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Fronius LaserHybrid Ultracompact Twin, Operating Instructions Manual

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Fronius LaserHybrid Ultracompact Twin Operating Instructions Manual Download Page 88

88

Replacing the welding torch and welding torch inner 

liners

Safety

Preparatory work

CAUTION! 

A welding torch that has become very hot through use can cause se-

vere burns. The welding torch must only be cleaned and its components checked 
when it is cool.

Remove the two Allen screws
(4 mm)
Remove the media cover

Remove the three Allen screws
(2.5 mm)
Remove the current interface cover

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1

2

1

2

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3

3

3

3

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Summary of Contents for LaserHybrid Ultracompact Twin

Page 1: ...Perfect Charging Perfect Welding Solar Energy 42 0426 0255 EN 003 16082017 LaserHybrid Ultracompact Twin Operating Instructions LaserHybrid EN...

Page 2: ...2...

Page 3: ...h the product Reading the instructions carefully will enable you to learn about the many different features it has to offer This will allow you to make full use of its advantages Please also note the...

Page 4: ...4...

Page 5: ...e intended purpose 21 Advantages 21 Application areas 22 System overview 22 Laser welding head scope of supply 23 Optional components 23 Requirements 24 System requirements and minimum equipment requi...

Page 6: ...58 Preparatory work 58 Removing the welding torch wearing parts 58 Threading the wire electrode 59 Fitting the welding torch wearing parts 62 Setting the radial air flow 64 Requirements 64 Setting the...

Page 7: ...ystem 98 Mounting positions for installing the laser optics system 101 Installing the laser optics system 102 Fitting the spatter guard plate 105 And finally 105 Creating a reference program and setti...

Page 8: ...8...

Page 9: ...and other material assets belonging to the operator inefficient operation of the LaserHybrid head All persons involved in commissioning operating maintaining and servicing the LaserHybrid head must be...

Page 10: ...liability for inadequate or incorrect work results Operation or storage of the LaserHybrid head outside the stipulated area will be deemed as not in accordance with the intended purpose The manufactur...

Page 11: ...ys using a protective visor and regulation filter element for laser protection class 4 worn in front of the laser safety goggles and the face Even when using this regulation filter element for laser p...

Page 12: ...tenance instructions on the shielding gas cylin der or the main gas supply Close the shielding gas cylinder valve or main gas supply if no welding is taking place Check the shielding gas cylinder or m...

Page 13: ...for possible problems and check and evaluate neighbouring devices resistance to interference according to national and international require ments Safety devices Power signal and data transfer lines...

Page 14: ...he welding wire emerging from the welding torch poses a high risk of injury piercing of the hand injuries to the face and eyes etc Therefore always keep the welding torch away from the body devices wi...

Page 15: ...thread of the adapter for the shielding gas connection using suitable Tef lon tape The operating instructions must always be at hand wherever the LaserHybrid head is being used In addition to the ope...

Page 16: ...tion of the device Any safety devices that are not functioning properly must be repaired before switching on the device Never bypass or disable safety devices Before starting up the LaserHybrid head e...

Page 17: ...nec essary Fronius recommends a 12 month calibration interval For more infor mation please contact your service centre The LaserHybrid head fulfils the fundamental requirements of the Low Voltage Dire...

Page 18: ...18...

Page 19: ...General information...

Page 20: ......

Page 21: ...e for any damages arising from such usage Proper use also includes Complying with all the instructions from the respective Operating Instructions for the individual components Performing all stipulate...

Page 22: ...um 2 Unreeling wirefeeders WF 25i REEL R SA 2R G W OPT i WF wire straightening section 4 100 880 CK 3 Lead power source Twin DeviceNet Interface LHSB connection option LHSB connection cable Software a...

Page 23: ...screwdriver 3 mm 1 ball ended hex screwdriver 4 mm 1 driving gear spanner 1 stick out gauge 1 PushIn coupling connection 1 hose 4x750 mm 1 flow rate meter up to 25 l min 1 set of Operating Instruction...

Page 24: ...rces The LHSB connection cable The P C Power Control parameter is available following successful installation of the LHSB connection The P C parameter is displayed on the power source under Setup menu...

Page 25: ...re quirements For a stable and reproducible laser twin process the following mechanical requirements must be met Precise torch guidance for robots or single purpose machines e g straight line car riag...

Page 26: ...otentials 9 are available IMPORTANT The laser twin welding process only works when used with filler metal from welding wire drums 1 Lead power source and trail power source The two power sources are r...

Page 27: ...cable for each power source Separate grounding earthing cable Shared grounding earthing cable earth socket Grounding earthing cable laid in a loop Grounding earthing cable coiled Welding circuit indu...

Page 28: ...The LHSB connection on the power sources means that various arc types can be com bined in the laser twin welding process The welding direction is defined by the wire pairing 1 2 mm lead power source 1...

Page 29: ...xcellent heat input and high welding speed The lead wire electrode usually has a wire diameter of 1 2 mm while the trail wire electrode has a wire diameter of 1 0 mm This ensures Targeted heat input G...

Page 30: ...in interfaces features an integral programmable logic controller PLC The signals are connected logically by the PLC Both power sources are therefore trig gered simultaneously by a signal from the robo...

Page 31: ...ontrol when standard robot interfaces are used Two identical robot interfaces are required for two power sources The two stand ard robot interfaces are installed in the switch cabinet Robot interfaces...

Page 32: ...signals are connected logically by this PLC Both power sources are therefore triggered simultaneously by a signal from the robot control Only one Twin fieldbus sys tem is required for two power sourc...

Page 33: ...ls must be connected logically by the robot control when standard fieldbus systems are used Two identical standard fieldbus systems are required for two power sources The two standard fieldbus systems...

Page 34: ...34...

Page 35: ...Control elements and connections...

Page 36: ......

Page 37: ...ctor Optional additional extractor with corresponding spatter guard sheet One of the two extractors is fitted prior to delivery depending on the configuration 4 Laser optics 5 Radial air flow 6 Gas no...

Page 38: ...ract button Wire threading button Gas test button 13 Robot holder 14 Laser optics system water cooling connection 15 Wirefeeding hose connections 16 LaserHybrid Ultracompact Twin hosepack 17 CrashBox...

Page 39: ...ssjet outlet air connection For connecting a hose matching the following specifications Internal diameter Di 50 mm Max length 10 m Crossjet outlet air 170 m h 3 Additional extractor connection for con...

Page 40: ...erHybrid interconnecting hosepack Fronius Hosepack incl compressed air for Crossjet and radial air flow water cooling for laser optics system and media coupling Item Designation Item Designation 1 Com...

Page 41: ...Start up...

Page 42: ......

Page 43: ...er welding head to the robot Label each of the power sources unreeling wirefeeders and wirefeeding hoses with 1 and 2 stickers Fit the upright consoles Fit the cooling unit parts to the upright consol...

Page 44: ...nnecting the blow out line red from the laser twin hosepack 2 Control line connection For connecting the control line for the drive unit from the laser twin ho sepack 3 GAS OUT For connecting the shie...

Page 45: ...r welding head to the robot Connecting the LaserHybrid Ultracompact Twin hosepack to the laser welding head Connecting the laser optics system Crossjet and additional extractor Laying the hosepack on...

Page 46: ...ximum permitted acceleration of the laser welding head is 3 g at 5 150 Hz based on the laser optics Fitting the laser welding head to the robot Refer to the Spare Parts List for collision protection d...

Page 47: ...k Remove the two Allen screws 4 mm Remove the media cover Remove the three Allen screws 2 5 mm Remove the current interface cover Remove the Allen screw 3 mm Remove the Allen screw on the oppo site si...

Page 48: ...he motor cover towards the rear and remove it Connecting the LaserHybrid Ul tracompact Twin hosepack to the laser welding head Feed in the hosepack Push the hexagon nut over the media Lightly tighten...

Page 49: ...connected on the opposite side b Power coolant cable with red hose 3 Connection for trail electrode T c Power coolant cable with transparent hose 2 Connection for lead electrode L d Crossjet compresse...

Page 50: ...k Fit the strain relief device from the right using an Allen screw 3 mm Position the robot connection flange without control elements Refit the robot connection flange using six Allen screws 4 mm Conn...

Page 51: ...ing an Allen screw 5 mm Tightening torque 8 Nm Power coolant cable with transparent hose 2 Connection for lead electrode L Power coolant cable with red hose 3 Connection for trail electrode T Connecti...

Page 52: ...p Fitting the current interface cover Position the current interface cover Fit the current interface cover using three Allen screws 2 5 mm Tightening torque 0 3 Nm Connect replace the external wire fe...

Page 53: ...e drive roller cover IMPORTANT The drive roller cover must be positioned without gaps bet ween it and the mounting plate 1 Secure the drive roller cover using two Allen screws 3 mm Position the media...

Page 54: ...over from the fibre optic cable connector Remove the protective cover from the fibre optic cable connection socket CAUTION Risk of damage to the laser welding head due to contamination from above Obse...

Page 55: ...Insert the fibre optic cable connector d Check that the rubber sleeve forms a complete seal around the fibre optic cable connector IMPORTANT The illustration on the right shows an incorrectly positio...

Page 56: ...air the protective function of the Crossjet Connect the hoses for the Crossjet outlet air and additional extractor correctly Connect the hoses for the Crossjet out let air and additional extractor to...

Page 57: ...ecure the LaserHybrid hosepack holders 3 to the profile support 2 Route the hoses cables and LaserHybrid hosepack into the openings on the Laser Hybrid hosepack holders 3 Position the upper part of th...

Page 58: ...ew on the oppo site side 3 mm Pull the drive roller cover towards the rear and remove it Removing the welding torch wearing parts 1 Remove the gas nozzle 2 5 mm Allen key 2 Unscrew the contact tips 7...

Page 59: ...rodes present from two welding wire drums 2 x WF 25i REEL R SA 2R G W stand alone unreeling wirefeeders Unreeling wirefeeders assembled and fitted according to Operating Instructions In stallation Ins...

Page 60: ...ssure lever upwards Swivel the feed rollers downwards Thread the wire electrode into the inta ke nozzle using needle nosed pliers Swing in the feed rollers Push the pressure lever downwards 3 2 7 8 9...

Page 61: ...ers downwards Close the feed rollers on the unreeling wirefeeder Set the torque mode on the unreeling wirefeeder Set the wirefeeder torque on the unreeling wirefeeder using the potentiometer Set the t...

Page 62: ...must be threaded in when fitting the welding torch wear ing parts 1 Fit the gas distributor 2 Screw in the contact tip adapter 8 mm box spanner Tightening torque 5 Nm IMPORTANT When fitting the gas d...

Page 63: ...63 EN 1 Screw in the contact tips 7 mm flat spanner Tightening torque 4 Nm 2 Position the gas nozzle and secure using a 2 5 mm Al len key Tightening torque 1 Nm 3 4...

Page 64: ...efore switching on the laser welding head Setting the radial air flow Remove the two Allen screws 3 mm Swivel the additional extractor to one side Disconnect the air hose The flow rate meter from the...

Page 65: ...t the flow rate meter to the hose and adapter Check whether the Crossjet supply complies with the given specification Switch on the Crossjet Set the flow rate to 25 l min using a small slotted screwdr...

Page 66: ...66 Connect the air hose Swing in the additional extractor Fit the additional extractor using two Allen screws 3 mm 12 12 14 13 14 13 14...

Page 67: ...de deter mined by the torch settings Adjustable axes The physical position of the arc process relative to the laser beam can be adjusted in two Cartesian coordinate axes Adjustment in the z axis can o...

Page 68: ...ew 3 mm quarter turn corresponds to an ad justment of 0 25 mm 2 Scale denoting adjustment range Illustration of both adjusting devices without covers Adjusting the x axis Undo the grub screw 1 3 mm Us...

Page 69: ...rub screw 1 Illustration of both adjusting devices without covers 0 5 2 0 10 3 mm 3 mm 1 NOTE The y setting range of 3 mm starts from the second gradu ation mark on the y scale In position 0 both the...

Page 70: ...e of the robot Switch on the pilot laser Position the laser welding head via the robot so that the laser optics are at an angle of 90 relative to the gauge Presets for finding parameters for the com p...

Page 71: ...the robot Perform a trial weld The best welding result will be used as the basis for the reference program If changes to the mechanical x y settings are required as a result of the trial weld over wri...

Page 72: ...the laser on signal Reset the gas test signal WARNING Work that is carried out incorrectly can cause serious injury or dam age The welding sequence must only be programmed by trained specialist per s...

Page 73: ...stance between the laser and the wire electrode should be 1 5 mm depending on the process LaserHybrid welding end position Stop the movement of the robot Reset the laser on signal Reset the welding st...

Page 74: ...ective glass is present in the laser optics system Test the Crossjet Test the extractor Test the shielding gas Torque mode must be set on the unreeling wirefeeder Parameter set tings on the pow er sou...

Page 75: ...20 x 1 2 mm contact tips 20 x contact tip adapters 10 x gas distributors 4 x gas nozzles 4 x welding torch inner liners cut to length Feed roller set incl pressure lever with axes Allen key set Allen...

Page 76: ...76...

Page 77: ...Maintenance...

Page 78: ......

Page 79: ...Preparatory work Remove the Allen screw 3 mm Remove the Allen screw on the oppo site side 3 mm Pull the drive roller cover towards the rear and remove it Remove the two Allen screws 4 mm Remove the m...

Page 80: ...o the unreeling wirefeeders Requirement 2 x stand alone unreeling wirefeeders e g WF 25i REEL R SA 2R G W Unreeling wirefeeders assembled and fitted according to Operating Instructions In stallation I...

Page 81: ...ading mode on the unreeling wirefeeder Open the feed rollers on the unreeling wirefeeder Fully open Fully open the adjusting screw Pull the pressure lever upwards Swivel the feed rollers downwards Man...

Page 82: ...nstructions and all documentation relating to the unreeling wire feeders Remove the unreeling wirefeeder from the empty welding wire drum Replace the welding wire drum Fit the unreeling wirefeeder to...

Page 83: ...rew 3 mm Remove the Allen screw on the oppo site side 3 mm Pull the drive roller cover towards the rear and remove it Removing the feed rollers Fully open Fully open the adjusting screw Remove the two...

Page 84: ...ivel the pressure lever upwards Push the feed rollers downwards Cut the wire electrodes at the outlet nozzles of the wirefeeding hoses Remove the wire electrodes from the welding torch 3 2 2 3 4 4 4 6...

Page 85: ...85 EN Remove the M4 screw Position the M6 Allen screw Screw in the M6 Allen screw The side panel will come loose Remove the side panel Remove the bottom feed rollers 6 6 7 8 M6 9 7 8 9 10 10...

Page 86: ...eed rollers using the slotted screwdriver Remove the top feed rollers Replacing the in let nozzles Removal Remove the inlet nozzles using need le nosed pliers Installation Insert the inlet nozzles usi...

Page 87: ...87 EN 3 4 5 6 The subsequent steps for installing the feed rollers are carried out in the reverse order to the steps for removal see page 85 step 6 onwards 1 3 4 5 6...

Page 88: ...ng torch that has become very hot through use can cause se vere burns The welding torch must only be cleaned and its components checked when it is cool Remove the two Allen screws 4 mm Remove the medi...

Page 89: ...orque when fitting 2 Nm Pull the welding torch with welding torch inner liners downwards Installation in the reverse sequence IMPORTANT When fitting the welding torch The wire electrodes for guiding t...

Page 90: ...en removed Remove the welding torch see pages 88 and 89 Pull out the inner liners Push in the new inner liners IMPORTANT The replacement inner liners are preconfigured to the correct length When inser...

Page 91: ...he welding torch wearing parts 1 Remove the gas nozzle 2 5 mm Allen key 2 Unscrew the contact tips 7 mm flat spanner CAUTION A welding torch that has become very hot through use can cause se vere burn...

Page 92: ...92 1 Unscrew the contact tip adapter using an 8 mm box spanner 2 Remove the gas distributor 3 Unscrew the nozzle fittings using an 11 mm box span ner 3 4 2 2 5...

Page 93: ...gs 11 mm box spanner Tightening torque 6 Nm 2 Fit the gas distributor IMPORTANT When fitting the gas distributor ensure that the recess on the gas distributor is positioned above the raised element on...

Page 94: ...94 3 Position the gas nozzle and secure using a 2 5 mm Al len key Tightening torque 1 Nm 5...

Page 95: ...rd sheet Removing the spatter guard plate Remove the two Allen screws 3 mm Push the spatter guard plate back wards and remove it Fitting the spatter guard plate Slot in the spatter guard plate and pus...

Page 96: ...96 Fit the spatter guard plate using two Al len screws 3 mm 2 2 2...

Page 97: ...c cable connector and fibre optic cable connection socket Position the laser welding head so that the laser optics system is vertical and as easily accessible as possible Disconnect the Crossjet outle...

Page 98: ...he arrows in the illustrations may differ from the work steps Remove the two Allen screws 3 mm Push the spatter guard plate back wards and remove it Unscrew the extraction pipe 28 mm Remove the two Al...

Page 99: ...99 EN Remove the two Allen screws 3 mm Swivel the additional extractor to one side Disconnect the air hose Remove the two Allen screws 3 mm 1 2 1 6 7 8 8 8 1 2x 9...

Page 100: ...100 Pull the Crossjet forwards Remove the four Allen screws from the underside of the laser welding head 2 5 mm Disconnect the coolant hose 10 10 11 11 11 11 11 13 12...

Page 101: ...system by pulling it upwards Mounting posi tions for install ing the laser optics system A Mounting position for laser optics system with camera module B Mounting position for laser optics system wit...

Page 102: ...s IMPORTANT When inserting the laser op tics system ensure that the pins on the un derside of the laser optics system are inserted into the openings provided Insert the laser optics system into the la...

Page 103: ...103 EN Connect the coolant hose Insert the Crossjet from the front Secure the Crossjet with two Allen screws 3 mm 5 5 6 6 2x 7 7...

Page 104: ...104 Connect the air hose Screw in the extraction pipe 28 mm Swing in the additional extractor Fit the additional extractor using two Allen screws 3 mm 8 8 8 9 9 14 13 14 10 11...

Page 105: ...two Al len screws 3 mm And finally Note The numbering of the arrows in the illustrations may differ from the work steps Position the media cover Secure the media cover using two Al len screws 4 mm 1...

Page 106: ...ove the robot to the reference point on the gauge 1 the focal spot of the laser is within the crosshairs on the gauge Thread the wire electrodes up to the gauge Check the position of the wire electro...

Page 107: ...he reference program and slowly move the robot to the reference point on the adjusting gauge Thread in the wire electrodes until they are touching the adjusting gauge Check the position of the lead wi...

Page 108: ...rtically when changing the protective glass welding torch pointing towards the ground 5 Before changing the protective glass Switch on the Crossjet and extractor Clean the welding head with compressed...

Page 109: ...h cleaning device switch off the Crossjet and extractor during the cleaning process Changing the fibre optic cable 11 When changing the fibre optic cable the laser welding head must be positioned hori...

Page 110: ...110...

Page 111: ...Appendix...

Page 112: ......

Page 113: ...60 x 150 x 610 mm Max laser power on the workpiece 6000 W Max current capacity of the welding torch 100 D C 2 x 300 A corresponds to 36 s of welding 24 s pause Max welding current at 100 D C 10 min 40...

Page 114: ...114 Spare parts list LaserHybrid Ultracompact Twin...

Page 115: ...115...

Page 116: ...116...

Page 117: ...DVHU EULG 8OWUD RPSDFW 7 1 FURVVMHW _ OHDGLQJ _ WUDLOLQJ HQJLQH VXSSO ZDWHU EDFN _ HDGLQJ _ WUDLOLQJ JDV ZDWHU IRUZDUG FURVVMHW LQ ZDWHU EDFN ZDWHU IRUZDUG EORZ RXW HQJLQH VXSSO ZDWHU EDFN ZDWHU IRUZ...

Page 118: ...118...

Page 119: ...119...

Page 120: ...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...

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