas nozzle crossjet branching Crossjet air supply duct connections Exhaust air crossjet Extraction...

  • Page 39: Commissioning

    Commissioning...

  • Page 41: General

    General Safety WARNING! Work performed incorrectly can cause serious injury and damage to property. This setting work must only be carried out by trained and qualified per- sonnel. Please observe the safety rules in the Operating Instructions, and the "Safety Inspection" section in particular. Setup Regula- The power sources have been tested according to degree of protection IP 23.
  • Page 42 Connect power source to robot control Connect remote control Set up laser welding head: Installing the Laser Welding Head on the Robot Installing and Connecting SplitBox SB 360i LaserHybrid Connect crossjet Connecting LaserHybrid Hosepack to Laser Welding Head Connecting/changing Wirefeeding Hose to/on Laser Welding Head Installing/Changing Wirefeed Rollers Connect laser optics and extra extraction Preparing Welding Torch...

  • Page 43: Installing The Laser Welding Head On The Robot

    Installing the Laser Welding Head on the Robot Connection Op- tions on the Ro- 90 mm 406,5 mm Installing the La- Install the laser welding head in line ser Welding Head with the robot manufacturer's specifi- on the Robot cations for the robot.

  • Page 44: Installing And Connecting Splitbox Sb 360I Laserhybrid

    Installing and Connecting SplitBox SB 360i LaserHy- brid Installing Split- Separate the SplitBox SB 360i LaserHybrid and SplitBox mount Box SB 360i Lase- Install a suitable holder for the SplitBox mount on your robot rHybrid on Robot IMPORTANT Please observe the robot manufacturer's assembly instructions. Fit the SplitBox mount on the holder using 4 x Allen screws size 6 mm Tightening torque = 24 Nm...
  • Page 45 Fix the interconnecting hosepack strain-relief device in place using 2 x Allen screws size 4 mm Open the ear clamps (x 2) Insert the interconnecting hosepack into the ear clamps Close the ear clamps Insert SplitBox SB 360i LaserHybrid into the SplitBox mount as illustrated Fix SplitBox in place in the SplitBox mount using 3 x screws TX25 at the top and 3 x screws TX25 at the bottom...

  • Page 46: Connecting Splitbox Sb 360I Laserhybrid

    Connecting Split- Connect interconnecting hosepack to Box SB 360i Lase- SplitBox: rHybrid Power cable Welding torch cooling return flow (red) Welding torch cooling supply line (blue) Protective gas shield SpeedNet (from interconnecting hosepack) SpeedNet (remote control) Gas purging connection Connect LaserHybrid hosepack to wel- ding torch connection (FSC) Close clamping lever Open cover on LaserHybrid hosepack...
  • Page 47 IMPORTANT! When connecting crossjet air outlet hoses, make sure that cutting rings are present! Connect crossjet air outlet (x 2) Fix the hoses in place on the connecti- on using hexagon nuts size 24 mm Tightening torque = 50 Nm IMPORTANT! Use flat spanner size 22 mm to hold the items in place when fixing the hexagon nuts in place on the connection...

  • Page 48: Connecting Crossjet

    Connecting Crossjet Connecting Insert the crossjet exhaust hose into Crossjet the opening Position the fixing plate so that it sits in a groove on the crossjet exhaust hose (x 2 – on opposite side too) Install the fixing plate using 2 x Allen screws size 3 mm (x 2 –...
  • Page 49 Pull the protective hoses across the connections...

  • Page 50: Connecting Laserhybrid Hosepack To Laser Welding Head

    Connecting LaserHybrid Hosepack to Laser Welding Head Connecting Lase- IMPORTANT! When connecting the LaserHybrid hosepack, ensure that pins and connec- rHybrid Hosepack tions on the interface do not get bent or damaged. to Laser Welding Align the LaserHybrid hosepack to be as straight as possible. Head Connect the LaserHybrid hosepack Fix the LaserHybrid hosepack in place:...

  • Page 51: Connecting/Changing Wirefeeding Hose To/On Laser Welding Head

    Put CrashBox cable together Lay cable in groove Connecting/ Insert wirefeeding hose into laser wel- changing Wire- ding head feeding Hose to/ on Laser Welding Head Press and hold locking button Insert the wirefeeding hose into the lo- cking device as far as is needed to re- lease the locking button Release the locking button Keep pushing the wirefeeding hose un-...

  • Page 52: Installing/Changing Wirefeed Rollers

    Installing/Changing Wirefeed Rollers Installing/Chang- IMPORTANT! The wire electrode has to be pulled out in order to change the wirefeed roll- ing Wirefeed Roll- Disconnect external wirefeeding hose Swing the clamping stirrup open Remove the screwable shaft Remove the wirefeeder roller Remove the hexagon nut size 10 mm –...

  • Page 53: Connecting Laser Optics And Extra Extraction

    Connecting Laser Optics and Extra Extraction Connecting Laser CAUTION! Risk of damage to the laser welding head as a result of contamination Optics from above. Please observe the Operating Instructions, specifications and safety instruc- tions issued by the manufacturer of the laser optics Prior to connection, position the laser welding head so that the longitudinal axis on the laser welding head is outside of the horizontal (>...
  • Page 54 Position the laser welding head so that the longitudinal axis on the laser wel- ding head is outside of the horizontal (> 90°) Clean connection area using compres- sed air Remove protective cover from fiber op- tic cable connection Clean fiber optic cable plug using com- pressed air Remove protective cover from fiber op- tic cable plug...
  • Page 55 IMPORTANT! When connecting the fiber optic cable, pay attention to the position of the register pin on the plug. Connect fiber optic cable: Press the key Pull the rubber sleeve back in the direction of the optics Connect the fiber optic cable plug Check whether the rubber sleeve is se- aling neatly around the fiber optic cable plug...

  • Page 56: Connecting Extra Extraction

    Connect optics cooling supply line (blue marking) Connect optics cooling return flow Put the laser welding head into a vertical position Connecting Extra Push the hose across the connection Extraction Fix the hose in place with the hose clamp...
  • Page 57 Position bracket for robot connection Push the slot nut up so that the top hole on the slot nut is positioned below the top hole on the bracket for the robot connection. Fasten, but do not completely tighten, the slot nut and bracket for the robot connection using a short Allen screw size 6 mm Insert 2 x register pins...
  • Page 58 For assembly: the 3 x shorter screws are located one be- low the other; the 2 x longer screws opposi- te each other. Insert the remaining 4 x Allen screws size 6 mm Fix the bracket for the robot connection in place using 5 x Allen screws size 6 Tightening torque = 24 Nm...

  • Page 59: Preparing Welding Torch

    Preparing Welding Torch Preparing Weld- Open knurled nut ing Torch Insert the inner liner into the welding torch from underneath Use the entire contact tip to insert the entire inner liner into the welding torch...
  • Page 60 Place the union nut over the contact tip Tighten union nut size 12 mm Tightening torque = 3 Nm Put the gas nozzle in position Fix the gas nozzle in position using Al- len screw size 4 mm Fold the bracket downward Tighten the knurled nut...

  • Page 61: Installing Hosepack On Robot

    Installing Hosepack on Robot Installing Hose- IMPORTANT! The LaserHybrid hosepack holder option is not included with the laser weld- pack on Robot ing head as standard. 6 x 4 Nm 44,0360,0099 4 Nm 4 Nm Robot arm Opening for LaserHybrid hose- pack Beam Adapter insert for extraction hose...

  • Page 62: Threading The Wire Electrode

    Threading the Wire Electrode Threading the IMPORTANT! Carefully deburr the end of the wire electrode before threading the wire on it. Wire Electrode Requirement: Wirefeeding hose connected Wire electrode threaded in wirefeeder reel Correct wirefeeder rollers and inlet nozzles present in laser welding head Close clamping stirrup Press the wire-threading button until the wire electrode comes out of the...

  • Page 63: Setting Up Laser Welding Head

    Setting up Laser Welding Head Stick Out There are two different mounting plates for the laser welding head, depending on the ap- plication: Mounting plate 21 mm Mounting plate 17.5 mm The TCP cannot be on the laser fo- The TCP can be on the laser focus, cus.

  • Page 64: Adjustable Axes

    Adjustable Axes The physical location of the arc process in relation to the laser beam can be adjusted on three Cartesian coordinate axes: CAUTION! Risk of damage to the fiber optic when workpiece surface is posi- tioned at a right angle to the laser welding head. If the laser optics are at a 90°...

  • Page 65: Setting Up X-Axis

    Scale for additional adjustment option on the z-axis Adjustment range 0 / +10 mm Basic position for the Trumpf optics holder = 0 Loosen the 2 x Allen screws size 5 mm in order to make additional adjustments on the z-axis and move the optics holder. Tightening torque for the Allen screws = 10 Nm Adjusting screw with division for z-axis Adjustment range +12 / -7 mm...

  • Page 66: Setting Up Y-Axis

    Setting Up Y-Axis NOTE! The x-axis and y-axis are set up with the cover removed from the drive unit. Re-fit the cover on the drive unit after set-up. Loosen 2 x Allen screws size 5 mm (1) Set up the y-axis using the adjusting screw and Allen key size 5 mm: 1 x turn equates to 1.0 mm After setting up the y-axis, re-tighten the 2 x Allen screws size 5 mm (1)

  • Page 67: Setting Up Z-Axis

    Setting Up Z-Axis NOTE! The z-axis is set up with the cover removed from the drive unit and with the control box removed. Re-fit the drive unit after setting up the control box and cover. Loosen 2 x Allen screws size 5 mm (1) Loosen 2 x Allen screws size 5 mm (2) Set up the z-axis using the adjusting screw and Allen key size 5 mm:...

  • Page 68: Creating Reference Program

    Creating Reference Program Safety WARNING! Work performed incorrectly can cause serious injury and damage to property. This setting work must only be carried out by trained and qualified per- sonnel. Please observe the safety rules in the Operating Instructions, and the "Safety Inspection"...
  • Page 69 Document the distance from the wire electrode to the laser focus on the x- and y-axis using the scaling on the gauge Store the settings as a reference program in the robot Carry out a test weld The best welding results are used as a basis for the reference program. If changes are required to the mechanical x/y settings because of the test weld, over- write the first reference program you created...

  • Page 70: Signal Sequence For Laserhybrid Welding

    Signal Sequence for LaserHybrid Welding Safety WARNING! Work performed incorrectly can cause serious injury and damage to property. The welding process may only be programmed by trained personnel. Please observe the safety rules in the Operating Instructions, and the "Safety In- spection"...
  • Page 71 LaserHybrid welding end position: Stop robot movement Reset signal "Laser on" Reset signal "Welding on" Wait until the current flow signal = zero Robot end position: IMPORTANT! The robot end position is not the end of the weld seam. Reset signal "Crossjet on" Reset signal "Extraction on"...

  • Page 72: Measures Before Starting Welding

    Measures before Starting Welding Measures before Check the coolant flow on the laser optics cooling system Starting Welding Check the coolant flow on the welding torch cooling system (visual inspection in the coolant tank of the cooling unit) Check whether a protective glass is present in the laser optics Check whether all covers are correctly mounted on the laser welding head Test CrossJet Test extraction...

  • Page 73: Operation Recommendations For Laserhybrid Welding System

    Operation Recommendations for LaserHybrid Weld- ing System Operation Rec- To ensure smooth operation, the following objects should always be available for a Lase- ommendations rHybrid welding system: for LaserHybrid Welding System LaserHybrid service station Compressed-air gun supplied with 6 bar Movable tool trolley containing the following tools and spare parts: 20 x contact tips, for each diameter 10 x gas distributors...

  • Page 75: Maintenance

    Maintenance...

  • Page 77: Replacing The Welding Torch And Welding Torch Wearing Parts

    Replacing the Welding Torch and Welding Torch Wearing Parts Safety CAUTION! Burning hazard due to hot welding torch, as a result of operation. The welding torch must only be cleaned and its components only checked after the welding torch has cooled down. Welding Torch Spare Parts Replacing the...
  • Page 78 Open knurled nut Loosen the union nut using the torch Pull the welding torch down and off NOTE! The torch key and torque wrench (tightening torque = 18 +/- 2 Nm) must be used to assemble the welding torch 18 +/- 2 Nm...

  • Page 79: Replacing Welding Torch Wearing Parts

    Replacing Weld- ing Torch Wear- ing Parts IMPORTANT! Before assembly, clean the gas distributor, the thread on the union nut and the torch body.

  • Page 80: Replacing The Spatter Guard Plate And Extra Extraction

    Replacing the Spatter Guard Plate and Extra Ex- traction Replacing the Please note: Spatter Guard the numbering on the arrows in the illustrations may not match the work steps. Plate Remove 2 x Allen screws size 2.5 mm Remove spatter guard Assemble by performing the steps in the re- verse order Replacing the Ex-...

  • Page 81: Replacing The Laser Optics

    Replacing the Laser Optics Safety WARNING! Work performed incorrectly can cause serious injury and damage to property. This assembly work must only be carried out by trained and qualified personnel. Please observe the safety rules in the Operating Instructions, and the "Safety Inspection"...
  • Page 82 Remove 2 x register pins: Position and connect extractor tool for register pins Hit the vibrating mass on the ext- ractor tool backward and then re- move the register pins Remove bracket for robot connection Position the laser welding head so that the longitudinal axis on the laser welding head is outside of the horizontal (>...
  • Page 83 Disconnect radial air stream Remove 2 x Allen screws size 2.5 mm Remove spatter guard Remove 2 x Allen screws size 2.5 mm Remove extra extraction...

  • Page 84: Removing The Laser Optics

    Remove 4 x Allen screws size 3 mm Remove crossjet IMPORTANT! When removing the crossjet, make sure that the O-rings do not get lost. Removing the La- Remove 6 x threaded pins ser Optics size 2.5 mm Remove 4 x Allen screws size 4 mm Remove 2 x Allen screws size 4 mm...
  • Page 85 Loosen 2 x Allen screws size 4 mm CAUTION! Dropping the laser op- tics may lead to damage beyond repair. Remove and handle the laser op- tics carefully. Push the laser optics out from the gui- de and holder Remove the laser optics IMPORTANT! When removing the laser optics, make sure that the springs connec- ted underneath do not get lost.

  • Page 86: Inserting The Laser Optics

    Inserting the La- IMPORTANT! When replacing the laser optics, ensure that the laser optics and welding ser Optics torch are compatible in terms of the focal length. CAUTION! Dropping the laser op- tics may lead to damage beyond repair. Insert and handle the laser optics carefully.
  • Page 87 Fit fixing clamp Insert 2 x Allen screws Tighten the Allen screws slightly size 4 mm Connect the fiber optic cable on the la- ser optics see page 53, work step 2 onward Position the laser welding head via the robot so that the laser optics are at a 90°...

  • Page 88: Checking/Adjusting Laser Optics Focus

    Checking/Adjust- After replacing Trumpf laser optics, check the focus and, if necessary, adjust it, in order to ing Laser Optics even out any optic tolerances. Focus A pilot laser with low power is required for the described adjustment work. Checking Laser Optics Focus Depending on the mounting plate present, adjust the relevant stick out for the wire electrode: Mounting plate 21 mm ...
  • Page 89 Set up focus in y direction: Using the Allen screw threaded pins (2), set up the laser optics in the y di- rection size 2.5 mm The installed springs take care of the +/ - movement. Screw the Allen screw threaded pins (1) and (3) tight size 2.5 mm Set up focus in positive x direction:...

  • Page 90: Fixing The Laser Optics

    Fixing the Laser NOTE! To prevent the laser optics from warping on the laser head, ensure you Optics perform the following work steps in the exact same sequence. Set up terminal Tighten 2 x Allen screws size 4 mm Tightening torque = 5.7 Nm Screw fixing clamp tight with 2 x Allen screws size 4 mm...

  • Page 91: Final Tasks

    Final Tasks IMPORTANT! Check the laser optics' focus before assembling the crossjet. IMPORTANT! When installing the crossjet, make sure that the O-rings are present. Install the crossjet with 4 x Allen screws size 3 mm Tightening torque = 2.5 Nm Install the extra extraction with 2 x Al- len screws size 2.5 mm...
  • Page 92 Position bracket for robot connection Push the slot nut up so that the top hole on the slot nut is positioned below the top hole on the bracket for the robot connection. Fasten, but do not completely tighten, the slot nut and bracket for the robot connection using an Allen screw size 6 mm Insert 2 x register pins...

  • Page 93: Laser Optics - Overview

    Insert the remaining 4 x Allen screws size 6 mm Fix the bracket for the robot connection in place using 5 x Allen screws size 6 Tightening torque = 24 Nm Laser Optics – Overview TRUMPF PRECITEC HIGHYAG + 4,101,078 * + 4,100,714 * + 4,101,068 * 4x M5 x 16 mm...

  • Page 94: Checking Position Of The Wire Electrode In Relation To The Laser Focus

    Checking Position of the Wire Electrode in relation to the Laser Focus Safety WARNING! Work performed incorrectly can cause serious injury and damage to property. This setting work must only be carried out by trained and qualified per- sonnel. Please observe the safety rules in the Operating Instructions, and the "Safety Inspection"...

  • Page 95: Example: Reference Program Application After Welding Torch Change

    Example: Refer- Switch off power source ence Program Ap- Change welding torch plication after After the welding torch has been changed and the wearing parts have been fitted: Welding Torch switch on power source Change Set the stick out to either 14 or 20 mm, depending on the application Upload the reference program and slowly move to the reference position on the ad- justing gauge Thread the wire electrode until this is touching the adjusting gauge...

  • Page 96: Measures To Reduce Contamination Of The Optics

    Measures to Reduce Contamination of the Optics Measures to Re- Crossjet and Extraction duce Contamina- tion of the Optics Please observe the values for the crossjet and extraction specified in these Operating Instructions. Switch on the crossjet and extraction at least five seconds before the start of welding. Do not switch off the crossjet and extraction until the laser welding head is safely in the smoke-free zone.
  • Page 97 Automated Torch Cleaning Device 10. When using an automatic torch cleaning device: Switch on the crossjet and extraction during the cleaning process. Changing the Fiber Optic Cable 11. The laser welding head must be in a horizontal position when you are changing the fiber optic cable so that no dust can fall into the optics from above.

  • Page 99: Appendix

    Appendix...

  • Page 101: Technical Data

    1.0–1.6 mm 360i LH Voltage rating (V-Peak) 141 V Cooling system Liquid cooling Coolant Original Fronius coolant Hosepack length 4.2 m/7.5 m Minimum cooling capacity in accordance with IEC 60974- 1400/1500 W subject to hosepack length Coolant pressure min./max. 3.0/5.0 bar Minimum flow of coolant 1.0 l/min...

  • Page 102: Spare Parts List: Laserhybrid Tpsi

    Spare parts list: LaserHybrid TPSi...
  • Page 112 FRONIUS INTERNATIONAL GMBH Froniusplatz 1, A-4600 Wels, Austria Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940 E-Mail: sales@fronius.com www.fronius.com www.fronius.com/addresses Under http://www.fronius.com/addresses you will find all addresses of our Sales & service partners and Locations...

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