Fronius iWave 300i Manuals

Manuals and User Guides for Fronius iWave 300i. We have 1 Fronius iWave 300i manual available for free PDF download: Operating Instructions Manual

Fronius iWave 300i Operating Instructions Manual (232 pages)

welding system Push - CONV Push - PAP PushPull - CONV

Brand: Fronius | Category: Robotics | Size: 24 MB

Table of Contents
3
Safety Instructions
7
Explanation of Safety Instructions
7
General
7
Intended Use
8
Environmental Conditions
8
Obligations of the Operating Company
8
Obligations of Personnel
8
Grid Connection
8
Personal Protection and Protection of Others
9
Danger from Toxic Gases and Vapors
9
Danger from Flying Sparks
10
Risks from Mains Current and Welding Current
10
Stray Welding Currents
11
EMC Device Classifications
12
EMC Measures
12
EMF Measures
13
Particular Hazard Areas
13
Requirement for the Shielding Gas
14
Danger from Shielding Gas Cylinders
14
Danger Posed by Shielding Gas Leak
15
Safety Measures at the Setup Location and During Transport
15
Safety Measures in Normal Operation
16
Maintenance and Repair
16
Safety Inspection
17
Disposal
17
Safety Symbols
17
Data Backup
17
Copyright
17
System Configurations
19
System Configurations - Conventional Robot
21
Conventional Robot - Push
21
Conventional Robot - Pushpull
23
Conventional Robot - Plasma
25
Conventional Robot - Arctig
27
Powersharing Mode
28
Conventional Robot - Hot Wire
29
System Configurations - PAP
31
PAP Robot - Push
31
PAP - Plasma
33
PAP - Hot Wire
35
System Components
37
CWF 25I R Wirefeeder
39
Device Concept
39
Intended Use
39
Notes on the Device
40
Description of the Warnings on the Device
42
Splitbox Hosepack SB TP 95I con R
44
Device Concept
44
Intended Use
44
Notes on the Device
44
Crashbox/I TIG/PAP
46
Device Concept
46
Note on the Repair of Crashboxes
46
Crashbox /I
47
Device Concept
47
Note on the Repair of Crashboxes
47
TTB 450I / 500I W R Robot Welding Torch
48
Device Concept
48
PTB 200I / 350I Robot Plasma Torches
49
Device Concept
49
TTB 360I / 720I W R Arctig Robot Welding Torches
50
Device Concept
50
Notes on the Device
51
TPHP 500I R Torch Hosepack
52
Device Concept
52
Notes on the Device
52
Hosepack Holder for Conventional Robots (Clamp/I TIG con Index Disc+)
54
Pushpull Hosepack CWF 25I Drive R/G/W/FSC
55
Device Concept
55
KD Drive
56
Wire Buffer
57
Notes on the Device
57
THP 720I R/W/Con/Arctig Torch Hosepack
59
Device Concept
59
Notes on the Device
59
CW Standard Cold-Wire Feed
61
Device Concept
61
Notes on the Device
62
CW Highend Cold-Wire Feed
63
Device Concept
63
Notes on the Device
64
Options
65
Powerliner
65
Thpi Mounting Adapter
66
Mounting Bracket
67
TIG Crashbox Signal Cable(Crashbox Signal Cable/I TIG)
68
Trailing Gas Nozzle
68
Water-Cooled Gas Nozzle for PTW 350I Plasma Welding Torch
69
Operating Controls, Connections and Mechanical Components
71
Safety
73
CWF 25I R Wirefeeder
74
Front, Back
74
Cold Wire Drive Unit KD Drive
76
Controls, Connections, and Mechanical Components
76
Splitbox Hosepack SB TP 95I con R
77
Splitbox, Hosepack
77
TPHP 500I R Torch Hosepack
79
Operating Controls, Connections, and Mechanical Components
79
THP 720I R/W/Con/Arctig Torch Hosepack
81
Controls, Connections, and Mechanical Components
81
Function of the Gas-Test, Wire-Return and Wire Threading Buttons
83
Installing System Components - Conventional Robot
85
General
87
Safety
87
Installation Sequence for Conventional Push Robots
88
Installation Sequence of Conventional Robots - Pushpull
88
Install the CWF 25I R Wirefeeder
89
Fitting the CWF 25I R Wirefeeder
89
Fitting the Tpsi Robot Flange and Tpsi Crashbox
91
Mounting the Crashbox /I on a Conventional Robot
91
Install the TPHP 500I R Welding Torch Hosepack
94
Fitting the TPHP 500I R Torch Hosepack
94
Connect the Wirefeeding Hose
97
Connecting the Wirefeeding Hose
97
Installing System Components - PAP Robot
101
General
103
Safety
103
Installation Sequence PAP Robot
104
Mounting Splitbox Hosepack SB TP 95I con R
105
Install the CWF 25I R Wirefeeder
107
Fitting the Robot Flange /I TIG/PAP and Crashbox/I TIG/PAP
109
Fitting the Robot Flange and Crashbox
109
Fitting the Crashbox Dummy
111
Install the TPHP 500I R Welding Torch Hosepack
112
Fitting the TPHP 500I R Torch Hosepack
112
Connect the Wirefeeding Hose
117
Connecting the Wirefeeding Hose
117
Installing Additional System Components
125
Connecting the Extension Hosepack
127
Install the Cold-Wire Feed
128
Mounting the CW Standard Cold-Wire Feed with Mounting Clamp
128
Mounting the CW Standard Cold-Wire Feed with Mounting Rail
129
Fitting the CW Highend Cold-Wire Feed
141
Mounting the Pushpull Hosepack CWF 25I Drive R/G/W/FSC
143
Mounting the KD Drive Cold-Wire Drive Unit on the Torch Hosepack
143
Installing the Wire Buffer
146
Connecting the Control Line to the Wire Buffer
146
Routing the Pushpull Hosepack
147
Connecting the KD Drive Cold-Wire Drive Unit
148
Fitting the Welding Torch
152
TTB 450I / 500I W R: Fitting the Welding Torch Wear Parts
152
Fitting the Welding Torch
158
Removing the Welding Torch
158
Fitting the Plasma Welding Torch
159
General
159
Setting Gage
159
PTB 200I / 350I W R: Fitting the Welding Torch Wear Parts
160
PTB 200I / 350I W R: Setting the Tungsten Electrode
161
Fitting the Water-Cooled Gas Nozzle to the PTB 350I Plasma Torch (Option)
165
Install the Trailing Gas Nozzle
166
Fitting the Trailing Gas Nozzle
166
Fitting the Thpi Mounting Adapter
170
Fitting the Wirefeeding Hose / Inner Liner
171
Overview
171
Cwf25I R for CW Highend Cold-Wire Feed - Conventional Robot
171
Head of the Torch Hosepack for CW Highend Cold-Wire Feed - PAP
172
Commissioning
181
Inserting/Changing Feed Rollers
183
General
183
Insert / Change Feed Rollers in CWF 25I R
183
Inserting/Changing Feed Rollers in KD Drive
185
Threading in the Welding Wire
190
Setting the Contact Pressure
192
Setting the Contact Pressure on the KD Drive
193
Setting up the CW Standard Cold-Wire Feed
194
Setting Options
194
Changing the Welding Torch Wear Parts
196
Setting up the CW Highend Cold-Wire Feed
198
Setting Options
198
Setting the Wire Feed Angle
198
Commissioning
200
Requirements
200
General
200
Troubleshooting, Maintenance, and Disposal
201
Troubleshooting
203
Safety
203
Fault Diagnosis, Troubleshooting - Plasma Welding Torches
206
Care and Maintenance
208
Safety
208
During each Start-Up
208
Special Care of O-Rings
208
Each Time the Welding Torch or Torch Hosepack Is Changed
209
Every 6 Months
209
Replacing the Wire-Guide Insert in the Wire Buffer
209
Changing the Working Direction of the Wire Buffer
210
Replacing the Wire Buffer Lever
212
Plasma Welding Torch Maintenance
213
Maintenance Activities with each Start-Up of the Plasma Welding Torch
213
Monthly Maintenance Activities
213
Technical Data
215
Technical Data
217
CWF 25I R
217
TTB 450I W R, TTB 500I W R
217
TPHP 500I W R
218
TTB 360I Arctig, TTB 720I Arctig, THB 720I R/W/Conv/Arctig
219
TPHP 95I EXT /WSB TP 95I con R/W
221
Crashbox Iwave
222
Crashbox /I
222
CWF 25I Drive R/G/W/FSC
225
PTB 200I, PTB 350I
225
Loading Limits, Dimension "X
227

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