Table of 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 ........................
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Setting Up the LaserHybrid Welding System..................Installing the Laser Welding Head on the Robot..................Connection Options on the Robot......................Mount WF 25i Robacta Drive on the laser welding head..............Mounting the Laser Welding Head on the Robot .................. Installing and Connecting SplitBox SB 360i LaserHybrid ................Installing SplitBox SB 360i LaserHybrid on Robot ................
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General ..............................Checking Position of the Wire Electrode in relation to the Laser Focus ..........Example: Use of the Reference Program after Welding Torch Replacement........Measures to Reduce Contamination of the Optics ..................Measures to Reduce Contamination of the Optics ................Appendix Technical Data ............................
Safety Instructions Explanation of DANGER! Safety Instruc- tions 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.
For the location of the safety and danger notices on the LaserHybrid head, refer to the sec- tion headed "General" in the Operating Instructions for the LaserHybrid head. Before switching it on, resolve any faults that could compromise safety. Your personal safety is at stake! Intended Use The LaserHybrid head is to be used exclusively for its intended purpose.
Personal Protec- Please take the following precautions for your own personal safety: tive Equipment 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.
Shielding gas is colorless and odorless and may suppress the oxygen in the ambient air in the event of leakage. Ensure there is a sufficient supply of fresh air with a ventilation flow rate of at least 20 m³ per hour. Please observe the safety and maintenance information for the shielding gas cylinder or the main gas supply.
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 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 imme- diate vicinity of where the welding work is taking place.
Slag may fly off from workpieces that are cooling down. For this reason, be sure to wear regulation-compliant protective equipment and ensure that other people are sufficiently protected even when reworking workpieces. Leave the welding torch and other parts with a high operating temperature to cool before working on them.
Safety Measures The cell for the LaserHybrid welding process must meet the following requirements: at the Installation be light-proof in relation to surrounding rooms Location is shielded with at least 1 mm steel plate and/or approved laser protective glass to pro- tect against UV and laser beams The laser welding process and the arc welding process must be stopped automatically and immediately as soon as the cell is opened.
BGV A2, Section 5 Electrical Plants and Equipment BGV D1, Sections 33 / Welding, Cutting and Related Work Methods VDE 0701-1 Repairing, Modifying and Testing Electrical Devices; General Requirements VDE 0702-1 Repeating Tests on Electrical Devices Modifications Do not carry out any alterations, installations, or modifications to the LaserHybrid head without first obtaining the manufacturer’s permission.
Intended Use The WF 25i LaserHybrid 90° 10 kW FW is intended exclusively for automated MIG/MAG welding in combination with Fronius system components. Any other use does not constitute proper use. The manufacturer is not responsible for any damage resulting from improper use.
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.
Alignment CAUTION! Danger of serious damage by laser radi- ation reflected directly into the laser op- tics! This can cause serious damage to the fiber optic. ► Always avoid 90° angles to the work- piece surface when aligning the Lase- rHybrid head.
Other LaserHy- LaserHybrid System with SplitBox SB 360i LaserHybrid Installed on the Wall brid Systems (10) (11) (12) Welding wire drum Wirefeeding hose Unwinding wirefeeder: Interconnecting hosepack WF 25i REEL 4R Robot + OPT/i WF wire straightener SplitBox SB 360i LaserHybrid (4,100,880,CK) + wall bracket SB 360i LH + WF MOUNTING Wall...
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LaserHybrid System with SplitBox SB 360i LaserHybrid Installed on the Power Source (10) (11) Remote control Unwinding wirefeeder: WF 25i REEL 4R Control line for unwinding wire- + OPT/i WF reel carriage D300 feeder Hosepack LaserHybrid Power source TPS 500i MHP 360i LH/W/FSC/FW + robot interface + cooling unit CU 1400i Pro MC or...
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 –...
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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 –...
Control Panel WF Function 25i Robacta Drive Gas-test button / WF 60i Robacta To set the required quantity of Drive CMT gas on the gas pressure regulator After pressing the gas-test button, gas is released for 30 s. Pressing the button again ends the process early Function F1 button...
Function Option 1 Thread the wire electrode at the preset feeder inching speed: Press and hold the wire-threading button After pressing the wire-threading button, the wire electrode will be threaded in by 1 mm (0.039 in.) After a brief pause, the wirefeeder continues threading in the wire elec- trode –...
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Item Description SpeedNet connection for connecting the SpeedNet cable from the interconnecting hosepack SpeedNet connection for connecting system add-ons e.g. the remote control Gas purging connection Connection for welding torch cooling – coolant return flow (red) for connecting the coolant return flow hose from the interconnecting hosepack Connection for welding torch cooling –...
Connection Specifications Connection Spec- ifications Item Name Laser optics water cooling connection (return opposite) Fiber optic cable for laser bending radius > 200 mm CrossJet extraction connection for connecting a hose as per the following data: Inner diameter Di = 51 mm Outer diameter Do = 57 mm Max.
Max. length = 10 m Recommended extraction unit: min. fan power = 200 m³/h min. negative pressure = 20,000 Pa External wirefeeding hose (Fronius) Radial air supply for connecting a hose as per the following data: Outer diameter Do = 6 mm...
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 personnel. ► Observe the safety rules in the OI, in particular the "Safety Inspection" section. Setup Regula- The power sources have been tested according to protection class IP 23.
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Initial situation: Robot and robot control are present and ready for operation Set up welding system: Mount upright brackets Mount cooling unit on upright bracket Connect power source to cooling unit Set up welding wire drum Mount WF MOUNTING drum onto the welding wire drum Set up and connect unwinding wirefeeder Connect power source with robot control Connect remote control...
Installing the Laser Welding Head on the Robot Connection Op- tions on the Ro- 90 mm 238 mm Mount WF 25i Ro- If the drive unit WF 25i Robacta Drive is not mounted to the laser welding head when it is bacta Drive on the delivered, mount it following the instructions below.
The laser welding head does not have any collision protection fitted as standard. Fronius therefore recommends the use of a commercially available collision protection solution for robotic applications in order to prevent damage to the laser welding head in the event of a crash.
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...
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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...
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...
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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...
Connecting Crossjet Connecting the Insert CrossJet exhaust air hose into CrossJet the opening Position fixing plate so that it is in a groove of the CrossJet exhaust hose (x2 - also on the opposite side) Secure fixing plate with 2 Allen screws, 3 mm (x2 - also on the opposite side) Depending on the robot movement,...
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Pull protective hoses over the connec- tions...
Connecting LaserHybrid Hosepack to Laser Welding Head Mounting the IMPORTANT! Only mount the drive unit when the power source is switched off. Hosepack on the WF Robacta Drive CAUTION! (Conventional) Risk of damage due to dirty or wet coupling points ►...
Connecting/ Place the starting piece on the wirefee- Changing the ding hose Wirefeeding Hose Screw the starting piece as far as it will on the Laser go onto the wirefeeding hose Welding Head Press the green locking button and hold it Push the wirefeeding hose into the dri- ve unit until the tension on the locking button is released...
Installing/Changing Wirefeed Rollers Inserting/Replac- ing the WF 25i Ro- bacta Drive Feed Rollers 0 mm * * If the roller mount is opened as far as it will go with the slight resistance, the roller mount stays in this po- sition.
Connecting Laser Optics and Extra Extraction Connecting the CAUTION! Laser Optics Risk of damage to the laser welding head as a result of contamination from above. ► Observe the OI, specifications, and safety instructions from the manufacturer of the la- ser optics ►...
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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 the protective cover from the fiber optic cable connection Clean connector of the fiber optic cable using compressed air Remove protective cover from the...
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IMPORTANT! When connecting the fiber optic cable, pay attention to the position of the register pin on the connector! Connect fiber optic cable: Press the button Withdraw the rubber sleeve in the direction of the optics Connect the fiber optic cable connector Check whether the rubber sleeve is cleanly sealed all around the fiber optic...
Connect the optics cooling supply (blue marking) Connect the optics cooling return Position laser welding head in the vertical line Connecting the Push hose over the connection Additional Ex- Secure hose with hose clamp traction System...
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Apply robot connection bracket Push slot nut upwards, so that the top hole of the slot nut is positioned under the top hole of the robot connection bracket. Use a short Allen screw (6 mm) to lightly fix the slot nut and robot connec- tion bracket Insert register pins (x2) Position and connect extractor tool for...
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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 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...
Steel inner liner: Mounting the IMPORTANT! When removing or attaching the welding torch, ensure that the coupling Welding Torch point is clean and dry. Remove any coolant that has escaped from the coupling point. onto the WF Ro- bacta Drive (Con- ventional)
Installing Hosepack on Robot Placing the Hose- IMPORTANT! The optional LaserHybrid hosepack holder is not included in the scope of pack on the Ro- supply for the laser welding head. 6 x 5 Nm 44,0360,0099 (14) 8 Nm 2,9 Nm (10) (12) (11)
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Installation Mount the mounting plate (2) to the robot arm (1) according to the instructions of the robot manufacturer Cut the profile 10 50 x 50 mm (3) to length according to the robot arm Mount the profile 10 50 x 50 mm (3) using slot nuts and 4 hexagonal bolts, size 17 mm, to the mounting plate (2) Tightening torque = 10 Nm Remove Allen screw, size 3 mm (12), and dismantle the lower sheet metal part (10)
Adapting the Additional Extraction System 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 personnel. ► Observe the safety rules in the OI, in particular the "Safety Inspection" section. Adapting the Ad- To make components more accessible, the position of the additional extraction system can ditional Ex-...
Threading the Wire Electrode Threading the IMPORTANT! Before threading the wire electrode, carefully deburr the end of the wire Wire Electrode electrode! Requirement: Wirefeeding hose connected Wire electrode is threaded into the unwinding wirefeeder Correct wirefeed rollers and inlet nozzles available in the laser welding head Press the wire threading button until the wire electrode comes out of the welding torch...
Setting up Laser Welding Head Stick Out NOTE! When setting the spatial position of the welding torch, pay attention to a general stick out of 15-20 mm. Standard stick out = 20 mm ► Using an adjustment device, compen- sate for a stick out < 20 mm in the x, y, and z axis according to the focal length of the laser optics.
Adjustment De- The laser welding head is equipped with an adjustment device, which allow for precise po- vice on the Laser sitioning in the x, y, and z coordinate axes. Welding Head Scale for the x axis Adjustment screw with graduati- on for the x axis Adjustment range +/- 5 mm Allen screw, 5 mm...
Adjusting the y Loosen 2 Allen screws by 1 turn res- Axis pectively size 4 mm Adjust y axis by turning the adjustment screw (3): Allen key, size 5 mm ¼-turn corresponds to 0.25 mm After adjusting the y axis, re-tighten the 2 Allen screws Adjusting the z Loosen threaded pin on the adjustment...
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 personnel. ► Observe the safety rules in the OI, in particular the "Safety Inspection" section. General A pilot laser with low power is required for the described adjustment work.
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Document the distance of the wire electrode to the laser focus in the x and y axis in accordance with the scaling on the gauge Save the settings in the robot as the reference program Carry out a test weld The best welding result is used as the basis for the reference program.
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. ► Observe the safety rules in the OI, in particular the "Safety Inspection" section CAUTION! Risk of damage to the optical fiber due to the laser welding head being perpendicu- lar to the workpiece surface during welding.
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Set signal "Laser on" Set signal "Start robot" 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"...
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...
Operation Recommendations for LaserHybrid Weld- ing System Recommenda- For smooth operation, the following items should always be available when using a Lase- tions for the Op- rHybrid welding system: eration of a LaserHybrid LaserHybrid service station Welding System Compressed-air gun supplied with 6 bar Mobile tool trolley with the following tools and spare parts: 20 x contact tips, for each diameter 10 x gas distributors...
Replacing the Welding Torch and Welding Torch Wearing Parts Safety CAUTION! Risk of burns due to the intensely heated welding torch during operation. ► The welding torch may only be cleaned, and its components checked, once it has cooled down. Mounting Wear- ing Parts on the Welding Torch...
Replacing the Spatter Guard Plate and Extra Ex- traction Replacing the Remove 4 Allen screws Spatter Guard size 2.5 mm Plate Replace the spatter guard plate Assemble in reverse order IMPORTANT! When assembling the spatter guard plate, ensure that it is sealed flush with the outer edges of the laser welding head marked in the figure.
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. ► Observe the safety rules in the OI, in particular the "Safety Inspection" section. Preparation CAUTION! Risk of damage to the laser welding head as a result of contamination from above.
Disconnect the hose for the radial air flow Removing the La- Loosen the Allen screws ser Optics M5 x 20 mm, size 4 mm Do not remove the screws. It must be possible to move the clamp. Loosen the Allen screws M5 x 25 mm, size 4 mm Remove the screws Remove the bracket...
Installing the La- CAUTION! ser Optics If dropped, the laser optics unit can be damaged to such an extent that it is rendered unusable. ► Insert and handle laser optics carefully. Optical adjustment gauge Positioning area on the laser op- with tics with...
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Place the laser optics with the optical adjustment gauge onto the laser wel- ding head Push the laser optics with the optical adjustment gauge forward as far as it will go onto the mounting bracket Push the slot nuts under the holes of the optical adjustment gauge Secure the optical adjustment gauge with 2 Allen screws to the slot nuts...
Remove 2 Allen screws M5 x 16 mm, size 4 mm Remove 2 Allen screws M8 x 16 mm, size 6 mm Remove the optical adjustment gauge Insert register pins on both robot connection brackets Tighten the screws on both robot connection brackets Tightening torque = 24 Nm Check the position of the laser focus using the reference program Final Tasks...
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 personnel. ► Observe the safety rules in the OI, in particular the "Safety Inspection" section. General A pilot laser with low power is required for the described adjustment work.
Example: Use of Switch off power source the Reference Change welding torch Program after Welding torch replacement is complete, wearing parts have been fitted: Welding Torch switch on power source Replacement Adjust stick out to 15 - 20 mm according to application Upload the reference program and slowly approach the reference position on the ad- justment gauge Thread in wire electrode until this touches the adjustment gauge...
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.
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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. IMPORTANT! Clean with compressed air before changing.
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...
WF 25i Robacta X / I (10 min/40°C) 100% D.C.*, 500 A Drive /W M21 (EN 439) X / I (10 min/40°C) 100% D.C.*, 500 A C1 (EN 439) [mm] 0.8-1.6 [in.] 0.032-0.063 Ø [L/min] [gal./min] 0.26 [bar] [psi] [bar] [psi] Supply voltage [V DC] Nominal current [A]...
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FRONIUS INTERNATIONAL GMBH Froniusstraße 1, A-4643 Pettenbach, Austria E-Mail: sales@fronius.com www.fronius.com Under www.fronius.com/contact you will find the addresses of all Fronius Sales & Service Partners and locations Find your spareparts online...
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