Fronius LaserHybrid FW WF 25i Operating Instructions Manual
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Summary of Contents for Fronius LaserHybrid FW WF 25i
- Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating instructions WF 25i LaserHybrid FW WF 60i LaserHybrid FW CMT LaserHybrid SB 360i LaserHybrid 42,0426,0306,EA 007-16032021 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
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Page 3: Table Of Contents
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 Danger from Welding Current Stray Welding Currents EMC Measures... - Page 4 Grid Connection Setting up the LaserHybrid welding system Setting up the CMT LaserHybrid welding system Installing the Laser Welding Head on the Robot Connection options on the robot Mounting the drive unit on the laser welding head Mounting the Laser Welding Head on the Robot Installing and Connecting SplitBox SB 360i LaserHybrid Mounting the SplitBox SB 360i LaserHybrid on the robot Connecting SplitBox SB 360i LaserHybrid...
- Page 5 Preparation Removing the Laser Optics Installing the laser optics Final Tasks Checking Position of the Wire Electrode in relation to the Laser Focus Safety General Checking Position of the Wire Electrode in relation to the Laser Focus Example: Use of the Reference Program after Welding Torch Replacement Measures to Reduce Contamination of the Optics Measures to Reduce Contamination of the Optics Appendix...
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Page 6: Safety Instructions
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. -
Page 7: Intended Use
Your personal safety is at stake! Intended Use The LaserHybrid head is to be used exclusively for its intended purpose. The LaserHybrid head is intended exclusively for LaserHybrid welding of aluminum, CrNi and steel materials. Any other use does not constitute proper use. The manufacturer is not responsible for any damage resulting from improper use. -
Page 8: Personal Protective Equipment
Personal Protect- Please take the following precautions for your own personal safety: ive 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 protection) protect their eyes from laser beams by wearing regulation-compliant safety glasses for lasers. -
Page 9: Danger From Flying Sparks
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 cylin- der or the main gas supply. When no welding is taking place, close the valve of the shielding gas cylinder or the main gas supply. -
Page 10: Particular Hazard Areas
Persons with pacemakers must seek advice from their doctor before staying in the imme- diate vicinity of where the welding work is taking place. Supporting measures to avoid EMC problems: Grid power supply If electromagnetic interference occurs despite a grid connection that complies with regulations, take additional measures (e.g., use a suitable grid filter). -
Page 11: Informal Safety Measures
Special regulations apply in areas where there is a risk of fire or explosion – observe relevant national and international regulations. Power sources for work in spaces where electrical hazards pose a greater risk (e.g. the boiler room) must be marked with a (Safety) sign. The power source should not be loc- ated in these types of spaces, however. -
Page 12: Safety Measures In Normal Operation
Use instructions and checks within the company to ensure that the vicinity of the work- place is always clean and organized. Only set up and operate the device in accordance with the degree of protection shown on the rating plate. When setting up the device, ensure an all-round clearance of 0.5 m (1 ft. -
Page 13: Modifications
Copyright Copyright of these Operating Instructions remains with the manufacturer. Text and illustrations were accurate at the time of printing. Fronius reserves the right to make changes. The contents of the Operating Instructions shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for improvement, or can point out any mistakes that you have found in the Operating Instructions, we will be most grateful for your comments. -
Page 15: General Information
General information... -
Page 17: General
Intended use The laser welding heads are intended exclusively for automated MIG/MAG welding in combination with Fronius system components. Any other use does not constitute proper use. The manufacturer shall not be held liable for any loss resulting from improper use. -
Page 18: Laser Welding Head Versions
Laser welding The laser welding head is available in 4 versions, depending on application, accessibility head versions and space constraints: Version (1): Drive unit on the left with central robot support and 2 mounting brackets * Version (2): Drive unit on the right with central robot support and 2 mounting brackets * Version (3): Drive unit on the left with extension **, right-hand robot support and one mounting bracket *... -
Page 19: Applications
Version (4): Drive unit on the right with extension **, left-hand robot support and one mounting bracket * The laser welding head is supplied configured for the relevant application. Applications Laser welding head version (1) + (2): Example 1: Two-sided, simultaneous fillet weld - PB welding position Angle of contact of the laser: approx. -
Page 20: Scope Of Supply
Laser welding head version (3) + (4): Example 2: Simultaneous butt weld on both sides - PC welding position Angle of contact of laser: 90° (3) - 90° The position of the wire electrode relative to the laser is defined by the laser welding head. -
Page 21: Optional Components
additionally for CMT applications: Wire buffer kit Optional Com- The following components are optionally available for the laser welding head: ponents Seam tracking system, e.g. secured at the front on the welding head Process monitoring to increase the weld seam quality, e.g. connected to the laser optics Focus monitoring... -
Page 22: Requirements
Requirements Mechanical The following mechanical requirements must be met in order to ensure a stable and Requirements repeatable LaserHybrid process: Accurate welding torch guidance for robots or single-purpose machines (e.g. longit- udinal chassis) Precise weld seam preparation Low component tolerances Precise and very fast weld seam management systems with little deviation Robot Require- The laser welding head weighs around 19 kg. -
Page 23: Alignment
Alignment CAUTION! Danger of serious damage by laser radiation reflected directly into the laser optics! This can cause serious damage to the fiber optic. ▶ Always avoid 90° angles to the work- piece surface when aligning the Lase- rHybrid head. -
Page 24: System Overview
System Overview System overview LaserHybrid system with SplitBox SB 360i LaserHybrid installed on the robot (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) + Mounting SB 360i LH *** + WF MOUNTING Drum... - Page 25 CMT LaserHybrid system with SplitBox SB 360i LaserHybrid and wire buffer installed on the robot (12) (13) (10) (11) (14) Welding wire drum * Wirefeeding hose Unwinding wirefeeder: Interconnecting hosepack WF 25i REEL 4R Wire buffer + OPT/i WF wire straightener Wire buffer control line (4,100,880,CK) (10)
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Page 26: Other Laserhybrid Systems
Other LaserHy- The following LaserHybrid systems can also be fitted with the WF 60i LaserHybrid 90° 10 brid systems kW FW CMT laser welding head. In this case, the wire buffer and control line are also included. LaserHybrid system with SplitBox SB 360i LaserHybrid installed on the wall (10) (11) (12) - Page 27 LaserHybrid system with SplitBox SB 360i LaserHybrid installed on the power source (10) (11) Remote control Unwinding wirefeeder: Control line for unwinding WF 25i REEL 4R wirefeeder + OPT/i WF Reel carriage D300 TPS 500i power source LaserHybrid + robot interface MHP 360i LH/W/FSC/FW hosep- + CU 1400i Pro MC or CU 2000i MC Single cooling unit...
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Page 28: Design Versions
Design versions The following design versions can also be fitted with the WF 60i LaserHybrid 90° 10 kW FW CMT laser welding head. In this case, the wire buffer and control line are also included. Power source is in the welding cell (I) TPS 500i - power source HP 95i CON W/1.2 m/95 mm²... - Page 29 Power source is not in the 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 –...
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Page 31: Operating Controls And Connections
Operating controls and connections... -
Page 33: Product Description
Product description Product descrip- tion (12) (11) (10) Item Name Robot support (central / left / right depending on configuration) Mounting brackets Laser optics Adjustment device Gas nozzle MTB torch body Additional extraction Drive unit WF 25i Robacta Drive / WF 60i Robacta Drive CMT Drive unit support (10) MHP robot hose pack... -
Page 34: Control Panel Wf 25I Robacta Drive / Wf 60I Robacta Drive Cmt
(11) CrossJet connection (12) External wirefeeding hose Control Panel WF Function 25i Robacta Drive / WF 60i Gas-test button Robacta Drive To set the required quantity of 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... - Page 35 by a maximum of 10 mm (0.39 in.) each time the button is pressed. If the wire electrode is retracted further, press the wire-return button again. Wire-threading button For threading the wire electrode into the torch hosepack without gas or current Whilst the button is being pressed, the wirefeeder operates at the preset feeder inching speed There are two options available for the wire threading:...
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Page 36: Product Description Sb 360I Laserhybrid
Product descrip- tion SB 360i LaserHybrid (10) (11) (12) (13) (14) Back Front Item Name (+) Current socket with fine thread For connecting the power cable from the interconnecting hosepack Shielding gas connection socket SpeedNet connection For connecting the SpeedNet cable from the interconnecting hosepack SpeedNet connection For connecting system add-ons, such as remote control Gas purging connection... -
Page 37: Connection Specifications
Connection Specifications Connection spe- cifications 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. -
Page 38: Compressed Air Diagram
Di = 41 mm max. length = 10 m Recommended extraction capacity = min. 120 m³/h External wirefeeding hose (Fronius) Radial air supply For connecting a hose as per the following data: outer diameter Do = 6 mm... -
Page 39: Pressure Monitoring In The Splitbox Sb 360I Laserhybrid
NOTE! The "VALVE ON" signal for controlling the solenoid valve (2) is transmitted on bit 26 (away from 0). Pressure monit- The pressure is measured after the solenoid valve. oring in the Split- If the pressure falls below 4.5 bar for longer than 2 seconds, then the "Powersource Box SB 360i Ready"... -
Page 41: Commissioning
Commissioning... -
Page 43: General
General Safety WARNING! Work performed incorrectly can cause serious injury and damage to property. ▶ This setting work must only be carried out by trained and qualified 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. -
Page 44: Setting Up The Cmt Laserhybrid Welding System
Initial situation: Robot and robot control are available and ready for operation Set up welding system: Mount upright consoles Mount cooling unit on upright console 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 the remote control... - Page 45 Mount upright consoles Mount cooling unit on upright console 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 the remote control Mount the wire buffer with mounting plate (e.g.
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Page 46: Installing The Laser Welding Head On The Robot
Installing the Laser Welding Head on the Robot Connection The following connection options apply to all laser welding head versions. options on the robot 90 mm 238 mm Example: Laser welding head version 1 – Drive unit on the left with central robot support and 2 mounting brack-... -
Page 47: Mounting The Drive Unit On The Laser Welding Head
Head on the The laser welding head does not have any collision protection fitted as standard. Fronius therefore recommends the use of a commercially available collision protection Robot solution for robotic applications in order to prevent damage to the laser welding head in the event of a crash. -
Page 48: Installing And Connecting Splitbox Sb 360I Laserhybrid
Installing and Connecting SplitBox SB 360i Lase- rHybrid Mounting the Disconnect SplitBox SB 360i LaserHybrid and SplitBox mount SplitBox SB 360i Depending on the robot, mount an appropriate support for the SplitBox mount on the LaserHybrid on robot the robot IMPORTANT! Observe robot manufacturer's mounting instructions. - Page 49 Secure strain-relief device of the inter- connecting hosepack using 2 Allen screws size 4 mm Open clamps (x2) Insert interconnecting hosepack into the clamps Close clamps Insert SplitBox SB 360i LaserHybrid into the SplitBox mount as per the dia- gram Secure SplitBox into the SplitBox mount using 3 TX25 screws from above and 3 TX25 from below...
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Page 50: Connecting Splitbox Sb 360I Laserhybrid
Connecting Split- Connect interconnecting hosepack to Box SB 360i SplitBox: LaserHybrid 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 welding torch connection (FSC) Close clamping lever Open cover on LaserHybrid hosepack... - Page 51 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 connec- tion 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 connec-...
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Page 52: Connecting Crossjet
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,... - Page 53 Pull protective hoses over the connec- tions...
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Page 54: Connecting Laserhybrid Hosepack To Laser Welding Head
Connecting LaserHybrid Hosepack to Laser Weld- ing Head Mounting the IMPORTANT! Only mount the drive unit when the power source is switched off. Hosepack on the WF Robacta CAUTION! Drive (Conven- tional) Risk of damage due to dirty or wet coupling points ▶... -
Page 55: Connecting/Changing The Wirefeeding Hose On The Laser Welding Head
Connecting/ Place the starting piece on the Changing the wirefeeding hose Wirefeeding Hose Screw the starting piece as far as it on the Laser will go onto the wirefeeding hose Welding Head Press the green locking button and hold it Push the wirefeeding hose into the drive unit until the tension on the lock- ing button is released... -
Page 56: Installing/Changing Wirefeed Rollers
Installing/Changing Wirefeed Rollers Inserting/repla- cing the WF 25i Robacta drive feed rollers 0 mm * * If the roller mount is opened as far as it will go with slight resistance, the roller mount will stay in this pos- ition. - Page 57 Torx 40 1 Nm 0.74 lb-ft...
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Page 58: Inserting/Replacing The Wf 60I Robacta Drive Cmt Drive Feed Rollers
Inserting/repla- cing the WF 60i Robacta Drive CMT drive feed rollers 0 mm * * If the roller mount is opened as far as it will go with slight resistance, the roller mount will stay in this pos- ition. 42,0411,0160 12 mm... - Page 59 42,0411,0160 12 mm 5 Nm 3.69 lb-ft...
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Page 60: Connecting Laser Optics And Extra Extraction
Connecting Laser Optics and Extra Extraction Connecting the NOTE! laser optics The following activities were described on the basis of version (1) - Drive unit on the left with central robot support and 2 mounting brackets *. The procedure for the other three versions is the same. CAUTION! Risk of damage to the laser welding head due to contamination from above. - Page 61 Position the laser welding head so that the longitudinal axis of the laser weld- ing head is outside the horizontal (> 90°) Clean connection area using com- pressed air Remove the protective cover from the fiber optic cable connection Clean connector of the fiber optic cable using compressed air Remove the protective cover from the fiber optic cable connector...
- Page 62 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 Pull back the rubber sleeve in the direction of the optics Connect the fiber optic cable con- nector Check whether the rubber sleeve is cleanly sealed all around the fiber...
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Page 63: Connecting The Additional Extraction System
Connect the optics cooling supply (blue marking) Connect the optics cooling return Position the laser welding head in the vertical line Connecting the Push hose over the connection additional extrac- Secure hose with hose clamp tion system... - Page 64 Attach the mounting bracket Push slot nut upwards, so that the top hole of the slot nut is positioned under the top hole of the mounting bracket. Use a short Allen screw (6 mm) to lightly fix the slot nut and mounting bracket Insert register pins (x2) Fit and screw on extractor tool for...
- Page 65 For installation: the 3 shorter screws are one below the other; the 2 longer screws are opposite. Insert the remaining 4 Allen screws, size 6 mm Fix the mounting bracket in place using 5 Allen screws size 6 mm Tightening torque = 24 Nm...
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Page 66: Preparing Welding Torch
Preparing Welding Torch Fitting the inner Plastic inner liner: liner in the torch body Steel inner liner:... -
Page 67: Mounting The Welding Torch On The Wf Robacta Drive (Conventional)
Mounting the IMPORTANT! When removing or attaching the welding torch, ensure that the coupling welding torch on point is clean and dry. Remove any coolant that has escaped from the coupling point. the WF Robacta Drive (conven- tional) 45,0200,1261 42,0411,1315... -
Page 69: Installing Hosepack On Robot
Installing Hosepack on Robot Placing the IMPORTANT! The optional LaserHybrid hosepack holder is not included in the scope of hosepack on the supply for the laser welding head. robot 6 x 5 Nm 44,0360,0099 (14) 8 Nm 2,9 Nm (10) (12) (11) 27 Nm... - Page 70 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 disassemble the lower sheet metal part...
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Page 71: Adapting The Additional Extraction System
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 To make components more accessible, the position of the additional extraction system Additional... -
Page 72: Threading The Wire Electrode
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 elec- trode comes out of the welding torch Setting the Con-... -
Page 73: Setting The Contact Pressure On The Wf 60I Robacta Drive Cmt
Contact pressure standard values for steel rollers: Al, AlSi 1 - 2 AlMg 2 - 4 3 - 5 CuSi 5 - 7 Steel 6 - 8 CrNi 6 - 8 Setting the con- NOTE! tact pressure on Set the contact pressure in such a way that the wire electrode is not deformed but the WF 60i Robacta Drive nevertheless ensures proper wirefeeding. -
Page 74: Setting Up Laser Welding Head
Setting up Laser Welding Head Stick Out NOTE! When setting the spatial position of the welding torch, pay attention to a gen- eral stick out of 15-20 mm. Standard stick out = 20 mm ▶ Using an adjustment device, com- pensate for a stick out <... -
Page 75: Adjustment Device On The Laser Welding Head
Adjustment The laser welding head is equipped with an adjustment device, which allows for precise device on the positioning in the x, y, and z coordinate axes. laser welding head Scale for the y axis Adjustment screw with gradu- ation for the y axis Adjustment range +/- 5 mm Allen screw, 5 mm ¼-turn corresponds to an adjust-... -
Page 76: Adjusting The Y Axis
Adjust x axis by turning the adjustment screw: Allen key, size 5 mm ¼-turn corresponds to 0.25 mm Adjusting the y Loosen threaded pin on the adjust- axis ment device size 2.5 mm Adjust y axis by turning the adjustment screw (3): Allen key, size 5 mm ¼-turn corresponds to 0.25 mm... -
Page 77: Creating Reference Program
Creating Reference Program Safety WARNING! Work performed incorrectly can cause serious injury and damage to property. ▶ This setting work must only be carried out by trained and qualified 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. - Page 78 Default setting for the parameter finding of the component to be welded: Using the robot, approach the gauge so that the laser focus is in the cross hairs of the gauge Using the robot, lower the laser weld- ing head until the wire electrode touches the gauge Using the x and y adjustment units on the laser welding head, position the...
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Page 79: Signal Sequence For Laserhybrid Welding
Signal Sequence for LaserHybrid Welding Safety WARNING! Work performed incorrectly can cause serious injury and damage to property. ▶ The welding process may only be programmed by trained personnel. ▶ 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 perpendic- ular to the workpiece surface during welding. - Page 80 Requirement: The laser must be ready for beam release. Set signal "Arc on" Wait for the current flow signal ("arc standing") Set signal "Laser on" Set signal "Start robot" LaserHybrid welding end position: Stop robot movement Reset signal "Laser on" Reset signal "Welding on"...
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Page 81: Measures Before Starting Welding
Measures before Starting Welding Measures before Check the coolant flow on the laser optics cooling system Starting Welding Check the coolant flow on the welding torch cooling system (visual inspection in the coolant tank of the cooling unit) Check whether a protective glass is present in the laser optics Check whether all covers are correctly mounted on the laser welding head Test CrossJet Test extraction... -
Page 82: Operation Recommendations For Laserhybrid Welding System
Operation Recommendations for LaserHybrid Weld- ing System Recommenda- For smooth operation, the following items should always be available when using a tions for the LaserHybrid welding system: Operation 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... -
Page 83: Maintenance
Maintenance... -
Page 85: Replacing The Welding Torch And Welding Torch Wearing Parts
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... -
Page 86: Replacing The Spatter Guard Plate And Extra Extraction
Replacing the Spatter Guard Plate and Extra Extraction Replacing the Remove 4 Allen screws spatter guard size 2.5 mm plate Replace the spatter guard plate Assemble in reverse order Replacing the Loosen 4 Allen screws Additional size 2.5 mm Extraction Sys- Replace the extraction system... -
Page 87: Replacing The Laser Optics
Replacing the Laser Optics Safety WARNING! Work performed incorrectly can cause serious injury and damage to property. ▶ This assembly work must only be carried out by trained and qualified personnel. ▶ Observe the safety rules in the OI, in particular the "Safety Inspection" section. Preparation CAUTION! Risk of damage to the laser welding head due to contamination from above. - Page 88 IMPORTANT! Only disconnect the coolant hose at the laser optics end, never from the fiber optic cable. Loosen Allen screw and disconnect coolant hose from the laser optics size 2.5 mm Disconnecting the fiber optic cable from the laser optics Disconnection of the fiber optic cable from the laser optics is carried out in the reverse order to connection, see...
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Page 89: Removing The Laser Optics
Removing the Loosen the Allen screws Laser 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 CAUTION! If dropped, the laser optics unit can be damaged to such an extent that it is... - Page 90 Optical adjustment gauge with (a) register pins (b) holes for screw fixing Positioning area on the laser optics with (c) holes for register pins (d) threaded holes Place the optical adjustment gauge onto the laser optics so that the register pins engage in the holes for the register pins on the laser optics Secure the optical adjustment gauge with 2 Allen screws M5 x 16 mm, size 4 mm...
- Page 91 Place the laser optics with the optical adjustment gauge onto the laser weld- ing 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...
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Page 92: Final Tasks
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 mounting brackets Tighten the screws on both mounting brackets Tightening torque = 24 Nm Check the position of the laser focus using the reference program Final Tasks... -
Page 93: Checking Position Of The Wire Electrode In Relation To The Laser Focus
Checking Position of the Wire Electrode in relation to the Laser Focus Safety WARNING! Work performed incorrectly can cause serious injury and damage to property. ▶ This setting work must only be carried out by trained and qualified personnel. ▶ Observe the safety rules in the OI, in particular the "Safety Inspection"... -
Page 94: Example: Use Of The Reference Program After Welding Torch Replacement
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 adjustment gauge Thread in wire electrode until this touches the adjustment gauge... -
Page 95: Measures To Reduce Contamination Of The Optics
Measures to Reduce Contamination of the Optics Measures to Crossjet and Extraction Reduce Contam- ination of the Please observe the values for the crossjet and extraction specified in these Operat- Optics ing Instructions. Switch on the crossjet and extraction at least five seconds before the start of weld- ing. - Page 96 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.
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Page 97: Appendix
Appendix... -
Page 99: Technical Data
1.0 - 1.6 mm Voltage rating (V-Peak) 141 V Cooling system Liquid cooling Coolant Original Fronius coolant Hosepack length 4.2 m / 7.5 m Lowest cooling capacity as per 1400 / 1500 W IEC 60974-2, depending on the hosepack length Coolant pressure min./max. -
Page 100: Wf 25I Robacta Drive /W
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 Ø 0.032-0.063 [in.] [l/min] [gal./min] 0.26 [bar] [psi]... -
Page 101: Mtb 700 Lh /W
MTB 700 LH /W 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) 1.0-1.6 [mm] Ø 0.039-0.063 [in.] D.C. = duty cycle MTB 500i LH /W X / I (10 min/40 °C) - Page 104 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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