Fronius LaserHybrid MHP 360i LH Operating Instructions Manual Download | Manualshive

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Requirements

Mechanical Re-
quirements

The following mechanical requirements must be met in order to ensure a stable and re-
peatable LaserHybrid process:
-

Accurate welding torch guidance for robots or single-purpose machines (e.g. longitu-
dinal chassis)

-

Precise weld seam preparation

-

Low component tolerances

-

Precise and very fast weld seam management systems with little deviation

Robot Require-
ments

The laser welding head weighs around 19 kg. The optics weigh a further 3 kg approximate-
ly. A total weight of around 30 kg should be expected for the complete laser welding head
when fitted with optics and hosepack.
It must therefore be possible for the robot axles to move a weight of 30 kg safely with the
accelerations specified.

IMPORTANT!

The maximum permitted acceleration for the laser welding head is 3 g at 5–

150 Hz, based on use of the laser optics.

Ground Connec-
tion

Grounding cable with bifilar winding

Grounding cable coiled

-

-

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Summary of Contents for LaserHybrid MHP 360i LH

Page 1: ... Perfect Charging Perfect Welding Solar Energy 42 0426 0279 EN 004 03102018 WF 25i LaserHybrid 10 kW SB 360i LaserHybrid Operating Instructions LaserHybrid EN US ...

Page 2: ...2 ...

Page 3: ...roduct Reading the instructions carefully will enable you to learn about the many different features your Fronius product has to offer This will allow you to make full use of its advan tages Please also note the safety rules to ensure greater safety when using the product Careful handling of the product will repay you with years of safe and reliable operation These are essential prerequisites for ...

Page 4: ...4 ...

Page 5: ...aring Parts 15 Calibrating Power Sources 16 The CE label 16 Copyright 16 General Information 17 General 19 General 19 Intended Use 19 Applications 19 Scope of Supply 20 Optional Components 20 Gas nozzle cross jet 21 Requirements 22 Mechanical Requirements 22 Robot Requirements 22 Ground Connection 22 Alignment 23 System Overview 24 System Overview 24 Other LaserHybrid Systems 25 Setup Variants 27 ...

Page 6: ...n Robot 61 Installing Hosepack on Robot 61 Threading the Wire Electrode 62 Threading the Wire Electrode 62 Setting up Laser Welding Head 63 Stick Out 63 Adjustable Axes 64 Adjustment Mechanisms on the Laser Welding Head 64 Setting Up X Axis 65 Setting Up Y Axis 66 Setting Up Z Axis 67 Creating Reference Program 68 Safety 68 General 68 Creating Reference Program 68 Signal Sequence for LaserHybrid W...

Page 7: ...94 Safety 94 General 94 Checking Position of the Wire Electrode in relation to the Laser Focus 94 Example Reference Program Application after Welding Torch Change 95 Measures to Reduce Contamination of the Optics 96 Measures to Reduce Contamination of the Optics 96 Appendix 99 Technical Data 101 WF 25i LaserHybrid 10 kW laser welding head 101 LaserHybrid hosepack MHP 360i LH 101 Spare parts list L...

Page 8: ...8 ...

Page 9: ...ctions all applicable local rules and regulations regarding accident prevention and environmental protection must also be followed All safety instructions and warning signs on the LaserHybrid head itself must be kept in a legible state not be damaged marked not be removed not be covered pasted or painted over For the location of the safety and danger notices on the LaserHybrid head refer to the se...

Page 10: ...tion 10 C to 40 C 14 F to 104 F During transport and storage 25 C to 55 C 13 F to 131 F Relative humidity Up to 50 at 40 C 104 F Up to 90 at 20 C 68 F Ambient air free of dust acids corrosive gases or substances etc Altitude above sea level up to 2000 m 6561 ft 8 16 in Obligations of the Operating Com pany The operating company must only allow persons to work with the LaserHybrid head if they are ...

Page 11: ...f the welding fumes and gases Take the following precautionary measures for fumes and harmful gases Do not breathe them in Extract them from the work area using appropriate equipment Ensure that there is sufficient fresh air Use breathing apparatus with air supply if there is insufficient ventilation When no welding is taking place close the valve of the shielding gas cylinder or the main gas supp...

Page 12: ...h electrical and electronic equipment If electromagnetic interference is discovered the operator is obliged to take action to rectify the situation Check and evaluate possible problems and the interference immunity of equipment in the vicinity according to national and international regulations Safety devices Grid power lines signal lines and data transfer lines EMC and telecommunications equipmen...

Page 13: ...espools and welding wires Do not insert body parts into rotating gear wheels on the wire drive or into rotating drive parts Covers and side parts must only be opened removed during maintenance and repair work During operation Ensure that all covers are closed and all side parts have been mounted properly Keep all covers and side parts closed Welding wire from the welding torch poses a high risk of...

Page 14: ...rmal Safety Measures The Operating Instructions must always be at hand wherever the LaserHybrid head is be ing used In addition to the Operating Instructions all applicable local rules and regulations regarding accident prevention and environmental protection must also be made available and be fol lowed All safety and danger notices on the LaserHybrid head must be kept in a legible state Safety Me...

Page 15: ... damage and functionality of the safety devices Safety Inspection The operator is required to have the LaserHybrid head tested by an electrician after every alteration installation or modification and all repairs and maintenance and at least every 12 months to ensure that it is in its correct state Modifications Do not carry out any alterations installations or modifications to the LaserHybrid hea...

Page 16: ...tic Compatibility Directives and therefore has CE sign Copyright Copyright of these operating instructions remains with the manufacturer Text and illustrations are technically correct at the time of going to print The right to make modifications is reserved 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 ...

Page 17: ...General Information ...

Page 18: ......

Page 19: ...IG MAG welding in connection with Fronius system components Any other use does not constitute proper use The manufacturer is not responsible for any damage resulting from improper use Proper use also means Following all the instructions in these operating instructions for the individual compo nents Carrying out all the specified inspection and servicing work The WF 25i LaserHybrid 10 kW will be re...

Page 20: ... set Mounting plate 17 5 mm Gas nozzle crossjet Description No Extractor tool for register pins 44 0450 1223 1 Gauge for adjusting the focal spot 42 0201 1216 1 Stick out gauge 42 0201 1742 1 Allen key size 6 mm for adjusting the position on the holder unit 42 0435 0001 1 Allen key size 5 mm for adjusting the position on the holder unit 42 0410 0014 1 Allen key size 4 mm for adjusting the position...

Page 21: ...ts off the plasma flare at a defined height IMPORTANT Because the gas nozzle cross jet is situated very closely to the opening of the gas out let this can result in swirling gas and subsequently pores Furthermore if the air current experiences resistance this can lead to acute pore for mation The plasma flare contains welding spatter and welding fume If the plasma flare is blown out the surroundin...

Page 22: ...ttle deviation Robot Require ments The laser welding head weighs around 19 kg The optics weigh a further 3 kg approximate ly A total weight of around 30 kg should be expected for the complete laser welding head when fitted with optics and hosepack It must therefore be possible for the robot axles to move a weight of 30 kg safely with the accelerations specified IMPORTANT The maximum permitted acce...

Page 23: ...leading Always avoid 90 angles to the workpiece surface when aligning the LaserHybrid head y 5 NOTE Failure to do so will cause serious damage to the optical fi ber because the laser radiation will be reflected directly on to the laser optics ...

Page 24: ...ide i or RI FB Pro i 1 Welding wire drum 2 Wirefeeder reel WF 25i REEL 4R OPT i WF Wire straightening path 4 100 880 CK WF MOUNTING Drum 3 Control line for wirefeeder reel 4 Remote control 5 Power source TPS 500i robot interface Cooling unit CU 1400i Pro MC or CU 2000i MC Single Upright bracket screwed in place 6 Wirefeeding hose 7 Interconnecting hosepack 8 Robot 9 SplitBox SB 360i LaserHybrid 10...

Page 25: ...100 880 CK WF MOUNTING Wall 3 Control line for wirefeeder reel 4 Remote control 5 Power source TPS 500i Robot interface Cooling unit CU 1400i Pro MC or CU 2000i MC Single Upright bracket screwed in place 6 Wirefeeding hose 7 Interconnecting hosepack 8 Robot 9 SplitBox SB 360i LaserHybrid 10 Hosepack LaserHybrid 11 WF 25i LaserHybrid 10 kW 12 Cleaning station LaserHybrid 1 2 3 4 5 6 7 11 10 8 9 12 ...

Page 26: ...ot interface Cooling unit CU 1400i Pro MC or CU 2000i MC Single Upright bracket screwed in place Interconnecting hosepack 4 SplitBox SB 360i LaserHybrid 5 Wirespool D300 6 Wirefeeder reel WF 25i REEL 4R OPT i WF reel carriage D300 7 Hosepack LaserHybrid 8 Wirefeeding hose 9 Robot 10 WF 25i LaserHybrid 10 kW 11 Cleaning station LaserHybrid 5 6 2 1 3 8 10 7 9 4 11 ...

Page 27: ...urce HP 95i CON W 1 2 m 95 mm interconnecting hosepack SB 360i LaserHybrid SplitBox mounted on the power source MHP 360i LH W FSC FW 7 5m LaserHybrid hosepack Wirespool WF 25i REEL 4R wirefeeder reel WF reel carriage D300 Wirefeeding hose L 10 m Laser welding head Area of application For test systems only no wirespool in series production Power Source Not Located in Welding Cell I TPS 500i power s...

Page 28: ...elding feed movements Example Longitudinal seams on boilers battery trays etc Power Source Is on a Gantry and Moves Too TPS 500i power source HP 95i CON W 10 m 95 mm interconnecting hosepack SB 360i LaserHybrid SplitBox mounted on gantry MHP 360i LH W FSC FW 4 2 m or 7 5m LaserHybrid hosepack Welding wire drum WF 25i REEL 4R wirefeeder reel WF MOUNTING Drum Wirefeeding hose L 20 m Laser welding he...

Page 29: ...Operating controls and connections ...

Page 30: ......

Page 31: ...toring A LaserHybrid hosepack with extra data line is needed for optional pressure mon itoring Pressure is monitored in SplitBox SB 360i LaserHybrid see page 33 for the laser welding head and LaserHybrid hosepack 4 Supply to radial fan flow 5 Supply to gas nozzle crossjet 6 Fiber optic cable 7 LaserHybrid hosepack connection 8 Control box 9 Drive unit cover 1 2 13 4 7 10 8 9 12 11 2 3 3 6 5 21 20 ...

Page 32: ...a extraction 19 Laser optics water cooling connections 20 Connection to radial air stream 21 Crossjet Item Description 1 2 3 4 5 6 7 8 14 13 12 11 9 8 10 Item Description 1 Current socket with fine thread for connecting the power cable from the interconnecting hosepack 2 Shielding gas connection socket 3 SpeedNet connection for connecting the SpeedNet cable from the interconnecting hosepack 4 Spee...

Page 33: ...ecting the coolant supply line hose from the interconnecting hosepack 8 SplitBox SB 360i LaserHybrid mount 9 Welding torch connection FSC for connecting the LaserHybrid hosepack 10 11 Connection crossjet OUT 12 Connection crossjet IN 13 Interconnecting hosepack for the power source not included in the SB 300i LaserHybrid in its original state the interconnecting hosepack is inserted into SB 300i L...

Page 34: ...0 mm stick out on the LaserHybrid welding torch depending on the appli cation and design Move to reference point Using the gauge check the position of the wire electrode in relation to the focal point in the x y z direction Further information can be found on page 94 Signal Analysis The signal from the collision protection is sent to the robot control via a robot interface In the event of a collis...

Page 35: ...10 m 2 Crossjet supply for connecting a hose in accordance with the following data Internal diameter Di 12 mm External diameter Da 14 mm Atmospheric overpressure in flow condition pmin 4 5 bar at both connections Vmin total 1460 Nl min 3 Radial air supply for connecting a hose in accordance with the following data External diameter Da 6 mm The hose connects the radial air supply 3 to the radial ai...

Page 36: ...6 LaserHybrid hosepack connection MHP 360i LH W FSC 4 2 m MHP 360i LH W FSC 7 5 m 7 Gas nozzle crossjet 8 Extra extraction connection for connecting a hose in accordance with the following data Internal diameter Di 40 mm Extraction capacity required Qmin 280 m h Atmospheric underpressure pmin 21000 Pa 9 Laser optics water cooling connection 10 Connection to radial air stream NOTE The welding torch...

Page 37: ... MHP LH 1 2 3 4 5 6 7 8 Item Description 1 Compressed air supply min 6 bar 2 Solenoid valve 3 Internal pressure measurement 4 Pressure measurement option 5 Radial air stream branching 6 Gas nozzle crossjet branching 7 Crossjet air supply duct connections 8 Exhaust air crossjet 9 Extraction 5 4 6 9 7 8 7 4 ...

Page 38: ...38 ...

Page 39: ...Commissioning ...

Page 40: ......

Page 41: ...Initial situation Robot and robot control are present and ready for operation Set up welding system Install upright brackets Install cooling unit on upright bracket Connect power source to cooling unit Set up welding wire drum Assemble WF Mounting Drum on welding wire drum Set up and connect wirefeeder reel WARNING Work performed incorrectly can cause serious injury and damage to property This set...

Page 42: ...efeeding Hose to on Laser Welding Head Installing Changing Wirefeed Rollers Connect laser optics and extra extraction Preparing Welding Torch Install LaserHybrid hosepack on robot Threading the Wire Electrode Other activities prior to start up Setting up Laser Welding Head Creating Reference Program Signal sequence for LaserHybrid welding Measures before starting welding Set up ground earth connec...

Page 43: ...er Welding Head on the Robot Connection Op tions on the Ro bot Installing the La ser Welding Head on the Robot 90 mm 406 5 mm Install the laser welding head in line with the robot manufacturer s specifi cations for the robot 1 1 ...

Page 44: ...nd SplitBox mount Install a suitable holder for the SplitBox mount on your robot IMPORTANT Please observe the robot manufacturer s assembly instructions Fit the SplitBox mount on the holder using 4 x Allen screws size 6 mm Tightening torque 24 Nm Insert the interconnecting hosepack strain relief device into the opening and push forward 1 2 3 3 3 3 3 4 4 ...

Page 45: ...nsert the interconnecting hosepack into the ear clamps Close the ear clamps Insert SplitBox SB 360i LaserHybrid into the SplitBox mount as illustrated Fix SplitBox in place in the SplitBox mount using 3 x screws TX25 at the top and 3 x screws TX25 at the bottom Tightening torque 3 5 Nm 5 7 6 5 5 6 7 8 8 8 9 10 10 10 10 10 10 9 10 ...

Page 46: ...ne blue d Protective gas shield e SpeedNet from interconnecting hosepack f SpeedNet remote control Gas purging connection Connect LaserHybrid hosepack to wel ding torch connection FSC Close clamping lever Open cover on LaserHybrid hosepack Connect connecting plug for welding torch cooling to the LaserHybrid hose pack Connect crossjet air inlet a b c d e f 1 3 2 4 2 3 4 6 5 5 6 ...

Page 47: ...uts 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 connection Connect hoses for optics cooling push in Blue marking coolant supply line Connecting Interconnecting Hosepack to Power Source Option 1 Data line 3 x 0 5 mm e g for analyzing additional pres sure monitoring 7 8 7 8 7 8 9 9 9 9 9 10 1 ...

Page 48: ...3 mm x 2 on opposite side too Retract protective hose IMPORTANT When connecting cross jet air outlet hoses make sure that cut ting rings are present Connect crossjet air outlet Fix the hose in place on the connection using hexagon nut size 24 mm Tightening torque 50 Nm IMPORTANT Use flat spanner size 22 mm to hold the items in place when fi xing the hexagon nuts in place on the connection Repeat t...

Page 49: ...49 EN US Pull the protective hoses across the connections 8 8 8 ...

Page 50: ...on the interface do not get bent or damaged Align the LaserHybrid hosepack to be as straight as possible Connect the LaserHybrid hosepack Fix the LaserHybrid hosepack in place Tighten the union nut using a torch key and torque wrench Tightening torque 11 Nm Remove 2 x Allen screws size 2 5 mm Remove 2 x Allen screws size 2 5 mm on the opposite side Remove drive unit cover 1 1 2 2 4 3 3 4 5 3 4 5 ...

Page 51: ...nd hold locking button Insert the wirefeeding hose into the lo cking device as far as is needed to re lease the locking button Release the locking button Keep pushing the wirefeeding hose un til the locking device locks in place and the locking button pops out Removal Press and hold locking button Pull wirefeeding hose out of locking de vice 7 6 6 6 7 1 1 3 2 4 5 2 3 4 5 1 2 ...

Page 52: ...ewable shaft Remove the wirefeeder roller Remove the hexagon nut size 10 mm use the driving wheel key supplied with the laser welding head to hold this on the wirefeeder roller Remove the wirefeeder roller The sequence is reversed for installati on 3 2 4 5 6 1 1 2 3 4 5 6 NOTE Do not replace the supplied wirefeeder components with other models Failure to use the specified V groove rollers in parti...

Page 53: ...or tool backward and then re move the register pins c Remove bracket for robot connec tion CAUTION Risk of damage to the laser welding head as a result of contamination from above Please observe the Operating Instructions specifications and safety instruc tions issued by the manufacturer of the laser optics Prior to connection position the laser welding head so that the longitudinal axis on the la...

Page 54: ...aser wel ding head is outside of the horizontal 90 Clean connection area using compres sed air Remove protective cover from fiber op tic cable connection Clean fiber optic cable plug using com pressed air Remove protective cover from fiber op tic cable plug 3 4 5 4 5 7 6 6 7 ...

Page 55: ...le plug INCORRECTLY positioned rubber sleeve The rubber sleeve does not seal completely Check whether the rubber sleeve is se aling neatly around the fiber optic cable plug IMPORTANT The illustration shows an incorrectly positioned rubber sleeve The rubber sleeve shown forms a kink in the area around the arrow which means that it does not seal completely Connect optics cooling using Allen screw si...

Page 56: ...blue marking Connect optics cooling return flow Put the laser welding head into a vertical position Connecting Extra Extraction Push the hose across the connection Fix the hose in place with the hose clamp 1 1 1 1 11 12 12 12 12 13 2 1 1 2 ...

Page 57: ...cket for the robot connection Fasten but do not completely tighten the slot nut and bracket for the robot connection using a short Allen screw size 6 mm Insert 2 x register pins Position and connect extractor tool for register pins Hit the vibrating mass on the extractor tool forward and then position the re gister pins 3 4 3 4 5 5 5 6 7 7 8 6 7 8 ...

Page 58: ... located one be low the other the 2 x longer screws opposi te each other Insert the remaining 4 x Allen screws size 6 mm Fix the bracket for the robot connection in place using 5 x Allen screws size 6 mm Tightening torque 24 Nm 5x 10 9 9 9 9 10 ...

Page 59: ...ing Welding Torch Preparing Weld ing Torch Open knurled nut Insert the inner liner into the welding torch from underneath Use the entire contact tip to insert the entire inner liner into the welding torch 1 1 2 2 3 3 ...

Page 60: ...he contact tip Tighten union nut size 12 mm Tightening torque 3 Nm Put the gas nozzle in position Fix the gas nozzle in position using Al len screw size 4 mm Fold the bracket downward Tighten the knurled nut 4 5 4 5 8 6 7 6 7 8 9 9 ...

Page 61: ...on the lower sheet metal part 8 Remove the top and side plastic parts and insert the hoses cables and LaserHybrid hosepack into the openings on the LaserHybrid hosepack holders Put the top plastic part in position and fix in place with the side plastic parts 1 Robot arm 2 Beam 3 Opening for extraction hose 4 Opening for wirefeeding hose 5 Opening for fiber optic cable 6 Opening for LaserHybrid hos...

Page 62: ...threading the wire on it Requirement Wirefeeding hose connected Wire electrode threaded in wirefeeder reel Correct wirefeeder rollers and inlet nozzles present in laser welding head Close clamping stirrup Press the wire threading button until the wire electrode comes out of the welding torch Set contact pressure 2 1 1 2 3 3 3 ...

Page 63: ...ate 21 mm Stick out 20 mm Mounting plate 21 mm Mounting plate 17 5 mm The TCP cannot be on the laser fo cus For high outputs Guarantees a greater distance be tween the laser focus and the wire electrode tip with the same adjust ment travel The TCP can be on the laser focus depending on the application 1 2 3 NOTE When adjusting the physi cal location of the welding torch ensure there is a correct s...

Page 64: ... mm turn equates to adjustment travel of 0 25 mm 3 Adjusting screw with division for y axis Adjustment range 7 2 mm Allen screw size 5 mm turn equates to adjustment travel of 0 25 mm Reading accuracy using Nonius 0 1 mm 4 Scale for y axis y z x CAUTION Risk of damage to the fiber optic when workpiece surface is posi tioned at a right angle to the laser welding head If the laser optics are at a 90 ...

Page 65: ...ith division for z axis Adjustment range 12 7 mm Allen screw size 5 mm turn equates to adjustment travel of 0 25 mm Reading accuracy using Nonius 0 1 mm Setting Up X Axis Loosen 2 x Allen screws size 5 mm 1 Set up the x axis using the adjusting screw and Allen key size 5 mm 1 x turn equates to 1 0 mm After setting up the x axis re tighten the 2 x Allen screws size 5 mm 1 NOTE The x axis and y axis...

Page 66: ... adjusting screw and Allen key size 5 mm 1 x turn equates to 1 0 mm After setting up the y axis re tighten the 2 x Allen screws size 5 mm 1 NOTE The x axis and y axis are set up with the cover removed from the drive unit Re fit the cover on the drive unit after set up 1 1 1 1 1 2 2 2 3 ...

Page 67: ...x turn equates to 1 0 mm After setting up the z axis re tighten the 4 x Allen screws size 5 mm 1 and 2 Tightening torque for screw 1 6 5 Nm Tightening torque for screw 2 10 Nm NOTE The z axis is set up with the cover removed from the drive unit and with the control box removed Re fit the drive unit after setting up the control box and cover 1 1 2 2 1 1 2 2 1 2 3 3 3 1 ...

Page 68: ...relevant stick out mm must be adjusted for the wire electrode Mounting plate 21 mm Stick out 20 mm Mounting plate 17 5 mm Stick out 14 mm Observe the focal distance specification on the laser optics Fit the gauge 1 in the robot s work area Switch on pilot laser Position the laser welding head via the robot so that the laser optics are at a 90 angle to the gauge Presetting for identifying parameter...

Page 69: ...caling on the gauge Store the settings as a reference program in the robot Carry out a test weld The best welding results are used as a basis for the reference program If changes are required to the mechanical x y settings because of the test weld over write the first reference program you created 7 8 9 10 ...

Page 70: ...t robot WARNING Work performed incorrectly can cause serious injury and damage to property The welding process may only be programmed by trained personnel Please observe the safety rules in the Operating Instructions and the Safety In spection section in particular CAUTION Risk of damage to the fiber optic when workpiece surface is posi tioned at a right angle to the laser welding head in welding ...

Page 71: ...robot movement Reset signal Laser on Reset signal Welding on Wait until the current flow signal zero Robot end position IMPORTANT The robot end position is not the end of the weld seam Reset signal Crossjet on Reset signal Extraction on 1 2 3 4 1 2 ...

Page 72: ...ystem 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 Test shielding gas 1 2 3 4 5 6 7 ...

Page 73: ...d spare parts 20 x contact tips for each diameter 10 x gas distributors 4 x gas nozzles 4 x welding torch inner liners cut to length and finished 1 x wirefeeder roller set incl compression lever with axles Allen key set Side cutters Release spray Cleaning set optics from the respective optics manufacturer 1 x protective glass drawer packed so that it is dustproof as a spare At least 10 x protectiv...

Page 74: ...74 ...

Page 75: ...Maintenance ...

Page 76: ......

Page 77: ...ws in the illustrations may not match the work steps Remove 2 x Allen screws size 2 5 mm Remove 2 x Allen screws size 2 5 mm on the opposite side Remove drive unit cover CAUTION Burning hazard due to hot welding torch as a result of operation The welding torch must only be cleaned and its components only checked after the welding torch has cooled down 2 1 1 2 3 1 2 3 ...

Page 78: ...led nut Loosen the union nut using the torch key Pull the welding torch down and off 1 4 5 6 5 6 NOTE The torch key and torque wrench tightening torque 18 2 Nm must be used to assemble the welding torch 7 8 18 2 Nm ...

Page 79: ...79 EN US Replacing Weld ing Torch Wear ing Parts 1 2 3 IMPORTANT Before assembly clean the gas distributor the thread on the union nut and the torch body 1 4 2 3 1 2 1 2 1 3 ...

Page 80: ...llen screws size 2 5 mm Remove spatter guard Assemble by performing the steps in the re verse order Replacing the Ex tra Extraction Please note the numbering on the arrows in the illustrations may not match the work steps Disassemble spatter guard plate Remove 2 x Allen screws size 2 5 mm Remove extra extraction Assemble by performing the steps in the re verse order 11 10 10 1 2 13 12 12 1 2 3 ...

Page 81: ...ncorrectly can cause serious injury and damage to property This assembly work must only be carried out by trained and qualified personnel Please observe the safety rules in the Operating Instructions and the Safety Inspection section in particular CAUTION Risk of damage to the laser welding head as a result of contamination from above Please observe the Operating Instructions specifications and sa...

Page 82: ...RTANT Only shut off the coolant hose on the laser optics never on the fiber optic cable Loosen the Allen screw and shut off the coolant hose from the laser optics size 2 5 mm To shut off the fiber optic cable from the laser optics reverse the sequence used for con nection see page 53 work step 6 onward Clean the fiber optic cable and connection area with compressed air Pull rubber sleeve back in d...

Page 83: ...83 EN US Disconnect radial air stream Remove 2 x Allen screws size 2 5 mm Remove spatter guard Remove 2 x Allen screws size 2 5 mm Remove extra extraction 9 9 11 10 10 10 11 13 12 12 12 13 ...

Page 84: ... make sure that the O rings do not get lost Removing the La ser Optics Remove 6 x threaded pins size 2 5 mm Remove 4 x Allen screws size 4 mm Remove 2 x Allen screws size 4 mm Remove fixing clamp Loosen 2 x Allen screws size 4 mm 14 14 14 14 15 14 15 2 2 2 2 1 1 1 1 1 1 1 2 3 3 4 5 5 3 4 5 ...

Page 85: ...e laser optics IMPORTANT When removing the laser optics make sure that the springs connec ted underneath do not get lost The springs will be needed again for instal lation 6 6 6 8 7 7 7 8 8 CAUTION Dropping the laser op tics may lead to damage beyond repair Remove and handle the laser op tics carefully 7 8 ...

Page 86: ...tion is correct The plug on the fiber optic cable coo lant hoses and protective glass drawer must all be accessible the push button must be up Insert the laser optics so that the springs are underneath in the grooves Press the laser optics at the rear end down Move the laser optics into the holder and into the guide Insert 4 x Allen screws Tighten the Allen screws slightly size 4 mm 1 2 2 CAUTION ...

Page 87: ...d Position the laser welding head via the robot so that the laser optics are at a 90 angle to the reference gauge Connect radial air stream Connect coolant hose 1 to LaserHybrid hosepack to laser optics Connect coolant hose 2 to laser op tics Check adjust laser optics focus as de scribed in the following section 9 8 8 7 7 8 9 10 10 90 1 3 1 3 11 12 14 13 1 2 11 12 13 14 15 ...

Page 88: ...nt adjust the relevant stick out for the wire electrode Mounting plate 21 mm Stick out 20 mm Mounting plate 17 5 mm Stick out 14 mm Switch on pilot laser Upload reference program Move gauge 1 If the pilot laser s focus is in the cross hair on the gauge 1 you do not need to adjust the focus If the focus is different from the intersection point on the cross hair adjust the focus on the laser optics ...

Page 89: ...t up focus in positive x direction Loosen Allen screw threaded pins 1 by two turns Using the Allen screw threaded pins 3 set up the laser optics in the pos itive x direction size 2 5 mm Screw the Allen screw threaded pins 1 tight size 2 5 mm Set up focus in negative x direction Loosen Allen screw threaded pins 3 by two turns Using the Allen screw threaded pins 1 set up the laser optics in the neg ...

Page 90: ... Screw fixing clamp tight with 2 x Allen screws size 4 mm Tightening torque 3 8 Nm Tighten 2 x Allen screws size 4 mm Tightening torque 3 8 Nm NOTE To prevent the laser optics from warping on the laser head ensure you perform the following work steps in the exact same sequence 2x 1 1 2 1 2 3 3 3 2x 4 4 ...

Page 91: ...stalling the crossjet make sure that the O rings are present Install the crossjet with 4 x Allen screws size 3 mm Tightening torque 2 5 Nm Install the extra extraction with 2 x Al len screws size 2 5 mm Tightening torque 1 Nm Assemble spatter guard plate with 2 x Allen screws size 2 5 mm 1 1 1 1 1 2 2 2 3 3 3 ...

Page 92: ...cket for the robot connection Fasten but do not completely tighten the slot nut and bracket for the robot connection using an Allen screw size 6 mm Insert 2 x register pins Position and connect extractor tool for register pins Hit the vibrating mass on the extractor tool forward and then position the re gister pins 3 4 4 5 5 5 6 6 7 7 8 7 8 9 ...

Page 93: ...g 5 x Allen screws size 6 mm Tightening torque 24 Nm Laser Optics Overview Optics holder 2nd bracket for robot connection hidden 5x 10 9 9 9 10 11 PRECITEC HIGHYAG TRUMPF 4x M5 x 16 mm 2x M5 x 25 mm 4x M5 x 12 mm 2x M5 x 16 mm 2x M4 x 12 mm 4x M5 x 12 mm 4x M5 x 16 mm 4x M5 x 16 mm 4 101 078 4 100 714 4 101 068 ...

Page 94: ... move to the reference point on the gauge 1 the laser focus is in the cross hair on the gauge Thread the wire electrodes up to the gauge Check the position of the wire electro de in relation to the laser focus The position of the wire electrode must match the values documented on the gauge using scaling If necessary correct the position of the wire electrode in relation to the laser focus using th...

Page 95: ...n the application Upload the reference program and slowly move to the reference position on the ad justing gauge Thread the wire electrode until this is touching the adjusting gauge Check the position of the wire electrode in relation to the laser focus If the position is incorrect Adjust the x y position on the mechanical setting options for the laser welding head NOT on the robot IMPORTANT Never...

Page 96: ...tch on the extraction and crossjet Clean the welding head with compressed air as best as you can IMPORTANT Do not blast the protective glass with the air current directly Switch off crossjet Replace protective glass IMPORTANT When replacing the protective glass the extraction must be switched on and crossjet switched off 6 Keep the amount of time the protective glass drawer is open to the minimum ...

Page 97: ... on the crossjet and extraction during the cleaning process 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 ...

Page 98: ...98 ...

Page 99: ...Appendix ...

Page 100: ......

Page 101: ...r on workpiece 10 kW Max welding torch current carrying capacity 100 DC at 40 C M21 EN439 C1 EN439 360 A 360 A Max welding current 100 DC at 40 C 360 A Wire diameter 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 Minimum cooling capacity in accordance with IEC 60974 2 subject to hosepack length 1400 1500 W Coolant p...

Page 102: ...102 Spare parts list LaserHybrid TPSi PP PP 0RXQWLQJ SODWH QRW LQFOXGHG LQ VHW ...

Page 103: ...103 9 9 9 QJLQH 8QLW 5 1 5 5 75 7 6 EOXH UHG EODFN QRW LQFOXGHG LQ VHW QRW LQFOXGHG LQ VHW ...

Page 104: ...104 DVHU EULG PP PP PP 8 U1L 2SWLRQ 0LQL URVV HW ...

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Page 106: ...106 7UXPSI 2SWLF 5H HVLJQ IRFDO OHQJWK PP ...

Page 107: ...107 7UXPSI 2SWLF DPHUD 5H HVLJQ IRFDO OHQJWK PP ...

Page 108: ...108 3UHFLWHF 2SWLF IRFDO OHQJWK PP ...

Page 109: ...109 LJK DJ 2SWLF IRFDO OHQJWK PP ...

Page 110: ...110 ...

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Page 112: ... 1 A 4600 Wels Austria Tel 43 0 7242 241 0 Fax 43 0 7242 241 3940 E Mail sales fronius com www fronius com www fronius com addresses Under http www fronius com addresses you will find all addresses of our Sales service partners and Locations ...

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