Fronius MIG/MAG Operating Instructions Manual
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Fronius MIG/MAG Operating Instructions Manual

Fronius MIG/MAG Operating Instructions Manual

Tps/i robotics pull welding system tps/i robotics pushpull cmt welding system
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Perfect Welding
/ Perfect Charging /
TPS/i Robotics Pull welding system
TPS/i Robotics PushPull CMT
welding system
42,0426,0219,EN 014-06082020
Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Solar Energy
Operating Instructions
MIG/MAG robot welding system

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Summary of Contents for Fronius MIG/MAG

  • Page 1 / Perfect Charging / / Solar Energy Operating Instructions TPS/i Robotics Pull welding system TPS/i Robotics PushPull CMT MIG/MAG robot welding system welding system 42,0426,0219,EN 014-06082020 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).

  • Page 3: Table Of Contents

    Contents Safety rules ..............................Explanation of safety notices ........................ General ..............................Intended use ............................Environmental conditions........................Obligations of the operator........................Obligations of personnel ........................Mains connection ..........................Protecting yourself and others ......................Danger from toxic gases and vapours ....................Danger from flying sparks ........................Risks from mains current and welding current..................
  • Page 4 Device concept ............................. Application area ............................ Proper use ............................Warning notices on the device......................SplitBox SB 500i R............................. Device concept ............................. Proper use ............................Safety..............................Warning notices on the device......................SplitBox SB 60i R............................Device concept ............................. Proper use ............................Safety..............................
  • Page 5 Fitting the TPS/i welding system to a conventional robot ..............Optimum hosepack arrangement......................Fitting the SplitBox ............................. Fitting the wirefeeder holder ......................... Fitting the SB 500i R ..........................Fitting the SB 500i R (left variant) ......................Fitting the SB 60i R to the robot......................Fitting the SB 60i R to the balancer ......................
  • Page 6 Connecting the SplitBox to the system components................126 Fitting the inner liner (unreeling wirefeeder - SplitBox SB 500i R)............127 Fitting the inner liner (SplitBox - WF 25i with internal inner liner) ............128 Fitting the inner liner (unreeling wirefeeder - wire buffer) ..............129 Fitting the inner liner (wire buffer - WF Robacta Drive with internal wirefeeding hose) ......
  • Page 7 WF 25i Robacta Drive /W ........................174 WF 60i Robacta Drive CMT ........................175 WF 60i Robacta Drive CMT /G ......................175 WF 25i Robacta Drive /W ........................175 Robot welding torch ........................... 176 Gas-cooled robot welding torches ......................176 Water-cooled robot welding torches .....................

  • Page 9: Safety Rules

    Safety rules Explanation of DANGER! safety notices Indicates immediate danger. ► If not avoided, death or serious injury will result. WARNING! Indicates a potentially hazardous situation. ► If not avoided, death or serious injury may result. CAUTION! Indicates a situation where damage or injury could occur. ►...

  • Page 10: Intended Use

    Intended use The devices and components described in these Operating Instructions are intended ex- clusively for automated MIG/MAG applications in conjunction with Fronius components. Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage.

  • Page 11: Protecting Yourself And Others

    at the interface with the public grid see "Technical data" In this case, the plant operator or the person using the device should check whether the device may be connected, where appropriate by discussing the matter with the power sup- ply company.

  • Page 12: Danger From Flying Sparks

    Do not touch live parts either inside or outside the device. ing current During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed rollers and all pieces of metal that are in contact with the welding wire are live.

  • Page 13: Meandering Welding Currents

    Use the handle to ensure the power connections are tight before every use. In the case of power cables with a bayonet connector, rotate the power cable around the longitudinal axis by at least 180° and pretension. Do not wrap cables or leads around the body or parts of the body. The electrode (rod electrode, tungsten electrode, welding wire, etc.) must never be immersed in liquid for cooling Never touch the electrode when the power source is switched on.

  • Page 14: Emc Device Classifications

    In the case of automated MIG/MAG applications, ensure that only an insulated wire elec- trode is routed from the welding wire drum, large wirefeeder spool or wirespool to the wire- feeder. EMC Device Clas- Devices in emission class A: sifications...

  • Page 15: Specific Hazards

    Chains and ropes must be at the smallest angle possible to the vertical. Remove gas cylinder and wire-feed unit (MIG/MAG and TIG devices). If the wire-feed unit is attached to a crane holder during welding, always use a suitable, insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).

  • Page 16: Requirement For The Shielding Gas

    Odourless and colourless shielding gas may escape unnoticed if an adapter is used for the shielding gas connection. Prior to assembly, seal the device-side thread of the adapter for the shielding gas connection using suitable Teflon tape. Requirement for Especially with ring lines, contaminated shielding gas can cause damage to equipment and the shielding gas reduce welding quality.

  • Page 17: Safety Measures At The Installation Location And During Transport

    Safety measures A device toppling over could easily kill someone. Place the device on a solid, level surface at the installation such that it remains stable location and dur- The maximum permissible tilt angle is 10°. ing transport Special regulations apply in rooms at risk of fire or explosion Observe relevant national and international regulations.

  • Page 18: Commissioning, Maintenance And Repair

    Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under cer- tain conditions. Transport the coolant only in its original, sealed containers and keep well away from any sources of ignition. Used coolant must be disposed of properly in accordance with the relevant national and international regulations.

  • Page 19: Data Protection

    Fronius International GmbH hereby declares that the device is compliant with Directive 2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following address: http://www.fronius.com Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA.

  • Page 20: Description Of Warning Notices On The Device

    Description of On certain device versions, warning notices are attached to the device. Warning Notices on the Device The arrangement of the symbols may vary. Warning! Watch Out! There are possible hazards as shown by the symbols. Drive rolls can injure fingers. Welding wire and drive parts are at welding voltage during operation Keep hands and metal objects away.
  • Page 21 Welding sparks can cause explosion or fire. Keep flammables away from welding. Don’t weld near flammables. Welding sparks can cause fires.Have a fire extinguisher nearby and have a watch- person ready to use it. Do not weld on drums or any closed containers. Arc rays can burn eyes and injure skin.

  • Page 23: General Information

    General information...

  • Page 25: System Configurations - Conventional Robot

    System configurations - conventional robot PowerDrive with wire drum (7)* (1)* (9)** Wirefeeding hose with inner liner TPSi power source CU cooling unit Upright console HP interconnecting hosepack SplitBox SB 500i R MHP /i R welding torch hosepack WF 25i Robacta Drive MTB /i R robot welding torch Maximum wirefeed length: max.

  • Page 26: Powerdrive With Wire Drum And External Wirefeeding Hose

    PowerDrive with wire drum and ex- ternal wirefeeding (7)* hose (1)* (9)** Wirefeeding hose with inner liner TPSi power source CU cooling unit Upright console HP interconnecting hosepack SplitBox SB 500i R MHP /i R welding torch hosepack with external wirefeeding hose WF 25i Robacta Drive MTB /i R robot welding torch Maximum wirefeed length:...

  • Page 27: Pushpull With 4-Roller Unreeling Wirefeeder And Wire Drum

    PushPull with 4- roller unreeling (1)* (9)* wirefeeder and wire drum (10) (1)* (11)** Wirefeeding hose with inner liner SpeedNet cable COM Unreeling wirefeeder WF 25i REEL 4R TPSi power source CU cooling unit Upright console HP interconnecting hosepack SplitBox SB 500i R MHP /i R welding torch hosepack (10) WF 25i Robacta Drive...

  • Page 28: Pushpull With 4-Roller Unreeling Wirefeeder And Wirespool

    PushPull with 4- roller unreeling (7)* (9)* wirefeeder and wirespool (10) (11)** SpeedNet cable COM Unreeling wirefeeder WF 25i REEL 4R TPSi power source CU cooling unit Upright console HP interconnecting hosepack Wirefeeding hose with inner liner SplitBox SB 500i R MHP /i R welding torch hosepack with external wirefeeding hose (10) WF 25i Robacta Drive...

  • Page 29: Pushpull With Sb 60I, 4-Roller Unreeling Wirefeeder And Wirespool

    PushPull with SB 60i, 4-roller un- reeling wirefeeder and wirespool (10) (11)** (7)** SpeedNet cable COM Unreeling wirefeeder WF 25i REEL 4R TPSi power source CU cooling unit Upright console HP interconnecting hosepack Wirefeeding hose with inner liner SplitBox SB 60i R MHP /i R welding torch hosepack (10) WF 25i Robacta Drive...

  • Page 30: Pushpull With 2-Roller Unreeling Wirefeeder, Wire Drum And External Wirefeeding Hose

    PushPull with 2- (7)* roller unreeling wirefeeder, wire drum and exter- nal wirefeeding (10) hose (11)** Unreeling wirefeeder WF 30i REEL 2R SpeedNet cable COM TPSi power source CU cooling unit Upright console HP interconnecting hosepack Wirefeeding hose with inner liner SplitBox SB 500i R MHP /i R welding torch hosepack with external wirefeeding hose (10)

  • Page 31: Cmt With Sb 60I, 4-Roller Unreeling Wirefeeder And Wire Drum

    CMT with SB 60i, 4-roller unreeling (9)* wirefeeder and wire drum (10) (11)** (1)* (1)** Wirefeeding hose with inner liner SpeedNet cable COM Unreeling wirefeeder WF 25i REEL 4R TPSi power source CU cooling unit Upright console HP interconnecting hosepack SplitBox SB 60i R MHP /i R welding torch hosepack (10)

  • Page 32: Cmt With Sb 500I, 4-Roller Unreeling Wirefeeder, Wire Drum And External Wirefeeding Hose

    CMT with SB 500i, 4-roller unreeling (10)* wirefeeder, wire drum and exter- nal wirefeeding (11) hose (12)** (1)* (1)** Wirefeeding hose with inner liner SpeedNet cable COM Unreeling wirefeeder WF 25i REEL 4R TPSi power source CU cooling unit Upright console HP interconnecting hosepack Wire buffer SplitBox SB 500i R...

  • Page 33: Cmt With Sb 60I, 4-Roller Unreeling Wirefeeder And Wirespool

    CMT with SB 60i, 4-roller unreeling (9)* wirefeeder and wirespool (10) (11)** (7)** SpeedNet cable COM Unreeling wirefeeder WF 25i REEL 4R TPSi power source CU cooling unit Upright console HP interconnecting hosepack Wirefeeding hose with inner liner SplitBox SB 60i R MHP /i R welding torch hosepack (10) WF 60i Robacta Drive CMT...

  • Page 34: System Configurations - Pap

    System configurations - PAP PowerDrive with wire drum (7)* (1)* (9)** Wirefeeding hose with inner liner TPSi power source CU cooling unit Upright console HP interconnecting hosepack SplitBox SB 500i R MHP /i R welding torch hosepack WF 25i Robacta Drive MTB /i R robot welding torch Maximum wirefeed length: max.

  • Page 35: Pushpull With 4-Roller Unreeling Wirefeeder And Wire Drum

    PushPull with 4- roller unreeling (9)* (1)* wirefeeder and wire drum (10) (1)* (11)** Wirefeeding hose with inner liner SpeedNet cable COM Unreeling wirefeeder WF 25i REEL 4R TPSi power source CU cooling unit Upright console HP interconnecting hosepack SplitBox SB 500i R MHP /i R welding torch hosepack (10) WF 25i Robacta Drive...

  • Page 36: Pushpull With 4-Roller Unreeling Wirefeeder And Wirespool

    PushPull with 4- roller unreeling (9)* wirefeeder and wirespool (7)* (10) (11)** SpeedNet cable COM Unreeling wirefeeder WF 25i REEL 4R TPSi power source CU cooling unit Upright console HP interconnecting hosepack Wirefeeding hose with inner liner SplitBox SB 500i R MHP /i R welding torch hosepack (10) WF 25i Robacta Drive...

  • Page 37: Pushpull With 2-Roller Unreeling Wirefeeder And Wire Drum

    PushPull with 2- roller unreeling (9)* (3)* wirefeeder and wire drum (10) (11)** Unreeling wirefeeder WF 30i REEL 2R SpeedNet cable COM Wirefeeding hose with inner liner TPSi power source CU cooling unit Upright console HP interconnecting hosepack SplitBox SB 500i R MHP /i R welding torch hosepack (10) WF 25i Robacta Drive...

  • Page 38: Pushpull With Wire Buffer, 4-Roller Unreeling Wirefeeder And Wire Drum

    PushPull with wire buffer, 4-roll- er unreeling wire- (10)* feeder and wire drum (1)** (11) (1)* (1)* (12)** SpeedNet cable COM Unreeling wirefeeder WF 25i REEL 4R TPSi power source CU cooling unit Upright console HP interconnecting hosepack Wirefeeding hose with inner liner Wire buffer SplitBox SB 500i R (10)

  • Page 39: Pushpull With Wire Buffer, 4-Roller Unreeling Wirefeeder And Wirespool

    PushPull with wire buffer, 4-roll- (10)* er unreeling wire- (7)* feeder and (11) wirespool (12)** (7)** SpeedNet cable COM Unreeling wirefeeder WF 25i REEL 4R TPSi power source CU cooling unit Upright console HP interconnecting hosepack Wirefeeding hose with inner liner Wire buffer SplitBox SB 500i R (10)

  • Page 40: Pushpull With Sb 500I, 4-Roller Unreeling Wirefeeder And Wire Drum

    PushPull with SB 500i, 4-roller un- reeling wirefeeder (10)* and wire drum (1)** (11) (1)* (1)* (12)** Wirefeeding hose with inner liner SpeedNet cable COM Unreeling wirefeeder WF 25i REEL 4R TPSi power source CU cooling unit Upright console HP interconnecting hosepack SplitBox SB 500i R Wire buffer (10)

  • Page 41: Cmt With Sb 60I, 4-Roller Unreeling Wirefeeder And Wire Drum

    CMT with SB 60i, 4-roller unreeling (9)* wirefeeder and wire drum (10) (11)** (1)* (1)** Wirefeeding hose with inner liner SpeedNet cable COM Unreeling wirefeeder WF 25i REEL 4R TPSi power source CU cooling unit Upright console HP interconnecting hosepack SplitBox SB 60i R MHP /i R welding torch hosepack (10)

  • Page 42: Cmt With Sb 500I, 4-Roller Unreeling Wirefeeder And Wire Drum

    CMT with SB 500i, 4-roller unreeling (10)* (1)* wirefeeder and wire drum (11) (12)** (1)* (1)** Wirefeeding hose with inner liner SpeedNet cable COM Unreeling wirefeeder WF 25i REEL 4R TPSi power source CU cooling unit Upright console HP interconnecting hosepack SplitBox SB 500i R Wire buffer (10)

  • Page 43: Cmt With Sb 500I, 4-Roller Unreeling Wirefeeder And Wirespool

    CMT with SB 500i, 4-roller unreeling (10)* (7)* wirefeeder and wirespool (11) (12)** (7)** SpeedNet cable COM Unreeling wirefeeder WF 25i REEL 4R TPSi power source CU cooling unit Upright console HP interconnecting hosepack Wirefeeding hose with inner liner SplitBox SB 500i R MHP /i R welding torch hosepack (10) WF 60i Robacta Drive CMT...

  • Page 44: Interconnecting Hosepack

    Interconnecting hosepack General remarks The interconnecting hosepack connects the power source to the wirefeeder. With the TPS/ i welding system the interconnecting hosepack is available in two versions - one split and one continuous variant. 3 / 5 / 10 / 15 m (extension - split variant) 4 / 8 m (connection - continuous variant) General The interconnecting hosepack connects the power source to the SplitBox SB 60i R.

  • Page 45: Powerliner

    PowerLiner General The PowerLiner is a wirefeeder system for all standard wire types. Wire diameters of 0.6 mm to 1.6 mm may be used. The PowerLiner does not need an inner liner. The wire electrode is guided by rollers set at an angle of 90 degrees.

  • Page 46: Wf 25I Reel R /4R, Wf 30I Reel R /2R

    All indoor and automated MIG/MAG applications. Proper use The device is designed exclusively for wirefeeding in automated MIG/MAG welding appli- cations in conjunction with Fronius system components. Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage.

  • Page 47: Warning Notices On The Device

    Warning notices The device is fitted with safety symbols and a rating plate. The safety symbols and rating on the device plate must not be removed or painted over. The safety symbols warn against operating the equipment incorrectly, as this may result in serious injury and damage. 40,0006,3035 Example: WF 30i REEL R /2R/G/W Do not dispose of used devices with domestic waste.
  • Page 48 Keep hands, hair, clothing and tools away from moving parts. For example: Cogs Feed rollers Wirespools and welding wires Do not reach into the rotating cogs of the wire drive or into rotating drive components. Covers and side panels may only be opened / removed while maintenance or repair work is being carried out.

  • Page 49: Splitbox Sb 500I R

    The SplitBox (SB) 500i R, SB 500i R / L and SB 500i R PAP devices bring together the welding media for automated MIG/MAG welding and have been specially designed for mounting onto the robot. Two versions of the devices are available:...

  • Page 50: Warning Notices On The Device

    The safety symbols warn against operating the equipment incorrectly, as this may result in serious injury and damage. SB 500i R /G/W/FSC 4,040,080 Part No.: www.fronius.com XXXXXXXXXX Ser.No.: IEC 60 974-1/-10 Cl.A IP 43 60 V 0.8 A...
  • Page 51 Keep hands, hair, clothing and tools away from moving parts. For example: Cogs Feed rollers Wirespools and welding wires Do not reach into rotating drive components. Covers and side panels may only be opened / removed while maintenance or repair work is being carried out.

  • Page 52: Splitbox Sb 60I R

    Device concept The SB 60i R and SB 60i R /L are devices for bringing together the welding media in auto- mated MIG/MAG welding and are specially designed for mounting on robots. SB 60i R: Right version of the appliance, for fitting to the right side of the robot...

  • Page 53: Warning Notices On The Device

    Warning notices The device is fitted with safety symbols and a rating plate. The safety symbols and rating on the device plate must not be removed or painted over. The safety symbols warn against operating the equipment incorrectly, as this may result in serious injury and damage. Welding is dangerous.
  • Page 54 Do not dispose of used devices with domestic waste. Dispose of them according to the safety rules.

  • Page 55: Pushpull Hosepack

    PushPull hosepack General The Robacta MHPi RD hosepack is designed for gas-cooled and water-cooled robot appli- cations. It connects the SplitBox to the wirefeeder. The length of the hosepack depends on the robot. The following combinations are available: Robacta MHPi RD conventional SB500i ->...

  • Page 56: Wf Robacta Drive

    WF Robacta Drive General The WF 25i Robacta Drive and WF 60i Ro- bacta Drive CMT are designed for gas or water-cooled systems. The built-in motor ensures precise wirefeeding (pull system). The torch body is fitted to the Robacta Dri- Warning notices The device is fitted with safety symbols and a rating plate.

  • Page 57: Crashbox /I

    CrashBox /i General A CrashBox Drive /i PAP mounted onto the robot arm A CrashBox Drive /i mounted onto the robot arm with with Robacta Drive and MTB clamp system, Robacta Drive und MTB The CrashBox Drive /i is a protection device for the torch body, the drive unit and the torch interchangeable-coupling.

  • Page 58: Device Concept

    Device concept The CrashBox Drive /i is designed specifically for fitting to the robot arm and for holding gas-cooled and water-cooled robot hosepacks with robot drive units. For PAP systems, the torch hosepack runs through the CrashBox and then through the robot arm. In convention- al robot systems the torch hosepack runs along the robot arm and is attached to the clamp.

  • Page 59: Robot Welding Torch

    Robot welding torch Safety CAUTION! Risk of burns from hot torch body, hot torch body coupling and other hot welding torch components. Before starting work on the torch body, the torch body coupling and all other welding torch components: ► Allow the torch body, torch body coupling and all other welding torch components to cool down to room temperature (+25 °C, +77 °F) ►...

  • Page 60: Tpsi Wire Buffer

    TPSi wire buffer General As its name implies, the wire buffer acts as a buffer for the rapid reversing movements of the wire electrode needed during the CMT welding process. The wire buffer can also be used to help coordinate two drive systems that work in different ways.

  • Page 61: Wiresense

    WireSense General If OPT/i WireSense software activation is available on the power source, the surface, edg- es and weld seams of a workpiece can be measured with the wire electrode. The wire electrode functions as a sensor that can precisely scan a component by means of high-frequency reversing wire movement.

  • Page 62: Wiresense - Edge Detection

    WireSense - edge The WireSense edge detection is activated and an edge height between 0.5 and 20 detection mm is selected. The touch signal is output when the defined edge height is detected. In this way the position of the edge can be recorded. The WireSense Position signal indicates the height of the edge.

  • Page 63: Wiresense - Contour Detection

    WireSense - con- WireSense contour detection is active when WireSense edge detection = OFF or < 0.5 tour detection The touch signal is not active. The WireSense Position signal provides the actual height values (live values). The additional WireSense Break signal stops the forward movement of the wire elec- trode and stores the zero reference value (The zero reference value is useful for overcoming the distance to the component without wirefeeding if the reference value is not set directly on the component).

  • Page 64: Technical Details

    Technical details Edge detection Contour detection Edge detection and actual Height signals height signal The system outputs a touch The system supplies the signal when the edge is de- height information as actual tected and provides the values of the sampled path. height value of the detected edge.

  • Page 65: Controls, Connections And Mechanical Components

    Controls, connections and mechani- cal components...

  • Page 67: Splitbox

    SplitBox Safety WARNING! Danger from incorrect operation. This can result in severe personal injury and damage to property. ► All the functions described may only be used by trained and qualified personnel. ► Fully read and understand this document. ► Fully read and understand all the Operating Instructions for the system components, especially the safety rules.
  • Page 68 Method 2 Retracting the wire electrode in 1 mm increments (0.039 in. increments) – always press the wire retract button for less than one second (tap) IMPORTANT! Do not allow long lengths of wire electrode to be retracted, as the wire electrode is not wound onto the wirespool when retracted.

  • Page 69: Control Elements, Connections And Mechanical Components Of The Splitbox

    Control elements, connections and mechanical components of the SplitBox Safety WARNING! Danger from incorrect operation. This can result in severe personal injury and damage to property. ► All the functions described may only be used by trained and qualified personnel. ►...

  • Page 70: Sb 60I R:control Elements, Connections And Mechanical Components

    Blanking cover for option 1 Welding torch connection SpeedNet connection socket for connecting the SpeedNet cable from the interconnecting hosepack Blanking cover for option 5 Shielding gas connection (+) current socket for connecting the power cable from the interconnecting hosepack Blanking cover for option 2 (10) Wire infeed...

  • Page 71: Sb 60I R /L:control Elements, Connections And Mechanical Components

    Welding torch connection Coolant hoses to welding torch Blanking cover (SpeedNet or exter- nal sensor option) A - Welding torch end Wire infeed (via QuickConnect and inner liner) 16 bar gas purging (option) (10) Hosepack (fixed) preconfigured for gas / water-co- oled applications 3 / 4 / 8 m B - Power source end...
  • Page 72 Welding torch connection Coolant hoses to welding torch Blanking cover (SpeedNet or exter- nal sensor option) A - Welding torch end Wire infeed (via QuickConnect and inner liner) 16 bar gas purging (option) (10) Hosepack (fixed) preconfigured for gas / water-co- oled applications 3 / 4 / 8 m B - Power source end...

  • Page 73: Sb 500I R Pap Control Elements, Connections And Mechanical Components

    SB 500i R PAP control elements, connections and mechanical components Safety WARNING! Danger from incorrect operation. This can result in severe personal injury and damage to property. ► All the functions described may only be used by trained and qualified personnel. ►...
  • Page 74 Function (11) Cover (12) Implementation (13) Gas test / wire threading control panel (option) Side view...

  • Page 75: Wf 25I Robacta Drive Control Panel / Wf 60I Robacta Drive Cmt

    WF 25i Robacta Drive control panel / WF 60i Robacta Drive CMT WF 25i Robacta Function Drive / WF 60i Ro- bacta Drive CMT Gas-test button control panel For setting the required gas flow rate on the pressure regulator Gas will flow out for 30 seconds af- ter the gas-test button is pressed.
  • Page 76 Wire threading button For threading the wire electrode into the torch hosepack with no accompanying flow of gas or current While the button is pressed, the wirefeeder runs at the preset feeder inching speed. Wire threading can be performed using one of two methods: Method 1 Retracting the wire electrode using the preset feeder inching speed: Press and hold "Wire threading"...

  • Page 77: Wf 25I Reel R /4R, Wf 30I Reel R /2R

    WF 25i REEL R /4R, WF 30i REEL R /2R Safety WARNING! Danger from incorrect operation. This can result in severe personal injury and damage to property. ► All the functions described may only be used by trained and qualified personnel. ►...
  • Page 78 100 mm 3.9 in. 4 x M5 (13) (12) Top/underside Function Cover Protective cover for the 4-roller drive 4-roller drive Protective cover for the 2-roller drive 2-roller drive Opening for optional sash lock Control panel SpeedNet connection Blanking cover for optional component (10) Blanking cover for optional component (11)

  • Page 79: Control Panel

    Control panel Function Operating status LED Shows steady green when the de- vice is ready for use Gas-test button For setting the required gas flow rate on the pressure regulator Gas will flow out for 30 seconds af- ter the gas-test button is pressed. Press the button again to stop the gas flow prematurely.
  • Page 80 NOTE! If there was a ground earth connection with the contact tip before the wire retract button was pressed, the wire electrode will be retracted when the button is pressed until it is short-circuit-free - it retracts by no more 10 mm (0.39 in.) with each press of the button.

  • Page 81: Installation - Conventional Robot

    Installation - conventional robot...

  • Page 83: Fitting The Welding System To A Conventional Robot

    Fitting the welding system to a conventional robot Safety WARNING! Work that is carried out incorrectly can cause serious injury or damage. ► The following activities may only be carried out by trained and qualified personnel. ► The Operating Instructions for system components, particularly the chapter entitled "Safety rules", must be observed.

  • Page 84: Optimum Hosepack Arrangement

    Optimum hose- pack arrange- ment R < 200 mm R ≥ 200 mm...

  • Page 85: Fitting The Splitbox

    Fitting the SplitBox Fitting the wire- NOTE! feeder holder Depending on the robot, please also note the instructions and information on install- ing the wirefeeder in the User Information. Fitting the SB 500i R M6x16 6FSt 6FSt M6x16 * = 2x M8 x 20 mm Fitting the SB 500i R (left vari- ant)

  • Page 86: Fitting The Sb 60I R To The Robot

    Fitting the SB 60i NOTE! R to the robot Depending on the robot, please also note the instructions and information in the User Information on installing the holding plate for the SplitBox. The installation of the SplitBox SB 60i R is illustrated using the right version of the appli- ance.

  • Page 87: Mounting The Sb 60I R On The Wall

    Mounting the SB 60i R on the wall * = Depending on the surface, different fixings are required for fitting the wall bracket. The installer is responsible for selecting the correct fixings. NOTE! Use a balancer for hosepacks longer than 1.75 m. Position the balancer halfway along the length of the hosepack.

  • Page 88: Fitting The Tpsi Wire Buffer

    Fitting the TPSi wire buffer Fitting the TPSi wire buffer Fitting to the robot Fitting to a balancer...

  • Page 89: Fitting The Crashbox /I To The Robot

    Fitting the CrashBox /i to the robot Fitting the Crash- Box /i to the robot Observe the torques when fitting the robot flange: Max. tightening torque for screws of strength class 8.8 3.3 Nm 5.0 Nm 6.0 Nm 27.3 Nm 54 Nm 93 Nm 3,3 Nm...

  • Page 90: Installing The Crashbox/I Dummy On The Robot

    Installing the CrashBox/i Dum- Observe the torques when fitting the robot my on the robot flange: Max. tightening torque for screws of strength class 8.8 3.3 Nm 5.0 Nm 6.0 Nm 27.3 Nm 54 Nm 93 Nm...
  • Page 91 3,3 Nm...

  • Page 92: Preparing The Wf Robacta Drive And Fitting To A Conventional Robot

    Preparing the WF Robacta Drive and fitting to a con- ventional robot Fitting the gas- saver nozzle Torx 40 42,0411,0160 42,0411,0160 42,0411,0160...

  • Page 93: Fitting The Hosepack To The Wf Robacta Drive (Conventional)

    Fitting the hose- IMPORTANT! Only fit the drive unit when the power source is switched off. pack to the WF Robacta Drive CAUTION! (conventional) Danger of property damage due to dirty or wet coupling point. ► Whenever the hosepack is fitted or removed, ensure that the coupling point is clean and dry.

  • Page 94: Fitting The Wf Robacta Drive To The Crashbox (Conventional)

    Fitting the WF Ro- bacta Drive to the CrashBox (con- ventional) 10 Nm M6 x 12 mm 42 Nm Fitting the inner IMPORTANT! For the MTB 330i welding torch, the plastic inner liner is fitted from the front. liner inside the torch body Plastic inner liner:...
  • Page 95 Steel inner liner:...

  • Page 96: Fitting The Welding Torch To The Wf Robacta Drive (Conventional)

    Fitting the weld- CAUTION! ing torch to the WF Robacta Drive Danger of property damage due to dirty or wet coupling point. (conventional) ► Whenever the welding torch is fitted or removed, ensure that the coupling point is clean and dry. ►...

  • Page 97: Fitting The Interconnecting Hosepack

    Fitting the interconnecting hosepack Fitting the stand- ard interconnect- SB 500i ing hosepack to the robot Connecting the CAUTION! extension hose- pack Danger from electric current due to inadequate connections. This can result in serious injury and damage to property. ►...

  • Page 99: Connecting The Splitbox To The System Components

    Connecting the SplitBox to the system components Safety WARNING! An electric shock can be fatal. Before starting the work described below: ► Turn the power source mains switch to the "O" position ► Disconnect the power source from the mains ►...

  • Page 100: Fitting The Inner Liner (Unreeling Wirefeeder - Splitbox Sb 500I R)

    Fitting the inner liner (unreeling wirefeeder - Split- Box SB 500i R)

  • Page 101: Fitting The Inner Liner (Splitbox - Wf 25I With Internal Inner Liner)

    Fitting the inner liner (SplitBox - WF 25i with inter- nal inner liner)

  • Page 102: Fitting The Inner Liner (Unreeling Wirefeeder- Wf Robacta Drive With External Wirefeeding Hose)

    Fitting the inner liner (unreeling wirefeeder- WF Robacta Drive with external wirefeeding hose) Fitting the inner liner (wire buffer - WF Robacta Drive with external wirefeeding hose)

  • Page 103: Fitting The Inner Liner (Unreeling Wirefeeder - Wire Buffer)

    Fitting the inner liner (unreeling wirefeeder - wire buffer)

  • Page 104: Fitting The Inner Liner (Unreeling Wirefeeder - Splitbox Sb60I)

    Fitting the inner liner (unreeling wirefeeder - Split- Box SB60i)

  • Page 105: Fitting The Inner Liner Inside The Torch Hosepack

    Fitting the inner NOTE! liner inside the torch hosepack Ensure that the hosepack is straight when fitting the inner liner, otherwise the liner might not be inserted correctly. Steel inner liner Plastic inner liner...

  • Page 106: Connecting The Torch Hosepack To The Splitbox Sb 60I R

    Screw the clamping nipple onto the inner liner as far as it will go. The inner liner must be visible through the hole in the cap. Connecting the IMPORTANT! Whenever the torch hosepack is fitted or removed, ensure that the coupling torch hosepack to point is clean and dry.

  • Page 107: Connecting The Control Line To The Wire Buffer

    Connecting the NOTE! control line to the wire buffer Carefully place the control line in the strain-relief device provided (Figure 2).

  • Page 108: Fitting The Unreeling Wirefeeder

    In accordance with the Installation Instructions, mount the unreeling wirefeeder onto the wall bracket or the wire drum mount Use the QuickConnect option to connect the wirefeeding hose to the unreeling wire- feeder Use Fronius SpeedNet to connect the unreeling wirefeeder to the power source in the welding system...

  • Page 109: Installation - Pap

    Installation - PAP...

  • Page 111: Fitting The Welding System To A Pap Robot

    Fitting the welding system to a PAP robot Safety WARNING! Work that is carried out incorrectly can cause serious injury or damage. ► The following activities may only be carried out by trained and qualified personnel. ► The Operating Instructions for system components, particularly the chapter entitled "Safety rules", must be observed.

  • Page 112: Maximum Axis Rotation

    Maximum axis ro- tation -175° +90° +175° -200° -90° +200° Fourth robot axis: +/- 175° Fifth robot axis: +/- 90° Sixth robot axis: +/- 200° (4)+(6) Fourth + sixth robot axis: max. +/- 360° total! NOTE! Any axis rotation beyond these limits is not permitted and accelerates the wear of the PAP torch hosepack!

  • Page 113: Fitting The Splitbox

    Fitting the SplitBox Fitting the SB 500i R PAP...

  • Page 114: Fitting The Tpsi Wire Buffer

    Fitting the TPSi wire buffer Fitting the TPSi wire buffer Fitting to the robot Fitting to a balancer...

  • Page 115: Installing The Crashbox Drive /I Pap On The Robot

    Installing the CrashBox Drive /i PAP on the robot Installing the Dowel pin in the robot flange CrashBox on the robot Observe the torques when fitting the robot flange: Max. tightening torque for screws of strength class 8.8: 3.3 Nm 5.0 Nm 6.0 Nm 27.3 Nm...

  • Page 116: Installing The Crashbox/I Dummy On The Robot

    Installing the Dowel pin in the robot flange CrashBox/i Dum- my on the robot Observe the torques when fitting the robot flange: Max. tightening torque for screws of strength class 8.8: 3.3 Nm 5.0 Nm 6.0 Nm 27.3 Nm 54 Nm 93 Nm...

  • Page 118: Wf Robacta Drive

    WF Robacta Drive Fitting the gas- saver nozzle Torx 40 42,0411,0160 42,0411,0160 42,0411,0160 Fitting the hose- pack to the WF Robacta Drive...

  • Page 119: Fitting The Wf Robacta Drive To The Robot

    CAUTION! Danger of property damage due to dirty or wet coupling point. ► Whenever the hosepack is fitted or removed, ensure that the coupling point is clean and dry. ► Remove any coolant that has escaped from the coupling point. 45,0200,1261 42,0411,1315 Fitting the WF Ro-...
  • Page 120 BY2,0201,4896 42,0411,1315...

  • Page 121: Fitting The Inner Liner Inside The Torch Body

    Fitting the inner IMPORTANT! For the MTB 330i welding torch, the plastic inner liner is fitted from the front. liner inside the torch body Plastic inner liner:...

  • Page 122: Fitting The Welding Torch To The Wf Robacta Drive

    Steel inner liner: Fitting the weld- CAUTION! ing torch to the WF Robacta Drive Danger of property damage due to dirty or wet coupling point. ► Whenever the welding torch is fitted or removed, ensure that the coupling point is clean and dry.

  • Page 124: Fitting The Interconnecting Hosepack

    Fitting the interconnecting hosepack Fitting the PAP in- terconnecting hosepack to the robot IMPORTANT! Values for the "a" and "b" distances can be found in the leaflets for the different robot manufacturers.

  • Page 125: Connecting The Extension Hosepack

    Connecting the CAUTION! extension hose- pack Danger from electric current due to inadequate connections. This can result in serious injury and damage to property. ► All cables, leads and hosepacks must be properly connected, undamaged, correctly in- sulated and adequately dimensioned. Only on water-cooled hosepack = Interconnecting hosepack = Extension hosepack...

  • Page 126: Connecting The Splitbox To The System Components

    Connecting the SplitBox to the system components Safety WARNING! An electric shock can be fatal. Before starting the work described below: ► Turn the power source mains switch to the "O" position ► Disconnect the power source from the mains ►...

  • Page 127: Fitting The Inner Liner (Unreeling Wirefeeder - Splitbox Sb 500I R)

    Fitting the inner liner (unreeling wirefeeder - Split- Box SB 500i R)

  • Page 128: Fitting The Inner Liner (Splitbox - Wf 25I With Internal Inner Liner)

    Fitting the inner liner (SplitBox - WF 25i with inter- nal inner liner)

  • Page 129: Fitting The Inner Liner (Unreeling Wirefeeder - Wire Buffer)

    Fitting the inner liner (unreeling wirefeeder - wire buffer)

  • Page 130: Fitting The Inner Liner (Wire Buffer - Wf Robacta Drive With Internal Wirefeeding Hose)

    Fitting the inner liner (wire buffer - WF Robacta Drive with internal wire- feeding hose) Connecting the NOTE! control line to the wire buffer Carefully place the control line in the strain-relief device provided (Figure 2).

  • Page 133: Start-Up

    Start-up...

  • Page 135: Inserting/Replacing Feed Rollers

    Inserting/replacing feed rollers General The feed rollers are not installed in the device when it is first delivered. In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the diameter and alloy of the wire being welded. NOTE! Risk from inadequate feed rollers.

  • Page 136: 2-Roller Drive: Inserting/Replacing Feed Rollers

    2-roller drive: In- serting/replacing feed rollers CAUTION! Risk of crushing due to exposed feed rollers. ► Always fit the protective cover of the 2-roller drive after changing feed rollers.

  • Page 137: Inserting/Replacing The Wf 25I Robacta Drive Feed Rollers

    Inserting/replac- ing the WF 25i Ro- bacta Drive feed rollers 0 mm * * If the roller holder is opened as far as it will go be- yond the slight resistance, the roller holder remains in this position.

  • Page 139: Inserting/Replacing The Wf 60I Robacta Drive Cmt Feed Rollers

    Inserting/replac- ing the WF 60i Ro- bacta Drive CMT feed rollers 0 mm * * If the roller holder is opened as far as it will go be- yond the slight resistance, the roller holder remains in this position.
  • Page 140 42,0411,0160 12 mm 42,0411,0160 12 mm 5 Nm...

  • Page 142: Feeding In The Wire Electrode

    Feeding in the wire electrode Insulated routing WARNING! of wire electrode to wirefeeder Risk of serious injury and damage or an inferior weld as a result of earth contact or short-circuit of a non-insulated wire electrode. ► In the case of automated applications, ensure that only an insulated wire electrode is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeed- er (e.g.

  • Page 143: Setting The Contact Pressure For The Wf 25I Robacta Drive

    CAUTION! Risk of injury from moving or rotating parts in the welding system. ► Ensure that all covers are closed and that all parts are fitted properly and remain in place during operation. Setting the con- NOTE! tact pressure for the WF 25i Robac- Set the contact pressure in such a way that the wire electrode is not deformed but ta Drive...

  • Page 144: Setting The Contact Pressure For The Wf 60I Robacta Drive Cmt

    Setting the con- NOTE! tact pressure for the WF 60i Robac- Set the contact pressure in such a way that the wire electrode is not deformed but ta Drive CMT nevertheless ensures proper wirefeeding. IMPORTANT! In the event of a large change in contact pressure, a system calibration must be carried out.

  • Page 145: Start-Up

    Start-up Requirements When commissioning the wirefeeder, the following requirements must be met: All components installed and connected as described in the “Installation” chapter All appropriate welding media connected to wirefeeder Feed rollers inserted in the wirefeeder Wire electrode threaded in Feed roller contact pressure set Motor adjustment completed All covers closed, all side panels in place, all safety devices intact and in their proper...

  • Page 147: Troubleshooting, Maintenance And Disposal

    Troubleshooting, maintenance and disposal...

  • Page 149: Troubleshooting

    Troubleshooting Safety WARNING! Danger due to work that has been carried out incorrectly. This can result in severe personal injury and damage to property. ► All the work described below must only be carried out by trained and qualified person- nel.
  • Page 150 Power source does not function Mains switch is on, but indicators are not lit up Cause: There is a break in the mains lead; the mains plug is not plugged in Remedy: Check the mains lead, ensure that the mains plug is plugged in Cause: Mains socket or mains plug faulty Remedy:...
  • Page 151 Irregular wire feed speed Cause: Hole in the contact tip is too narrow Remedy: Use a suitable contact tip Cause: Faulty inner liner in welding torch Remedy: Check the inner liner for kinks, dirt, etc. Cause: The feed rollers are not suitable for the wire electrode being used Remedy: Use suitable feed rollers Cause:...
  • Page 152 Poor weld properties Cause: Incorrect welding parameters Remedy: Check the settings Cause: Poor ground earth connection Remedy: Ensure good contact to workpiece Cause: Inadequate or no protective gas shield Remedy: Check the pressure regulator, gas hose, gas solenoid valve, torch gas con- nection, etc.

  • Page 153: Care, Maintenance And Disposal

    Care, maintenance and disposal General Under normal operating conditions, the device requires only a minimum of care and main- tenance. However, it is vital to observe some important points to ensure the welding sys- tem remains in a usable condition for many years. Safety WARNING! Danger due to work that has been carried out incorrectly.

  • Page 154: Special Care Of O-Rings

    When repeatedly connecting and disconnecting the coolant hoses on the torch hosepack, grease the O-rings regularly. Unless a special grease is specified for the O-rings, use the O-ring grease from Fronius with item number 40,0009,0044. Whenever the Whenever the welding torch or torch hosepack is changed, ensure that the coupling point welding torch or is clean and dry.

  • Page 155: Recognising Faulty Wearing Parts

    Recognising faulty wearing parts Insulating parts – Burned-off outside edges, notches Nozzle fittings – Burned-off outside edges, notches – Heavily covered in welding spatter Spatter guard – Burned-off outside edges, notches Contact tips – Worn-out (oval) wire entry and wire exit holes –...

  • Page 156: Replacing The Wf 60I Robacta Drive Cmt Clamping Lever

    Replacing the WF 60i Robacta Drive CMT clamping le- Replacing the WF CAUTION! Robacta Drive gas-saver nozzle Danger of property damage due to dirty or wet coupling point. ► Whenever the welding torch is fitted or removed, ensure that the coupling point is clean and dry.

  • Page 157: Replacing The Sb 60I R Inner Liner

    42,0411,0160 Replacing the SB Removing the inner liner 60i R inner liner...
  • Page 158 Inserting the inner liner...

  • Page 159: Replacing The Tpsi Wire Buffer Wire Guide

    Replacing the NOTE! TPSi wire buffer wire guide Before starting work, thread the wire electrode out of the wire buffer. IMPORTANT! If using a wire electrode with a diameter of 1.6 mm (1/16 in.), fit the "original equipment kit 1.6 mm (1/16 in.)" to the sliding contact and wire guide in the wire buffer.

  • Page 160: Changing The Direction Of Operation Of The Tpsi Wire Buffer

    Changing the di- NOTE! rection of opera- tion of the TPSi After conversion, make sure the control line is fitted properly in the strain-relief de- wire buffer vice provided.

  • Page 161: Replacing The Tpsi Wire Buffer Lever

    Replacing the NOTE! TPSi wire buffer lever Before fitting the new wire buffer lever, turn the locating sleeve into the central po- sition (Figure 3).

  • Page 162: Fitting Wearing Parts To The Torch Body

    Fitting wearing parts to the torch body Fitting wearing parts to the torch body - MTW 700 i...

  • Page 163: Removing The Crashbox Pap From The Robot

    Removing the CrashBox PAP from the robot BY2,0201,4896...

  • Page 164: Disposal

    Disposal Dispose of in accordance with the applicable national and local regulations.

  • Page 165: Technical Data

    Technical data...

  • Page 167: Sb 500I R, R Left Variant, Pap

    40% D.C.* 650 A 60% D.C.* 600 A 100% D.C.* 500 A Maximum shielding gas pressure 7 bar / 101.53 psi Coolant Original Fronius Maximum coolant pressure 5 bar / 72.53 psi Degree of protection IP 43 Mark of conformity...

  • Page 168: Sb 60I R

    40% D.C.* 500 A 60% D.C.* 450 A 100% D.C.* 360 A Maximum shielding gas pressure 7 bar / 101.53 psi Coolant Original Fronius Maximum coolant pressure 5 bar / 72.53 psi Degree of protection IP 20 Mark of conformity...

  • Page 169: Crashbox /I

    CrashBox /i CrashBox /i Item numbers CrashBox /i 44,0350,3589 CrashBox /i XL 44,0350,3760 CrashBox /i XXL 44,0350,3380 CRASHBOX DRIVE /I PAP 44,0350,3379 CrashBox Drive /i PAP XXL 44,0350,3754 Reset accuracy (1) ± 0.05 mm Triggering torques in x/y direction See table on the following page Maximum deflection in x/y direction CrashBox /i ~ 45°...
  • Page 170 Triggering torques and weight/distance diagram The specified values only apply in a static state!

  • Page 171: Pushpull Hosepack

    PushPull hosepack General Duty cycle in % Max. welding current in A Voltage measurement (V-Peak): for mechanically-driven welding torches: 141 V The product conforms to the requirements of the IEC 60974-7 standard. Gas-cooled Push- MHP 400i RD / G Pull hosepacks X / I (10 min/40 °C) 40% D.C.* / 400 A...

  • Page 172: Water-Cooled Pushpull Hosepacks

    Water-cooled MHP 500i RD / W PushPull hose- X / I (10 min/40 °C) 100% D.C.* / 500 A packs M21 (EN 439) X / I (10 min/40 °C) 100% D.C.* / 500 A C1 (EN 439) 0.8-1.6 (0.032-0.063) [mm] Ø...
  • Page 173 MHP 500i RD / W / PAP X / I (10 min/40 °C) 100% D.C.* / 500 A M21 (EN 439) X / I (10 min/40 °C) 100% D.C.* / 500 A C1 (EN 439) 0.8-1.6 (0.032-0.063) [mm] Ø [in.] [W] ** [ft.

  • Page 174: Wf 25I Robacta Drive

    WF 25i Robacta Drive WF 25i Robacta X / I (10 min/40 °C) 60% D.C.* / 260 A Drive /G M21 (EN 439) 100% D.C.* / 210 A X / I (10 min/40 °C) 60% D.C.* / 320 A C1 (EN 439) 100% D.C.* / 260 A 0.8-1.6 [mm]...

  • Page 175: Wf 60I Robacta Drive Cmt

    WF 60i Robacta Drive CMT WF 60i Robacta X / I (10 min/40 °C) 60% D.C.* / 260 A (Standard) Drive CMT /G M21 (EN 439) 100% D.C.* / 210 A (Standard) 60% D.C.* / 260 A (CMT) 100% D.C.* / 210 A (CMT) X / I (10 min/40 °C) 60% D.C.* / 320 A (Standard)

  • Page 176: Robot Welding Torch

    Robot welding torch Gas-cooled robot MTB 250i G/R (TX, TXM) welding torches X / I (10 min/40 °C) 40% D.C.* / 250 A M21 (EN 439) 60% D.C.* / 200 A 100% D.C.* / 170 A X / I (10 min/40 °C) C1 (EN 439) 60% D.C* / 250 A 100% D.C.* / 200 A...

  • Page 177: Water-Cooled Robot Welding Torches

    MTB 400i G/R (TX, TXM) X / I (10 min/40 °C) 40% D.C.* / 400 A M21 (EN 439) 60% D.C.* / 320 A 100% D.C.* / 260 A X / I (10 min/40 °C) C1 (EN 439) 60% D.C.* / 400 A 100% D.C.* / 320 A 0.8-1.6 [mm]...
  • Page 178 MTB 500i W/R (TX, TXM) X / I (10 min/40 °C) 100% D.C.* / 500 A M21 (EN 439) X / I (10 min/40 °C) 100% D.C.* / 500 A C1 (EN 439) 1.0-1.6 [mm] 0.039-0.063 Ø [in.] MTB 700i W/R (TX, TXM) X / I (10 min/40 °C) 100% D.C.* / 700 A...

  • Page 179: Interconnecting Hosepacks

    Interconnecting hosepacks HP 70i Welding current at 10 min/40 °C (104 °F) 40% D.C.* / 400 A 60% D.C.* / 365 A 100% D.C.* / 320 A D.C. = Duty cycle HP 95i Welding current at 10 min/40 °C (104 °F) 40% D.C.* / 500 A 60% D.C* / 450 A 100% D.C.* / 360 A...
  • Page 180 FRONIUS INTERNATIONAL GMBH Froniusstraße 1 A-4643 Pettenbach AUSTRIA contact@fronius.com www.fronius.com Under www.fronius.com/contact you will find the addresses of all Fronius Sales & Service Partners and locations.

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