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Summary of Contents for Fronius MIG/MAG
- Page 1 Perfect Welding / Perfect Charging / / Solar Energy Operating Instructions TPS/i Robotics Push welding system MIG/MAG robot welding system 42,0426,0183,EN 016-30072020 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
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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 General ..............................Controls, connections and mechanical components Gas test/wire threading control panel ....................... Safety..............................Gas test/wire threading control panel (optional) ................... WF control elements and mechanical components ................... Safety..............................Control elements and mechanical components ..................WF 15i R, WF30i R connections........................ Connections ............................
- Page 5 Installation - PAP Fitting the welding system to a PAP robot ....................Safety..............................Fitting the TPS/i welding system to a PAP robot .................. Maximum axis rotation .......................... Fitting the wire-feed unit..........................Fitting the WF 15i/25i/30i R PAP ......................Installing the CrashBox /i PAP on the robot....................Installing the CrashBox /i PAP on the robot..................
- Page 6 Technical data WF wire-feed unit............................123 WF 15i R, WF 15i R PAP........................123 WF 25i R, WF 25i R PAP, WF 25i R / L....................123 WF 30i R, WF 30i R PAP, WF 30i R / L....................124 CrashBox /i ..............................
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Page 7: 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 8: 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 9: 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 10: 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 11: 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 12: 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 13: 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 14: 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 15: 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 16: 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 17: 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 19: General Information
General information... -
Page 21: System Configurations - Conventional Robot
System configurations - conventional robot Push with wire drum (7) ** (1) * Wirefeeding hose with inner liner TPSi power source CU cooling unit Upright console HP interconnecting hosepack Wirefeeder WF 15i R / WF 25i R / WF 30i R MHP /i R torch hosepack MTB /i R robot welding torch Maximum wirefeed length:... -
Page 22: Push With Wirespool
Push with wire- spool (7) ** (5) * TPSi power source CU cooling unit Upright console HP interconnecting hosepack Wirefeeding hose with inner liner Wirefeeder WF 15i R / WF 25i R / WF 30i R MHP /i R torch hosepack MTB /i R robot welding torch Maximum wirefeed length: max. -
Page 23: Push With 4-Roller Unreeling Wirefeeder And Wire Drum
Push with 4-roller unreeling wire- (1) * (9) ** feeder and wire drum (10) (1) * Wirefeeding hose with inner liner SpeedNet cable COM Unreeling wirefeeder WV 25i Reel 4R TPSi power source CU cooling unit Upright console HP interconnecting hosepack Wirefeeder WF 15i R / WF 25i R / WF 30i R MHP /i R torch hosepack (10) -
Page 24: System Configurations - Pap
System configurations - PAP Push with wire drum (7) ** (1) * Wirefeeding hose with inner liner TPSi power source CU cooling unit Upright console HP interconnecting hosepack Wirefeeder WF 15i R / WF 25i R / WF 30i R MHP /i R torch hosepack MTB /i R robot welding torch Maximum wirefeed length:... -
Page 25: Push With Wirespool
Push with wire- spool (7) ** (5) * TPSi power source CU cooling unit Upright console HP interconnecting hosepack Wirefeeding hose with inner liner Wirefeeder WF 15i R / WF 25i R / WF 30i R MHP /i R torch hosepack MTB /i R robot welding torch Maximum wirefeed length: max. -
Page 26: Push With 4-Roller Unreeling Wirefeeder And Wire Drum
Push with 4-roller unreeling wire- (9) ** (1) * feeder and wire drum (1) * (10) Wirefeeding hose with inner liner SpeedNet cable COM Unreeling wirefeeder WV 25i Reel 4R TPSi power source CU cooling unit Upright console HP interconnecting hosepack Wirefeeder WF 15i R / WF 25i R / WF 30i R MHP /i R torch hosepack (10) -
Page 27: Wf Wire-Feed Unit
For applications in which the torch hosepack is connected to the wirefeeder from the left. 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. -
Page 28: Warning Notices On The Device
The safety symbols warn against operating the equipment incorrectly, as this may result in serious injury and damage. WF 25i R /4R/G/W/FSC 4,049,035 Part No.: www.fronius.com 24020072 Ser.No.: IEC 60 974-5/-10 Cl.A IP 43 60 V 1.2 A... - Page 29 Keep hands, hair, clothing and tools away from moving parts. For example: Cogs Feed rollers Wirespools and wire electrodes 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.
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Page 30: 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 31 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.
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Page 32: 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) -
Page 33: Torch Hosepack
Torch hosepack General remarks The Robacta MHP hosepack is designed for gas-cooled and water-cooled robot applica- tions. It connects the TPS/i robot wirefeeders to the Robacta MTB robot welding torches. Scope of supply Robacta MHP PAP hosepack Robacta MHP conventional hosepack Robacta MHP hosepack Not supplied: Inner liners... -
Page 34: Crashbox /I
CrashBox /i General remarks CrashBox /i PAP fitted to robot arm CrashBox /i fitted to robot arm with clamp system The CrashBox /i is a protection device for the torch body, the drive unit, the wire brake and the torch body coupling. In the event of a collision, the CrashBox sends a signal to the robot control, which stops the robot immediately. -
Page 35: Device Concept
Device concept The CrashBox /i is designed specifically for fitting to the robot arm and for holding gas- cooled and water-cooled robot hosepacks and 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 36: Clamp System Scope Of Supply And Options
Clamp system M8 hexagon nut scope of supply M8 washer and options Clamp Torque angle gauge M8 x 40 mm Allen screw Optional (material for extension): M8 x 40 mm screw M8 washer Extension Torque angle gauge (10) M8 hexagon nut... -
Page 37: 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 39: Controls, Connections And Mechanical Components
Controls, connections and mechani- cal components... -
Page 41: Gas Test/Wire Threading Control Panel
Gas test/wire threading control panel 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. ►... - Page 42 IMPORTANT! 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 than 10 mm (0.39 in.) with each press of the button.
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Page 43: Wf Control Elements And Mechanical Components
WF control elements 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. ► Fully read and understand this document. ►... -
Page 44: Wf 15I R, Wf30I R Connections
WF 15i R, WF30i R connections Connections (9)(10) (11) (12) Function Welding torch connection Blanking cover for Option 2 Blanking cover for Option 2 Blanking cover for Option 3 Coolant connection for connecting the coolant connection socket on the interconnecting hosepack Coolant connection socket for connecting to the torch hosepack Blanking cover for Option 4... -
Page 45: Wf 15I R Pap, Wf 30I R Pap Connections
WF 15i R PAP, WF 30i R PAP connections Connections (10) (11) (12) Function Welding torch connection (+) current socket for connecting the interconnecting hosepack power cable Shielding gas connection SpeedNet connection for connecting the interconnecting hosepack SpeedNet cable Blanking cover for Option 3 Coolant connection for connecting the coolant connection socket on the interconnecting hosepack Coolant connection socket... -
Page 46: Wf 25I R Connections
WF 25i R connections Connections (8) (9) (10) (11) Function Welding torch connection Blanking cover for Option 2 Blanking cover for Option 1 Blanking cover for Option 2 Blanking cover for Option 3 Blanking cover for Option 4 SpeedNet connection for connecting the interconnecting hosepack SpeedNet cable Blanking cover for Option 2 Shielding gas connection... -
Page 47: Wf 25I R Pap Connections
WF 25i R PAP connections Connections (10) (11) (3)(4) Function Welding torch connection (+) current socket for connecting the interconnecting hosepack power cable Shielding gas connection Blanking cover for Option 1 SpeedNet connection for connecting the interconnecting hosepack SpeedNet cable Blanking cover for Option 3 Blanking cover for Option 4 Blanking cover for Option 2... -
Page 48: Wf 25I R / L Connections
WF 25i R / L connections Connections (10) (11) Function Wire feed (+) current socket for connecting the interconnecting hosepack power cable Shielding gas connection SpeedNet connection for connecting the interconnecting hosepack SpeedNet cable Blanking cover for Option 1 Blanking cover for Option 4 Blanking cover for Option 3 Blanking cover for Option 2 Blanking cover for Option 2... -
Page 49: Wf 30I R / L Connections
WF 30i R / L connections Connections (10) (11) (12) Function Wire feed (+) current socket for connecting the interconnecting hosepack power cable Shielding gas connection SpeedNet connection for connecting the interconnecting hosepack SpeedNet cable Blanking cover for Option 1 Coolant connection socket for connecting to the torch hosepack Blanking cover for Option 4... -
Page 51: Installation - Conventional Robot
Installation - conventional robot... -
Page 53: 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 54: Fitting The Wire-Feed Unit
Fitting the wire-feed unit 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 wire- feeder 2x M8 x 20 mm 2x M8 x 20 mm WF 15i / 25i / 30i R WF 25i / 30i R / L M6x16... - Page 55 NOTE! The coolant line must be routed under the wirefeeder. To do so, the wirefeeder must be removed from the holder and re-fitted after the line has been routed.
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Page 56: 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 57: 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 58 3,3 Nm...
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Page 59: Fitting The Clamp System
Fitting the clamp system Special tilt angle The positioning of the welding torch in relation to the workpiece is divided into fixed angles for the welding by the torque angle gauge. Special angles are available on request. torch 12,5° 12,5° 34,5°... -
Page 60: Fitting The Clamp System
Fitting the clamp system 42 Nm Fitting the clamp system with ex- tension 42 Nm 42 Nm... -
Page 61: Fitting The Mhp G / W Hosepack
Fitting the MHP G / W hosepack Fitting the MHP G / W conventional hosepack - Stand- Optimum hose- pack arrange- ment R < 200 mm R ≥ 200 mm... -
Page 62: Fitting The Tps/I Torch Neck
Fitting the TPS/i torch neck 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: ►... -
Page 63: 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 64 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.
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Page 65: Fitting The Interconnecting Hosepack
Fitting the interconnecting hosepack Fitting the Stand- ard interconnect- 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. ► All cables, leads and hosepacks must be properly connected, undamaged, correctly in- sulated and adequately dimensioned. -
Page 67: Connecting Wire-Feed Unit To System Components
Connecting wire-feed unit to 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 ► Ensure that the power source remains disconnected from the mains until all work has been completed CAUTION! Risk of injury and damage from loose connections. - Page 68 WF 25i / 30i R/L:...
- Page 69 IMPORTANT! After disconnecting the coolant connection from the hosepack, close the coolant connections on the hosepack using the hosepack's seal cap.
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Page 70: Fitting The Opt / I Mhp Wirebrake And Torch Body
Fitting the OPT / i MHP WireBrake and torch body 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: ►... -
Page 71: Technical Data
Technical data TCP offset 47 mm 1.85 in. Wire diameter 0.8 - 1.6 mm 0.03 - 0.06 in. Weight 450 g 0.99 Ib. Fitting the OPT/i MHP WireBrake 3 x 0,1 Nm ONLY when p > 5,5 bar NOTE! The front O-ring must only be removed at a system pressure of > 5.5 bar (step 3). At a system pressure of <... - Page 72 For steel inner liners: For plastic inner liners:...
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Page 73: Removing The Opt / I Mhp Wirebrake And Torch Body
Removing the OPT / i MHP WireBrake and torch body 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: ►... -
Page 75: Installation - Pap
Installation - PAP... -
Page 77: 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 78: 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 79: Fitting The Wire-Feed Unit
Fitting the wire-feed unit Fitting the WF 15i/ 25i/30i R PAP... -
Page 80: Installing The Crashbox /I Pap On The Robot
Installing the CrashBox /i PAP on the robot Installing the CrashBox /i PAP Observe the torques when fitting the robot 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 3,3 Nm... -
Page 81: 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 82 3,3 Nm...
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Page 83: Fitting The Mhpi/Mhp S G/W Pap Hosepack
Fitting the MHPi/MHP S G/W PAP hosepack Fitting the Robac- ta MHP G/W PAP hosepack 45,0200,1404 Special tool required IMPORTANT! Whenever the welding torch is fitted or removed, ensure that the coupling point is clean and dry. Remove any coolant that has escaped from the coupling point. -
Page 84: Opt / I Mhp Wirebrake" Option
“OPT / i MHP If you would like to fit the “OPT / i MHP WireBrake” option, read the “Fitting the OPT / i MHP WireBrake” op- WireBrake and torch body” chapter. tion... -
Page 85: 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 86 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.
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Page 87: Fitting The Mhpi/Mhp S G/W Pap Sm Hosepack
Fitting the MHPi/MHP S G/W PAP SM hosepack Fitting the Robac- ta MHP G/W PAP SM hosepack 45,0200,1404 Special tool required IMPORTANT! Whenever the welding torch is fitted or removed, ensure that the coupling point is clean and dry. Remove any coolant that has escaped from the coupling point. -
Page 88: Opt / I Mhp Wirebrake" Option
3 x 2 Nm “OPT / i MHP If you would like to fit the “OPT / i MHP WireBrake” option, read the “Fitting the OPT / i MHP WireBrake” op- WireBrake and torch body” chapter. tion... -
Page 89: 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 90 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.
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Page 91: 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. Table - Number... -
Page 92: 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 93: Connecting The Interconnecting Hosepack
Connecting the interconnecting hosepack... -
Page 94: Connecting Wire-Feed Unit To System Components
Connecting wire-feed unit to 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 ► Ensure that the power source remains disconnected from the mains until all work has been completed CAUTION! Risk of injury and damage from loose connections. -
Page 97: Start-Up
Start-up... -
Page 99: 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 101: 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 102: Setting The Contact Pressure
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 Set the contact pressure in such a way that the wire electrode is not deformed but nevertheless ensures proper wirefeeding. -
Page 103: 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 105: Troubleshooting, Maintenance And Disposal
Troubleshooting, maintenance and disposal... -
Page 107: 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 108 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 109 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:...
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Page 110: 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 111: 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 112 After replacing the inner liner: CAUTION! Risk of injury and damage from loose connections. ► All cables, leads and hosepacks must be properly connected, undamaged, correctly in- sulated and adequately dimensioned.
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Page 113: 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 114: Fitting Wearing Parts To The Torch Body - Mtw 700 I
Fitting wearing parts to the torch body - MTW 700 i Removing the CrashBox PAP from the robot (without mount- ing key) -
Page 116: Removing The Crashbox Pap From The Robot (With Mounting Key)
Removing the CrashBox PAP from the robot (with mounting key) -
Page 118: Changing The Torch Hosepack, Changing The Interconnecting Hosepack
Changing the If a robot wirefeeder or a media splitter is mounted in the third robot axis, take the following torch hosepack, into account when changing the torch hosepack or interconnecting hosepack: changing the in- terconnecting CAUTION! hosepack Risk of damage to the robot wirefeeder or media splitter from escaping coolant. ►... -
Page 119: Cleaning The Welding Torch
Cleaning the welding torch Disposal Dispose of in accordance with the applicable national and local regulations. -
Page 121: Technical Data
Technical data... -
Page 123: Wf Wire-Feed Unit
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 Wire speed 0.5 - 15 m/min 19.68 - 590.55 ipm... -
Page 124: Wf 30I R, Wf 30I R Pap, Wf 30I R / L
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 Wire speed 1 - 30 m/min 39.37 - 1181.10 ipm... -
Page 125: Crashbox /I
CrashBox /i Technical data, triggering tor- ques and weight/ distance diagram Item numbers CrashBox /i 44,0350,3589 CrashBox /i XL 44,0350,3760 CrashBox /i XXL 44,0350,3380 CrashBox /i PAP 44,0350,3663 CrashBox /i PAP XL 44,0350,3759 CrashBox /i PAP XXL 44,0350,0202 Reset accuracy (1) ±... - Page 126 CrashBox /i PAP XL Ø90 mm x 40 mm b) CrashBox /i PAP XXL Ø90 mm x 40 mm At a distance of 300 mm from the robot flange With bellows: Ø110 mm...
- Page 127 Triggering torques and weight/distance diagram The specified values only apply in a static state!
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Page 128: Torch Hosepack
Torch hosepack MHP 400i G / R I (ampere) 10 min/40°C 40% D.C.* / 400 M21 (EN 439) 60% D.C.* / 320 100% D.C.* / 260 I (ampere) 10 min/40°C 60% D.C.* / 400 C1 (EN 439) 100% D.C.* / 320 0.8 - 1.6 [mm] 0.031 - 0.063... -
Page 129: Mhp 700I W / R (0.95 - 2.25 M / 3.12 - 7.38 Ft.)
MHP 700i W / R I (ampere) 10 min/40°C 100% D.C.* / 700 (0.95 - 2.25 m / M21 (EN 439) 3.12 - 7.38 ft.) I (ampere) 10 min/40°C 100% D.C.* / 700 C1 (EN 439) 0.8-1.6 (0.031-0.063) [mm] Ø [in.] 0.95 / 1.10 / 1.25 / 1.45 / 1.75 / 1.95 / 2.25 [ft. -
Page 130: Mhp 700I W / R (3.25 - 4.25 M / 10.66 - 13.12 Ft.)
MHP 700i W / R I (ampere) 10 min/40°C 60% D.C.* 700 (3.25 - 4.25 m / M21 (EN 439) 100% D.C.* 580 10.66 - 13.12 ft.) I (ampere) 10 min/40°C 60% D.C.* 700 C1 (EN 439) 100% D.C.* 580 0.8-1.6 (0.031-0.063) [mm] Ø... -
Page 131: Mhp 700I W / R / Pap
MHP 700i W / R / I (ampere) 10 min/40°C 100% D.C.* / 700 M21 (EN 439) I (ampere) 10 min/40°C 100% D.C.* / 700 C1 (EN 439) 0.8 - 1.6 [mm] 0.031 - 0.063 Ø [in.] 0.93 / 0.96 / 1.04 / 1.06 / 1.09 / 1.12 / 1.13 / 1.15 / 1.18 / 1.19 / 1.2 / 1.22 / 1.31 / 1.35 / [ft. -
Page 132: 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 133: 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 134 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 M21 (EN 439) X / I (10 min/40 °C) 100% D.C.* / 700 A C1 (EN 439)
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Page 135: 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 136 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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