Fronius Pull Operating Instructions Manual
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Fronius Pull Operating Instructions Manual

Tps/i robotics
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Operating
instructions
TPS/i Robotics welding system
Pull
PushPull CMT
EN
Operating instructions
42,0426,0219,EN
021-15032022

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  • Page 1 Operating instructions TPS/i Robotics welding system Pull PushPull CMT Operating instructions 42,0426,0219,EN 021-15032022...

  • 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 Meandering welding currents EMC Device Classifications EMC measures...
  • Page 4 SplitBox SB 60i R Device concept Proper use Safety Warning notices on the device TPSi wire buffer General CrashBox /i General Also required for installation Device concept Areas of utilisation Information on repairing CrashBoxes Scope of supply WF Robacta Drive General Warning notices on the device PushPull hosepack...
  • Page 5 Control panel Assembling system components - conventional robot General Safety Assembly sequence, conventional robot Fitting the SplitBox SB 500i R Fitting the wirefeeder holder Fitting the SB 500i R Fitting the SB 500i R (left variant) Fitting the CrashBox /i to the robot Fitting the CrashBox /i to the robot Installing the CrashBox/i Dummy on the robot Fitting the WF Robacta Drive to a conventional robot...
  • Page 6 Fitting the gas-saver nozzle Fitting the inner liner inside the torch body Fitting the torch body to the WF Robacta Drive Fitting the OPT/i camera mount Load-bearing capacity of the OPT/i camera mount Safety Fitting the OPT/i camera mount Fitting the inner liner Fitting the inner liner (unreeling wirefeeder - SplitBox SB 500i R) Fitting the inner liner (unreeling wirefeeder- WF Robacta Drive with external wirefeeding hose)
  • Page 7 Technical data SB 500i R, R left variant, PAP SB 500i R, R left variant, PAP SB 60i R SB 60i R CrashBox /i CrashBox /i PushPull hosepack Gas-cooled PushPull hosepacks Water-cooled PushPull hosepacks WF 25i Robacta Drive WF 25i Robacta Drive /G WF 25i Robacta Drive /W WF 60i Robacta Drive CMT WF 60i Robacta Drive CMT /G...

  • Page 8: 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 9: Intended Use

    The devices and components described in these Operating Instructions are in- tended exclusively 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 10: Protecting Yourself And Others

    This may affect a number device types in terms of: Connection restrictions Criteria with regard to the maximum permissible mains impedance Criteria with regard to the minimum short-circuit power requirement 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 mat- ter with the power supply company.

  • Page 11: Danger From Flying Sparks

    Keep your face away from welding fumes and gases. Fumes and hazardous gases must not be breathed in must be extracted from the working area using appropriate methods. Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least 20 m³...
  • Page 12 Switch off unused devices. Wear a safety harness if working at height. Before working on the device, switch it off and pull out the mains plug. Attach a clearly legible and easy-to-understand warning sign to the device to prevent anyone from plugging the mains plug back in and switching it on again.

  • Page 13: Meandering Welding Currents

    Meandering If the following instructions are ignored, meandering welding currents can devel- welding currents op with the following consequences: Fire hazard Overheating of parts connected to the workpiece Damage to ground conductors Damage to device and other electrical equipment Ensure that the workpiece is held securely by the workpiece clamp. Attach the workpiece clamp as close as possible to the area that is to be welded.

  • Page 14: Emf Measures

    Equipotential bonding Earthing of the workpiece If necessary, establish an earth connection using suitable capacitors. Shield, if necessary Shield other devices nearby Shield the entire welding installation EMF measures Electromagnetic fields may pose as yet unknown risks to health: Effects on the health of persons in the vicinity, e.g. those with pacemakers and hearing aids Individuals with pacemakers must seek advice from their doctor before ap- proaching the device or any welding that is in progress...

  • Page 15: Requirement For The Shielding Gas

    Observe the information on the coolant safety data sheet when handling coolant. The coolant safety data sheet may be obtained from your service centre or down- loaded from the manufacturer's website. Use only suitable load-carrying equipment supplied by the manufacturer when transporting devices by crane.

  • Page 16: Danger From Escaping Shielding Gas

    Turn your face to one side when opening the valve of a shielding gas cylinder. Close the shielding gas cylinder valve if no welding is taking place. If the shielding gas cylinder is not connected, leave the valve cap in place on the cylinder.

  • Page 17: Safety Measures In Normal Operation

    Safety measures Only operate the device when all safety devices are fully functional. If the safety in normal opera- devices are not fully functional, there is a risk of tion injury or death to the operator or a third party damage to the device and other material assets belonging to the operator inefficient operation of the device Any safety devices that are not functioning properly must be repaired before...

  • Page 18: Safety Inspection

    (e.g. relevant product standards of the EN 60 974 series). 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: Description Of The Warning Notices On The Device

    Use a base that is insulated from the floor and work area to protect against electric shock. Before working on the device, switch off the device and pull out the mains plug or disconnect it from the power supply. Inhalation of welding fumes can be harmful to health.
  • Page 20 Use forced-air ventilation or a local extraction system to remove welding fumes. Remove welding fumes with a fan. Welding sparks can cause an explosion or fire. Keep flammable materials away from the welding process. Never weld close to flammable materials. Welding sparks can cause a fire.

  • Page 21: System Configurations

    System configurations...

  • Page 23: 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 torch hosepack WF 25i Robacta Drive MTB /i R robot welding torch Maximum wirefeed length: max.

  • Page 24: Powerdrive With Wire Drum And External Wirefeeding Hose

    PowerDrive with wire drum and (7)* external wirefeeding 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 25: Pushpull With 4-Roller Unreeling Wirefeeder And Wire Drum

    PushPull with 4- (1)* roller unreeling (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 torch hosepack (10) WF 25i Robacta Drive...

  • Page 26: 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 + OPT/i WF Reel carriage D300 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 27: Pushpull With Sb 60I, 4-Roller Unreeling Wirefeeder And Wirespool

    PushPull with SB 60i, 4-roller unreeling (10) wirefeeder and wirespool (11)** (7)** SpeedNet cable COM Unreeling wirefeeder WF 25i REEL 4R + OPT/i WF Reel carriage D300 TPSi power source CU cooling unit Upright console HP interconnecting hosepack SB 60i Wirefeeding hose with inner liner SplitBox SB 60i R MHP /i R torch hosepack...

  • Page 28: Pushpull With 2-Roller Unreeling Wirefeeder, Wire Drum And External Wirefeeding Hose

    PushPull with 2- (7)* roller unreeling wirefeeder, wire drum and ex- (10) ternal wirefeed- ing hose (11)** Unreeling wirefeeder WF 30i REEL 2R + WF Mounting Drum 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...

  • Page 29: Cmt With Sb 60I, 4-Roller Unreeling Wirefeeder And Wire Drum

    CMT with SB 60i, (9)* 4-roller unreel- ing 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 SB 60i SplitBox SB 60i R MHP /i R torch hosepack (10)

  • Page 30: Cmt With Sb 500I, 4-Roller Unreeling Wirefeeder, Wire Drum And External Wirefeeding Hose

    CMT with SB 500i, 4-roller un- (10)* reeling wirefeed- er, wire drum and (11) external wirefeeding 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...

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

    CMT with SB 60i, (9)* 4-roller unreel- ing wirefeeder (10) and wirespool (11)** (7)** SpeedNet cable COM Unreeling wirefeeder WF 25i REEL 4R + OPT/i WF Reel carriage D300 TPSi power source CU cooling unit Upright console HP interconnecting hosepack SB 60i Wirefeeding hose with inner liner SplitBox SB 60i R MHP /i R torch hosepack...

  • Page 32: 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 torch hosepack WF 25i Robacta Drive MTB /i R robot welding torch Maximum wirefeed length: max.

  • Page 33: Pushpull With 4-Roller Unreeling Wirefeeder And Wire Drum

    PushPull with 4- (9)* roller unreeling (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 torch hosepack (10) WF 25i Robacta Drive...

  • Page 34: Pushpull With 4-Roller Unreeling Wirefeeder And Wirespool

    PushPull with 4- (9)* roller unreeling wirefeeder and (7)* wirespool (10) (11)** SpeedNet cable COM Unreeling wirefeeder WF 25i REEL 4R + OPT/i WF Reel carriage D300 TPSi power source CU cooling unit Upright console HP interconnecting hosepack Wirefeeding hose with inner liner SplitBox SB 500i R MHP /i R torch hosepack (10)

  • Page 35: Pushpull With 2-Roller Unreeling Wirefeeder And Wire Drum

    PushPull with 2- (9)* roller unreeling (3)* wirefeeder and wire drum (10) (11)** Unreeling wirefeeder WF 30i REEL 2R + WF Mounting Drum 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 torch hosepack (10)

  • Page 36: Pushpull With Wire Buffer, 4-Roller Unreeling Wirefeeder And Wire Drum

    PushPull with wire buffer, 4- (10)* roller unreeling wirefeeder and (1)** (11) wire drum (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 37: Pushpull With Wire Buffer, 4-Roller Unreeling Wirefeeder And Wirespool

    PushPull with (10)* wire buffer, 4- (7)* roller unreeling wirefeeder and (11) wirespool (12)** (7)** SpeedNet cable COM Unreeling wirefeeder WF 25i REEL 4R + OPT/i WF Reel carriage D300 TPSi power source CU cooling unit Upright console HP interconnecting hosepack Wirefeeding hose with inner liner Wire buffer SplitBox SB 500i R...

  • Page 38: Cmt With Sb 60I, 4-Roller Unreeling Wirefeeder And Wire Drum

    CMT with SB 60i, (9)* 4-roller unreel- ing 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 SB 60i SplitBox SB 60i R MHP /i R torch hosepack (10)

  • Page 39: Cmt With Sb 500I, 4-Roller Unreeling Wirefeeder And Wire Drum

    CMT with SB (10)* 500i, 4-roller un- (1)* reeling wirefeed- er 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...

  • Page 40: Cmt With Sb 500I, 4-Roller Unreeling Wirefeeder And Wirespool

    CMT with SB (10)* 500i, 4-roller un- (7)* reeling wirefeed- er and wirespool (11) (12)** (7)** SpeedNet cable COM Unreeling wirefeeder WF 25i REEL 4R + OPT/i WF Reel carriage D300 TPSi power source CU cooling unit Upright console HP interconnecting hosepack Wirefeeding hose with inner liner SplitBox SB 500i R MHP /i R torch hosepack...

  • Page 41: System Components

    System components...

  • Page 43: Splitbox Sb 500I R

    Proper use The device is designed exclusively for bringing together the welding media in automated MIG/MAG welding applications 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 44: 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 45 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. During operation Ensure that all covers are closed and all side panels are fitted properly.

  • Page 46: Splitbox Sb 60I R

    Proper use The device is designed exclusively for bringing together the welding media in automated MIG/MAG welding applications 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 on the device and rating 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.
  • Page 48 Do not dispose of used devices with domestic waste. Dispose of them according to the safety rules.

  • Page 49: Tpsi Wire Buffer

    TPSi wire buffer General As its name implies, the wire buffer acts as a buffer zone for the rapid re- versing movements of the wire elec- trode 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 50: Crashbox /I

    ▶ XXL: for push/pull systems with a torch body length of 250–391 mm; for push/pull systems with a torch body length of up to 249 mm and with ex- tension. ▶ If there is a TX/i torch-neck changeover system or WireBrake in the welding system, select the next larger CrashBox.

  • Page 51: Also Required For Installation

    Also required for Depending on the particular robot: installation 1 x robot flange with screws Robot flange as per price list Observe torques: Max. tightening torque for screws of strength class 8.8 3.3 Nm / 2.43 lb-ft 5.0 Nm / 3.69 lb-ft 6.0 Nm / 4.43 lb-ft 27.3 Nm / 20.14 lb-ft 54 Nm / 39.83 lb-ft...

  • Page 52: 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.

  • Page 53: Wf Robacta Drive

    Robacta 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 Drive. Warning notices The device is fitted with safety symbols and a rating plate. The safety symbols on the device and rating plate must not be removed or painted over.

  • Page 54: Pushpull Hosepack

    PushPull hosepack General The Robacta MHPi RD hosepack is designed for gas-cooled and water-cooled ro- bot applications. 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 55: Robot Welding Torch

    Robot welding torch Safety CAUTION! Risk of burns from hot torch body, hot torch body coupling and other hot weld- ing torch components. Before starting work on the torch body, the torch body coupling and all other welding torch components: ▶...
  • Page 56 OPT CAM: Prepared for the camera recording option...

  • Page 57: Wf 25I Reel R /4R, Wf 30I Reel R /2R

    Proper use The device is designed exclusively for wirefeeding in automated MIG/MAG weld- ing applications 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 58: Warning Notices On The Device

    Warning notices The device is fitted with safety symbols and a rating plate. The safety symbols on the device and rating 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.
  • Page 59 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 com- ponents. Covers and side panels may only be opened / removed while maintenance or re- pair work is being carried out.

  • Page 60: Interconnecting Hosepack

    Interconnecting hosepack General The interconnecting hosepack connects the power source to the wirefeeder. With the TPS/i welding system the interconnecting hosepack is available in two ver- sions - one split and one standard variant. 3 / 5 / 10 / 15 m (extension - split variant) CON hosepacks 4 / 5.5 / 8 / 10 / 15 / 16 m (continuous variant) General The interconnecting hosepack connects the power source to the SplitBox SB 60i...

  • Page 61: Powerliner

    PowerLiner General The PowerLiner is a wirefeeder system for all standard wire types. Wire diamet- ers 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. Seventy-six rollers are used for each metre of wirefeeding hose.

  • Page 62: Wiresense

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

  • Page 63: Wiresense - Edge Detection

    WireSense - The WireSense edge detection is activated and an edge height between 0.5 edge detection and 20 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 64: Wiresense - Contour Detection

    WireSense - con- WireSense contour detection is active when WireSense edge detection = tour detection OFF or < 0.5 mm. 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 electrode and stores the zero reference value (The zero reference value is useful for overcoming the distance to the com- ponent without wirefeeding if the reference value is not set directly on the...

  • Page 65: Technical Details

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

  • Page 66: Opt/I Camera Mount

    OPT/i camera mount General Application example of a mounted OPT/i camera mount (44,0350,0080) The OPT/i camera mount can be used to mount seam tracking systems, cameras or similar on the robot welding torch. The camera mount is fitted instead of the torch body union nut; the TCP remains the same.

  • Page 67: Controls, Connections And Mechanical Components

    Controls, connections and mechan- ical components...

  • Page 69: General

    General Safety WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in serious personal injury and damage to property. ▶ All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

  • Page 70: Splitbox Sb 500I R / Sb 500I R Pap

    SplitBox SB 500i R / SB 500i R PAP SB 500i R con- trol elements, connections and mechanical com- ponents Front of SB 500i R (right variant) Rear of SB 500i R (right variant) (10) Front of SB 500i R (left variant) Rear of SB 500i R (left variant) Function Blanking cover for option 3...

  • Page 71: Sb 500I R Pap Control Elements, Connections And Mechanical Components

    Blanking cover for option 2 (10) Wire infeed Function (11) Cover (12) Bushing (13) Gas test / wire threading con- trol panel (option) Side view (right variant) SB 500i R PAP control ele- ments, connec- tions and mech- anical compon- ents Front Rear...

  • Page 72: Gas Test/Wire Threading Control Panel (Optional)

    Blanking cover for option 2 (10) Wire infeed Function (11) Cover (12) Bushing (13) Gas test / wire threading con- trol panel (option) Side view Gas test/wire Function threading con- trol panel (op- Operating status LED tional) Shows steady green when the device is ready for use Function Gas-test button...
  • Page 73 Press and hold the wire retract button After pressing the wire retract button, the wire electrode is retracted by 1 mm (0.039 in.). After a short pause, the wirefeeder continues to retract the wire elec- trode - if the wire retract button remains pressed, the speed increases every second by 10 m/min (393.70 ipm) up to the preset wire retract speed.
  • Page 74 the wirefeeding will be stopped and the wire electrode will be retracted again by 1 mm (0.039 in.). NOTE! If there is a ground earth connection with the contact tip before the wire threading button is pressed, the wire electrode will be retracted when the but- ton is pressed until it is short-circuit-free –...

  • Page 75: Splitbox Sb 60I R

    SplitBox SB 60i R SB 60i R: Hole for fitting to robot control ele- Cover ments, connec- Hole for fitting to robot tions and mech- Blanking cover / gas test / wire anical compon- threading control panel option ents Front Welding torch connection Coolant hoses to welding torch Blanking cover (SpeedNet or...

  • Page 76: Sb 60I R /L:control Elements, Connections And Mechanical Components

    SB 60i R /L: Hole for fitting to robot control ele- Cover ments, connec- Hole for fitting to robot tions and mech- Blanking cover / gas test / wire anical compon- threading control panel option ents Front Welding torch connection Coolant hoses to welding torch Blanking cover (SpeedNet or external sensor option)

  • Page 77: Wf 25I Robacta Drive / Wf 60I Robacta Drive Cmt

    WF 25i Robacta Drive / WF 60i Robacta Drive WF 25i Robacta Function Drive / WF 60i Robacta Drive Gas-test button CMT control For setting the required gas panel flow rate on the pressure regu- lator Gas will flow out for 30 seconds after the gas-test button is pressed.
  • Page 78 If the wire electrode is to be retracted further, the wire retract button must be pressed again. Wire threading button For threading the wire electrode into the torch hosepack with no accom- panying flow of gas or current While the button is pressed, the wirefeeder runs at the preset feeder inch- ing speed.

  • Page 79: Status Indicators

    Status indicators The following statuses may be indicated on the display of the WF 25i Robacta Drive / WF 60i Robacta Drive CMT: Normal operation Error in Stop / Robot not ready Gas testing is active No connection to the control Update Teach mode active Wire threading active...
  • Page 80 For applications with WireSwitch, when process line 1 is active For applications with WireSwitch, when process line 2 is active...

  • Page 81: Wf 25I Reel R /4R, Wf 30I Reel R /2R

    WF 25i REEL R /4R, WF 30i REEL R /2R Controls, con- nections and mechanical com- ponents (3) (2) Front of WF 25i REEL R /4R/G/W Front of WF 30i REEL R /2R/G/W (11) (10) Left side Rear 100 mm 3.9 in.

  • Page 82: Control Panel

    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) Blanking cover for optional component (12) M20 thread for connecting QuickConnect option...
  • Page 83 Function Wire retract button For retracting the wire electrode with no accompanying flow of gas or cur- rent The wire electrode can be retracted using one of two methods: Method 1 Retracting the wire electrode using the preset wire retract speed: Press and hold "Wire retract"...
  • Page 84 The wire electrode will be threaded 1 mm (0.039 in.) after the wire threading button is pressed After a short pause, the wirefeeder continues to thread the wire elec- trode. If the wire threading button remains pressed, the speed will in- crease every second at a rate of 10 m/min (393.70 ipm) until the pre- set feeder inching speed is reached If the wire electrode comes into contact with a ground earth connec-...

  • Page 85: Assembling System Components - Conventional Robot

    Assembling system components - conventional robot...

  • Page 87: General

    General 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 per- sonnel. ▶ The Operating Instructions for system components, particularly the chapter entitled "Safety rules", must be observed.

  • Page 88: Fitting The Splitbox Sb 500I R

    Fitting the SplitBox SB 500i R Fitting the NOTE! wirefeeder hold- Depending on the robot, please also note the instructions and information on in- stalling 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-...

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

    Fitting the CrashBox /i to the robot Fitting the Observe the torques when fitting the CrashBox /i to robot flange: the robot Max. tightening torque for screws of strength class 8.8 3.3 Nm / 2.43 lb-ft 5.0 Nm / 3.69 lb-ft 6.0 Nm / 4.43 lb-ft 27.3 Nm / 20.14 lb-ft 54 Nm / 39.83 lb-ft...

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

    Installing the Observe the torques when fitting the CrashBox/i robot flange: Dummy on the robot Max. tightening torque for screws of strength class 8.8 3.3 Nm / 2.43 lb-ft 5.0 Nm / 3.69 lb-ft 6.0 Nm / 4.43 lb-ft 27.3 Nm / 20.14 lb-ft 54 Nm / 39.83 lb-ft 93 Nm / 68.60 lb-ft...
  • Page 91 6 Nm / 4.43 lb-ft 3,3 Nm / 2.43 lb-ft...

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

    Fitting the WF Robacta Drive to a conventional robot Fitting the IMPORTANT! Only fit the drive unit when the power source is switched off. hosepack to the WF Robacta CAUTION! Drive (conven- tional) Danger of property damage due to dirty or wet coupling point. ▶...

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

    Fitting the WF Robacta Drive to the robot (con- ventional) 10 Nm / 7.38 lb-ft M6 x 12 mm 42 Nm / 30.98 lb-ft...

  • Page 94: Fitting The Wf Robacta Drive To The Robot

    Fitting the WF Robacta Drive to the robot Mount the index disk 45° from the scope of delivery of the extension NOTE! CB (for CrashBox) is stamped on one side of the extension. ▶ This side must be fitted to the index disk that has already been fitted. 42 Nm 30.98 lb-ft 42 Nm...

  • Page 95: Optimum Hosepack Arrangement

    Optimum hosep- ack arrangement R < 200 mm R ≥ 200 mm...

  • Page 96: Fitting The Interconnecting Hosepack

    Fitting the interconnecting hosepack Fitting the SB 500i Standard inter- connecting hosepack to the 3 Nm robot 2.21 lb-ft...

  • Page 97: Connecting The Mhp W Hosepack

    Connecting the MHP W hosepack Connecting the IMPORTANT! Whenever the torch hosepack is fitted or removed, ensure that the MHP W hosep- coupling point is clean and dry. Remove any coolant that has escaped from the coupling point. * Push in hosepack as far as it will go...
  • Page 98 IMPORTANT! Always route coolant hoses below the hosepack and then guide them to the connection socket: WFi R / SB 500i SB 60i...
  • Page 99 Coolant return (red) Coolant flow (blue) IMPORTANT! Connect the coolant hoses to the cooling unit correctly! Disconnecting the coolant hoses PUSH...

  • Page 100: Connecting The Splitbox Sb 500I R To The System Components

    Connecting the SplitBox SB 500i R 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 101 SB 500i R (left variant) NOTE! If present, lead the coolant hoses from the interconnecting hosepack under the SB 500i R and connect them to the torch hosepack.

  • Page 103: Assembling System Components - Pap Robot

    Assembling system components - PAP robot...

  • Page 105: General

    General 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 per- sonnel. ▶ The Operating Instructions for system components, particularly the chapter entitled "Safety rules", must be observed.

  • Page 106: Maximum Axis Rotation

    Maximum axis rotation -175° +90° +175° -200° -90° +200° Fourth robot axis: +/- 175° Fifth robot axis: +/- 90° fifth robot axis: +/- 120° - if the fourth robot axis = 0° and the sixth robot axis = 0° IMPORTANT! The maximum axis rotation of +/- 120° in the fifth robot ax- is only applies if there is NO axis rotation present in the fourth and sixth robot axes! Sixth robot axis: +/- 200°...

  • Page 107: Fitting The Splitbox Sb 500I R Pap

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

  • Page 108: 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 Drive /i PAP on Observe the torques when fitting the the robot robot flange: Max. tightening torque for screws of strength class 8.8: 3.3 Nm / 2.43 lb-ft 5.0 Nm / 3.69 lb-ft 6.0 Nm / 4.43 lb-ft...

  • Page 109: Installing The Crashbox Drive /I Pap Dummy On The Robot

    Installing the Dowel pin in the robot flange CrashBox Drive /i PAP Observe the torques when fitting the Dummy on the robot flange: robot Max. tightening torque for screws of strength class 8.8: 3.3 Nm / 2.43 lb-ft 5.0 Nm / 3.69 lb-ft 6.0 Nm / 4.43 lb-ft 27.3 Nm / 20.14 lb-ft 54 Nm / 39.83 lb-ft...
  • Page 110 8 Nm / 5.90 lb-ft 4 Nm / 2.95 lb-ft...

  • Page 111: Fitting The Wf Robacta Drive To A Pap Robot

    Fitting the WF Robacta Drive to a PAP robot Fitting the IMPORTANT! Only fit the drive unit when the power source is switched off. hosepack to the WF Robacta CAUTION! Drive (PAP) Danger of property damage due to dirty or wet coupling point. ▶...

  • Page 112: Fitting The Wf Robacta Drive To The Robot (Pap)

    11 Nm 8.11 lb-ft Fitting the WF Robacta Drive to the robot (PAP)
  • Page 113 BY2,0201,4896 42,0411,1315 18 Nm 13.28 lb-ft...

  • Page 115: Fitting The Interconnecting Hosepack

    Fitting the interconnecting hosepack Fitting the PAP NOTE! interconnecting The mounting of the holder for the interconnecting hosepack depends on the hosepack to the robot manufacturer and robot type. robot ▶ Mount the holder for the interconnecting hosepack according to the Installa- tion Instructions for the respective robot.

  • Page 116: Connecting The Splitbox Sb 500I R Pap To The System Components

    Connecting the SplitBox SB 500i R PAP 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 119: Assembling Further System Components

    Assembling further system com- ponents...

  • Page 121: Fitting The Splitbox Sb 60I R

    Fitting the SplitBox SB 60i R Fitting the SB NOTE! 60i R to the ro- 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 appliance.

  • Page 122: 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 123 Connecting the IMPORTANT! Whenever the torch hosepack is fitted or removed, ensure that the torch hosepack coupling point is clean and dry. Remove any coolant that has escaped from the to the SplitBox coupling point. SB 60i R The connection of the torch hosepack to the SplitBox SB 60i R is illustrated us- ing the right version of the appliance.

  • Page 124: Fitting The Tpsi Wire Buffer

    Fitting the TPSi wire buffer Fitting the TPSi wire buffer 4x 3 Nm 4x 2.21 lb-ft Fitting to the robot Fitting to a balancer...

  • Page 125: 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 126: Fitting The Unreeling Wirefeeder

    Use the QuickConnect option to connect the wirefeeding hose to the unreel- ing wirefeeder Use Fronius SpeedNet to connect the unreeling wirefeeder to the power source in the welding system...

  • Page 127: Connecting The Extension Hosepack

    Connecting the extension hosepack Connecting the WARNING! extension hosep- Danger from electric current due to defective system components and incor- rect operation. This can result in serious personal injury and damage to property. ▶ All cables, leads and hosepacks must always be securely connected, undam- aged and correctly insulated.

  • Page 129: Fitting The Torch Body To The Wf Robacta Drive

    Fitting the torch body to the WF Robacta Drive Fitting the gas- saver nozzle Torx 40 42,0411,0160 1 Nm 0.74 lb-ft 1 Nm / 0.74 lb-ft 42,0411,0160 42,0411,0160...

  • Page 130: Fitting The Inner Liner Inside The Torch Body

    Fitting the inner IMPORTANT! For the MTB 330i welding torch, the plastic inner liner is fitted liner inside the from the front. torch body Plastic inner liner:...
  • Page 131 Steel inner liner:...

  • Page 132: Fitting The Torch Body To The Wf Robacta Drive

    Fitting the torch CAUTION! body to the WF Robacta Drive Danger of property damage due to dirty or wet coupling point. ▶ Whenever the torch body is fitted or removed, ensure that the coupling point is clean and dry. ▶ Remove any coolant that has escaped from the coupling point.

  • Page 133: Fitting The Opt/I Camera Mount

    Fitting the OPT/i camera mount Load-bearing ca- CAUTION! pacity of the OPT/i camera Danger due to mechanical overload of the system components mount This can result in injury and damage to property. ▶ Load the OPT/i camera mount with a maximum of 1.5 kg. ▶...

  • Page 134: Fitting The Opt/I Camera Mount

    Fitting the OPT/i camera mount...

  • Page 135: Fitting The Inner Liner

    Fitting the inner liner Fitting the inner liner (unreeling wirefeeder - SplitBox SB 500i Fitting the inner liner (unreeling wirefeeder- WF Robacta Drive with external wirefeeding hose)

  • Page 136: Ing Hose)

    Fitting the PowerLiner (un- reeling wirefeed- er - WF Robacta Drive with ex- ternal wirefeed- ing hose) * Fasten screw only slightly (do not tighten)

  • Page 137: Fitting The Inner Liner (Unreeling Wirefeeder - Wire Buffer)

    Fitting the inner liner (unreeling wirefeeder - wire buffer)

  • Page 138: Fitting The Inner Liner (Splitbox - Wf 25I With Internal Inner Liner)

    Fitting the inner liner (SplitBox - WF 25i with in- ternal inner liner)

  • Page 139: Fitting The Inner Liner (Wire Buffer - Wf Robacta Drive With Internal Wirefeeding Hose)

    Fitting the inner liner (wire buffer - WF Robacta Drive with in- ternal wirefeed- ing hose)

  • Page 140: Fitting The Inner Liner (Wire Buffer - Wf Robacta Drive With External Wirefeeding Hose)

    Fitting the inner liner (wire buffer - WF Robacta Drive with ex- ternal wirefeed- ing hose)

  • Page 141: 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 142 Screw the clamping nipple onto the inner liner as far as it will go. The inner liner must be vis- ible through the hole in the lock.

  • Page 143: Start-Up

    Start-up...

  • Page 145: 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 suit- able for the diameter and alloy of the wire being welded. NOTE! Risk from inadequate feed rollers.

  • Page 146: Wf 30I Reel 2R: Inserting/Replacing Feed Rollers For The 2-Roller Drive

    WF 30i Reel 2R: inserting/repla- cing feed rollers for the 2-roller drive CAUTION! Risk of crushing due to exposed feed rollers. ▶ Always fit the protective cover of the 2-roller drive after changing feed rollers.

  • Page 147: Inserting/Replacing The Wf 25I Robacta Drive Feed Rollers

    Inserting/repla- cing the WF 25i Robacta Drive feed rollers 0 mm * * If the roller holder is opened as far as it will go beyond the slight resistance, the roller holder re- mains in this position.
  • Page 148 Torx 40 1 Nm 0.74 lb-ft...

  • Page 149: Inserting/Replacing The Wf 60I Robacta Drive Cmt Feed Rollers

    Inserting/repla- cing the WF 60i Robacta Drive CMT feed rollers 0 mm * * If the roller holder is opened as far as it will go beyond the slight resistance, the roller holder re- mains in this position.
  • Page 150 42,0411,0160 12 mm 42,0411,0160 12 mm 5 Nm 3.69 lb-ft...

  • Page 152: Feeding In The Wire Electrode

    Feeding in the wire electrode Insulated rout- WARNING! ing of wire elec- trode to Risk of serious injury and damage or an inferior weld as a result of earth contact wirefeeder 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 wirefeeder (e.g.

  • Page 153: Setting The Contact Pressure For The Wf 25I Robacta Drive

    CAUTION! Risk of injury due to springiness of spooled wire electrode. ▶ When inserting the wire electrode into the 4-roller drive, hold the end of the wire electrode firmly to avoid injuries caused by the wire springing back. CAUTION! Risk of injury from moving or rotating parts in the welding system. ▶...

  • Page 154: Setting The Contact Pressure For The Wf 60I Robacta Drive Cmt

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

  • Page 155: Start-Up

    Start-up Requirements When commissioning the welding system, the following requirements must be met: All components are installed and connected as described in the "Installa- tion" chapter All appropriate welding media is connected Feed rollers are inserted in wirefeeders or drive unit Wire electrode is threaded in Feed roller contact pressure is set Motor adjustment completed...

  • Page 157: Troubleshooting, Maintenance And Disposal

    Troubleshooting, maintenance and disposal...

  • Page 159: Troubleshooting

    Troubleshooting Safety WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in serious personal injury and damage to property. ▶ All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
  • Page 160 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 161 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 162 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 connection, etc.

  • Page 163: Care, Maintenance And Disposal

    Care, maintenance and disposal General Under normal operating conditions, the device requires only a minimum of care and maintenance. However, it is vital to observe some important points to ensure the welding system remains in a usable condition for many years. Safety WARNING! Danger from incorrect operation and work that is not carried out properly.

  • Page 164: Whenever The Welding Torch Or Torch Hosepack Is Changed

    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 coup- welding torch or ling point is clean and dry.

  • Page 165: 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 Heavily covered in welding spatter Penetration on the tip of the contact tip Gas nozzles Heavily covered in welding spatter...

  • Page 166: Replacing The Wf 60I Robacta Drive Cmt Clamping Lever

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

  • Page 167: Replacing The Sb 60I R Inner Liner

    1 Nm / 0.74 lb-ft 42,0411,0160 18 Nm 13.28 lb-ft Replacing the SB Removing the inner liner 60i R inner liner...
  • Page 168 Inserting the inner liner...

  • Page 169: 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 170: Changing The Direction Of Operation Of The Tpsi Wire Buffer

    Changing the NOTE! direction of op- After conversion, make sure the control line is fitted properly in the strain-relief eration of the TPSi wire buffer device provided.

  • Page 171: 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 position (Figure 3).

  • Page 172: 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 173: Removing The Crashbox Pap From The Robot

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

  • Page 174: Disposal

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

  • Page 175: Technical Data

    Technical data...

  • Page 177: Sb 500I R, R Left Variant, Pap

    °F) 60 % ED* 600 A 100 % ED* 500 A Maximum shielding gas pressure 7 bar / 101.53 psi Coolant Original Fronius Maximum coolant pressure 5 bar / 72.53 psi Protection class IP 43 Mark of conformity CE, CSA...

  • Page 178: Sb 60I R

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

  • Page 179: 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 (+/- 10%) CrashBox /i 21 Nm / 15.49 lb-ft CrashBox /i XL...
  • Page 180 CrashBox /i XL Ø90 mm x 60 mm CrashBox /i XXL Ø90 mm x 60 mm CrashBox Drive /i PAP Ø90 mm x 84.5 mm CrashBox Drive /i PAP XXL Ø90 mm x 84.5 mm At a distance of 300 mm from the robot flange With bellows: Ø110 mm...
  • Page 181 Triggering torques and weight/distance diagram...
  • Page 182 Weight [kg] The specified values only apply in a static state!

  • Page 183: Pushpull Hosepack

    PushPull hosepack Gas-cooled MHP 400i RD / G PushPull hosep- Welding current at 10 min/40°C acks M21 (EN 439) 40 % ED* / 400 A 60 % ED* / 320 A 100 % ED* / 260 A C1 (EN 439) 60 % ED* / 400 A 100 % ED* / 320 A Wire diameter...

  • Page 184: Water-Cooled Pushpull Hosepacks

    Water-cooled MHP 500i RD / W PushPull hosep- Welding current at 10 min/40 °C acks M21 (EN 439) 100 % ED* / 500 A C1 (EN 439) 100 % ED* / 500 A Wire diameter 0.8 - 1.6 mm 0.032 - 0.063 inch Lowest cooling capacity in accordance Length with standard IEC 60974-2, depend-...
  • Page 185 MHP 500i RD / W / PAP Welding current at 10 min/40 °C M21 (EN 439) 100 % ED* / 500 A C1 (EN 439) 100 % ED* / 500 A Wire diameter 0.8 - 1.6 mm 0.032 - 0.063 inch Lowest cooling capacity in accordance Length with standard IEC 60974-2, depend-...

  • Page 186: Wf 25I Robacta Drive

    WF 25i Robacta Drive WF 25i Robacta Welding current at 10 min/40°C Drive /G M21 (EN 439) 60 % ED* / 260 A 100 % ED* / 210 A C1 (EN 439) 60 % ED* / 320 A 100 % ED* / 260 A Wire diameter 0.8 - 1.6 mm 0.032 - 0.063 inch...

  • Page 187: Wf 60I Robacta Drive Cmt

    WF 60i Robacta Drive CMT WF 60i Robacta Welding current at 10 min/40°C Drive CMT /G M21 (EN 439) 60 % ED* / 260 A (Standard) 100 % ED* / 210 A (Standard) 60 % ED* / 260 A (CMT) 100 % ED* / 210 A (CMT) C1 (EN 439) 60 % ED* / 320 A (Standard)
  • Page 188 The product conforms to the requirements of the IEC 60974-7 standard ED = Duty cycle...

  • Page 189: Wf 25I Reel R /4R/G/W

    WF 25i REEL R /4R/G/W Supply voltage 24 V DC / 60 V DC Nominal current 0.5 A / 1.2 A Wire speed 1 - 25 m/min 39.37 - 984.25 ipm. Wire drive 4-roller drive Wire diameter 0.8 - 2.4 mm 0.03 - 0.09 in.
  • Page 190 WF 30i REEL R /2R/G/W Supply voltage 24 V DC / 60 V DC Nominal current 0.5 A / 0.9 A Wire speed 1 - 30 m/min 39.37 - 1181.10 ipm. Wire drive 2-roller drive Wire diameter 0.8 - 1.6 mm 0.03 - 0.06 in.

  • Page 191: Robot Welding Torch

    Robot welding torch Gas-cooled ro- MTB 250i G/R (TX, TXM) bot welding torches Welding current at 10 min/40°C M21 (EN 439) 40 % ED* / 250 A 60 % ED* / 200 A 100 % ED* / 170 A C1 (EN 439) 60 % ED* / 250 A 100 % ED* / 200 A Wire diameter...

  • Page 192: Water-Cooled Robot Welding Torches

    Wire diameter 0.8 - 1.6 mm 0.030 - 0.062 inch MTB 400i G/R (TX, TXM) Welding current at 10 min/40°C M21 (EN 439) 40 % ED* / 400 A 60 % ED* / 320 A 100 % ED* / 260 A C1 (EN 439) 60 % ED* / 400 A 100 % ED* / 320 A...
  • Page 193 MTB 500i W/R (TX, TXM) Welding current at 10 min/40 °C M21 (EN 439) 100% ED* / 500 A C1 (EN 439) 100% ED* / 500 A Wire diameter 1.0 - 1.6 mm / 0.039 - 0.063 inch MTB 700i W/R (TX, TXM) Welding current at 10 min/40 °C M21 (EN 439) 100% ED* / 700 A...

  • Page 194: Interconnecting Hosepacks

    Interconnecting hosepacks HP 70i Welding current at 10 min/40 °C (104 40% ED* / 400 A °F) 60% ED* / 365 A 100% ED* / 320 A ED = Duty cycle HP 95i Welding current at 10 min/40 °C (104 40% ED* / 500 A °F) 60% ED* / 450 A...
  • Page 196 SPAREPARTS ONLINE Fronius International GmbH Froniusstraße 1 4643 Pettenbach Austria contact@fronius.com www.fronius.com Under www.fronius.com/contact you will find the adresses of all Fronius Sales & Service Partners and locations.

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