Fronius Pull Operating Instructions Manual Download

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Fitting the gas-saver nozzle

129

Fitting the inner liner inside the torch body

130

Fitting the torch body to the WF Robacta Drive

132

Fitting the OPT/i camera mount

133

Load-bearing capacity of the OPT/i camera mount

133

Safety

133

Fitting the OPT/i camera mount

134

Fitting the inner liner

135

Fitting the inner liner (unreeling wirefeeder - SplitBox SB 500i R)

135

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

135

Fitting the PowerLiner (unreeling wirefeeder - WF Robacta Drive with external wirefeed-
ing hose)

136

Fitting the inner liner (unreeling wirefeeder - wire buffer)

137

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

138

Fitting the inner liner (wire buffer - WF Robacta Drive with internal wirefeeding hose)

139

Fitting the inner liner (wire buffer - WF Robacta Drive with external wirefeeding hose)

140

Fitting the inner liner inside the torch hosepack

141

Start-up

143

Inserting/replacing feed rollers

145

General

145

WF 25i Reel 4R: inserting/replacing feed rollers for the 4-roller drive

145

WF 30i Reel 2R: inserting/replacing feed rollers for the 2-roller drive

146

Inserting/replacing the WF 25i Robacta Drive feed rollers

147

Inserting/replacing the WF 60i Robacta Drive CMT feed rollers

149

Feeding in the wire electrode

152

Insulated routing of wire electrode to wirefeeder

152

Feeding in the wire electrode

152

Setting the contact pressure for the WF 25i Robacta Drive

153

Setting the contact pressure for the WF 60i Robacta Drive CMT

Troubleshooting, maintenance and disposal

Care, maintenance and disposal

Special care of O-rings

163

Whenever the welding torch or torch hosepack is changed

164

Changing the torch hosepack, changing the interconnecting hosepack

164

Every 6 months

164

Recognising faulty wearing parts

165

Replacing the WF 25i Robacta Drive clamping lever

165

Replacing the WF 60i Robacta Drive CMT clamping lever

166

Replacing the WF Robacta Drive gas-saver nozzle

166

Replacing the SB 60i R inner liner

167

Replacing the TPSi wire buffer wire guide

169

Changing the direction of operation of the TPSi wire buffer

170

Replacing the TPSi wire buffer lever

171

Fitting wearing parts to the torch body

172

Fitting wearing parts to the torch body - MTW 700 i

172

Removing the CrashBox PAP from the robot

173

Disposal

174

Summary of Contents for Pull

Page 1: ...Operating instructions TPS i Robotics welding system Pull PushPull CMT 42 0426 0219 EN 021 15032022 EN Operating instructions...

Page 2: ......

Page 3: ...24 PushPull with 4 roller unreeling wirefeeder and wire drum 25 PushPull with 4 roller unreeling wirefeeder and wirespool 26 PushPull with SB 60i 4 roller unreeling wirefeeder and wirespool 27 PushPu...

Page 4: ...General 62 Requirements 62 How it works 62 WireSense edge detection 63 WireSense contour detection 64 Technical details 65 OPT i camera mount 66 General 66 Drilling template 66 Controls connections a...

Page 5: ...t 105 Maximum axis rotation 106 Fitting the SplitBox SB 500i R PAP 107 Fitting the SB 500i R PAP 107 Installing the CrashBox Drive i PAP on the robot 108 Installing the CrashBox Drive i PAP on the rob...

Page 6: ...e 146 Inserting replacing the WF 25i Robacta Drive feed rollers 147 Inserting replacing the WF 60i Robacta Drive CMT feed rollers 149 Feeding in the wire electrode 152 Insulated routing of wire electr...

Page 7: ...cks 184 WF 25i Robacta Drive 186 WF 25i Robacta Drive G 186 WF 25i Robacta Drive W 186 WF 60i Robacta Drive CMT 187 WF 60i Robacta Drive CMT G 187 WF 60i Robacta Drive W CMT 187 WF 25i REEL R 4R G W 1...

Page 8: ...ice All persons involved in commissioning operating maintaining and servicing the device must be suitably qualified have sufficient knowledge of automated welding and read and carefully follow these o...

Page 9: ...p to 90 at 20 C 68 F The surrounding air must be free from dust acids corrosive gases or substances etc Can be used at altitudes of up to 2000 m 6561 ft 8 16 in Obligations of the operator The operato...

Page 10: ...y helmet Trousers with no turn ups Protective clothing refers to a variety of different items Operators should Protect eyes and face from UV rays heat and sparks using a protective visor and regulatio...

Page 11: ...european welding org Flammable vapours e g solvent fumes should be kept away from the arc s radi ation area Close the shielding gas cylinder valve or main gas supply if no welding is taking place Dan...

Page 12: ...of a power source can occur between the welding electrodes of two power sources Touching the potentials of both electrodes at the same time may be fatal under certain circumstances Arrange for the ma...

Page 13: ...in other areas Devices in emission class B Satisfy the emissions criteria for residential and industrial areas This is also true for residential areas in which the energy is supplied from the public l...

Page 14: ...while maintenance or repair work is being carried out During operation Ensure that all covers are closed and all side panels are fitted properly Keep all covers and side panels closed The welding wire...

Page 15: ...if an adapter is used for the shielding gas connection Prior to assembly seal the device side thread of the adapter for the shielding gas connection using suitable Teflon tape Requirement for the shi...

Page 16: ...pling over could easily kill someone Place the device on a solid level surface such that it remains stable The maximum permissible tilt angle is 10 Special regulations apply in rooms at risk of fire o...

Page 17: ...from use of other sys tem components or a different coolant In addition all warranty claims will be forfeited Cooling Liquid FCL 10 20 does not ignite The ethanol based coolant can ignite under certai...

Page 18: ...e of the approved collection and recycling facilities in your area Ig noring this European Directive may have potentially adverse affects on the envir onment and your health Safety symbols Devices wit...

Page 19: ...ation Keep hands and metal objects away 1 An electric shock can be fatal 1 1 Wear dry insulating gloves Do not touch the wire electrode with bare hands Do not wear wet or damaged gloves 1 2 Use a base...

Page 20: ...a supervisor ready who can operate the fire extinguisher 3 3 Do not weld on drums or closed containers 4 Arc rays can burn the eyes and injure the skin 4 1 Wear headgear and protective goggles Use ear...

Page 21: ...System configurations 21...

Page 22: ...22...

Page 23: ...osepack 8 WF 25i Robacta Drive 9 MTB i R robot welding torch Maximum wirefeed length max 6 m between wire drum and drive unit max 8 m with PowerLiner Possible wire diameters 0 8 1 2 mm Welding process...

Page 24: ...ernal wirefeeding hose 8 WF 25i Robacta Drive 9 MTB i R robot welding torch Maximum wirefeed length max 6 m between wire drum and drive unit max 8 m with PowerLiner Possible wire diameters 0 8 1 2 mm...

Page 25: ...h hosepack 10 WF 25i Robacta Drive 11 MTB i R robot welding torch Maximum wirefeed length max 15 m between drive unit and unreeling wirefeeder max 20 m with PowerLiner max 8 m between unreeling wirefe...

Page 26: ...feeding hose with inner liner 8 SplitBox SB 500i R 9 MHP i R welding torch hosepack with external wirefeeding hose 10 WF 25i Robacta Drive 11 MTB i R robot welding torch Maximum wirefeed length max 15...

Page 27: ...ith inner liner 8 SplitBox SB 60i R 9 MHP i R torch hosepack 10 WF 25i Robacta Drive 11 MTB i R robot welding torch Maximum wirefeed length max 4 m between drive unit and SB 60i R max 6 m between SB 6...

Page 28: ...ck with external wirefeeding hose 10 WF 25i Robacta Drive 11 MHP i R robot welding torch Maximum wirefeed length max 8 m between drive unit and unreeling wirefeeder max 10 m with PowerLiner Possible w...

Page 29: ...Drive CMT 11 MTB i R robot welding torch Maximum wirefeed length max 4 m between drive unit and SB 60i R max 6 m between SB 60i R and unreeling wirefeeder max 8 m between unreeling wirefeeder and wire...

Page 30: ...ack with external wirefeeding hose 11 WF 60i Robacta Drive CMT 12 MTB i R robot welding torch Maximum wirefeed length max 4 m between drive unit and wire buffer max 6 m between wire buffer and unreeli...

Page 31: ...er 8 SplitBox SB 60i R 9 MHP i R torch hosepack 10 WF 60i Robacta Drive CMT 11 MTB i R robot welding torch Maximum wirefeed length max 4 m between drive unit and SB 60i R max 6 m between SB 60i R and...

Page 32: ...k 8 WF 25i Robacta Drive 9 MTB i R robot welding torch Maximum wirefeed length max 6 m between wire drum and drive unit max 8 m with PowerLiner Possible wire diameters 0 8 1 2 mm Welding process Stand...

Page 33: ...R torch hosepack 10 WF 25i Robacta Drive 11 MTB i R robot welding torch Maximum wirefeed length max 15 m between drive unit and unreeling wirefeeder max 20 m with PowerLiner max 8 m between unreeling...

Page 34: ...g hose with inner liner 8 SplitBox SB 500i R 9 MHP i R torch hosepack 10 WF 25i Robacta Drive 11 MTB i R robot welding torch Maximum wirefeed length max 15 m between drive unit and unreeling wirefeede...

Page 35: ...ch hosepack 10 WF 25i Robacta Drive 11 MHP i R robot welding torch Maximum wirefeed length max 8 m between drive unit and unreeling wirefeeder max 10 m with PowerLiner Minimum length between wirefeede...

Page 36: ...ffer 10 MHP i R torch hosepack 11 WF 25i Robacta Drive 12 MTB i R robot welding torch Maximum wirefeed length max 4 m between drive unit and wire buffer max 6 m between wire buffer and unreeling wiref...

Page 37: ...liner 8 Wire buffer 9 SplitBox SB 500i R 10 MHP i R torch hosepack 11 WF 25i Robacta Drive 12 MTB i R robot welding torch Maximum wirefeed length max 4 m between drive unit and wire buffer max 6 m bet...

Page 38: ...10 WF 60i Robacta Drive CMT 11 MTB i R robot welding torch Maximum wirefeed length max 4 m between drive unit and SB 60i R max 6 m between SB 60i R and unreeling wirefeeder max 8 m between unreeling w...

Page 39: ...ck 11 WF 60i Robacta Drive CMT 12 MTB i R robot welding torch Maximum wirefeed length max 4 m between drive unit and wire buffer max 6 m between wire buffer and unreeling wirefeeder max 8 m between un...

Page 40: ...8 SplitBox SB 500i R 9 MHP i R torch hosepack 10 WF 60i Robacta Drive CMT 11 MTB i R robot welding torch Maximum wirefeed length max 4 m between drive unit and wire buffer max 6 m between wire buffer...

Page 41: ...System components 41...

Page 42: ...42...

Page 43: ...yond this purpose is deemed improper The manufacturer shall not be held liable for any damage arising from such usage Utilisation in accordance with the intended purpose also comprises carefully readi...

Page 44: ...www fronius com Ser No Part No XXXXXXXXXX 4 040 080 SB 500i R G W FSC Welding is dangerous The following basic requirements must be met to ensure the equipment is used properly Welders must be suffic...

Page 45: ...nd 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 co...

Page 46: ...med improper The manufacturer shall not be held liable for any damage arising from such usage Utilisation in accordance with the intended purpose also comprises carefully reading these operating instr...

Page 47: ...us The following basic requirements must be met to ensure the equipment is used properly Welders must be sufficiently qualified Suitable protective equipment must be used All persons not involved must...

Page 48: ...Do not dispose of used devices with domestic waste Dispose of them according to the safety rules 48...

Page 49: ...drive systems that work in different ways The rear drive system steadily feeds the wire elec trode into the wire buffer while the front highly dynamic drive motor moves it to and fro up to 70 times pe...

Page 50: ...ht Select the CrashBox size according to the following criteria L for push systems with a torch body length of up to 249 mm XL for push systems with a torch body length of up to 249 mm and with exten...

Page 51: ...x robot flange with screws Robot flange as per price list Observe torques Max tightening torque for screws of strength class 8 8 M4 3 3 Nm 2 43 lb ft M5 5 0 Nm 3 69 lb ft M6 6 0 Nm 4 43 lb ft M8 27 3...

Page 52: ...wing PushPull robot hosepacks MHP i G W RD hosepacks Information on repairing Crash Boxes NOTE Only send complete CrashBoxes for repair Incomplete CrashBoxes e g without a magnetic ring cannot be chec...

Page 53: ...this may result in serious injury and damage WF 25i Robacta Drive rating plate WF 60i Robacta Drive CMT rating plate Welding is dangerous The following basic requirements must be met to ensure the eq...

Page 54: ...nal SB500i WF 25i Robacta Drive SB60i WF 60i Robacta Drive CMT Robacta MHPi RD PAP SB500i WF 25i Robacta Drive SB500i WF 60i Robacta Drive CMT SB60i WF 60i Robacta Drive CMT Robacta MHPi RD convention...

Page 55: ...he following torch bodies are recommended for the CMT process MTB 250i 320i 400i 500i 700i 22 36 MTB 330i 22 The following maximum angles are permitted during the CMT process MTB 250i 320i 400i 500i 7...

Page 56: ...OPT CAM Prepared for the camera recording option 56...

Page 57: ...es between the welding wire drum and the robot wirefeeder While in operation the unreeling wirefeeder is synchronised with the power source It is supplied with power and controlled by the power source...

Page 58: ...of them according to the safety rules Welding is dangerous The following basic requirements must be met to ensure the equipment is used properly Anyone performing automated welding must be sufficient...

Page 59: ...e 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 mainte...

Page 60: ...t 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: ...ngth For Robacta Drive applications lengths of up to 10 m can be realised For CMT applications lengths of up to 6 m can be realised between the unreeling wirefeeder and wire buffer and 4 m between the...

Page 62: ...nal space require ments Requirements WireSense only works With automated applications In conjunction with CMT system components WF 60i Robacta Drive CMT SB 500i R with wire buffer or SB 60i R and WFi...

Page 63: ...ignal sequence overview 1 The robot sets the minimum edge height from which the edge detection is triggered WireSense Edge Detection 2 Signal from robot to start or stop WireSense WireSense Start 3 Si...

Page 64: ...omponent Signal sequence overview 1 For contour detection WireSense edge detection must be disabled WireSense Edge Detection OFF or 0 5 mm 2 Signal from the robot to start or stop contour detection Wi...

Page 65: ...ge The system supplies the height information as ac tual values of the sampled path Sampling rate approx 100 Hz approx 100 Hz Min sheet thickness 0 5 mm Max sheet thickness 20 mm Height measurement ac...

Page 66: ...m tracking system or camera is protected by the CrashBox The position of the mounted seam tracking system or camera is reproducible as it is positioned with a dowel pin Seam tracking system or camera...

Page 67: ...Controls connections and mechan ical components 67...

Page 68: ...68...

Page 69: ...ment must only be carried out by technically trained and qualified personnel Read and understand this document in full Read and understand all safety rules and user documentation for this device and a...

Page 70: ...t 7 8 5 2 10 Rear of SB 500i R left variant No Function 1 Blanking cover for option 3 2 Blanking cover for option 4 3 Blanking cover for option 1 4 Welding torch connection 5 SpeedNet connection for c...

Page 71: ...mech anical compon ents Front Rear No Function 1 current socket for connecting the power cable from the interconnecting hosepack 2 Shielding gas connection 3 SpeedNet connection for connecting the Sp...

Page 72: ...setting the required gas flow rate on the pressure regulator Gas will flow out for 30 seconds after the gas test button is pressed Press the button again to stop the gas flow prematurely 3 Wire retra...

Page 73: ...cted further the wire retract button must be pressed again 4 Wire threading button For threading the wire electrode into the torch hosepack with no accom panying flow of gas or current While the butto...

Page 74: ...t ton is pressed until it is short circuit free it retracts by no more than 10 mm 0 39 in with each press of the button If there is still a ground earth connection with the contact tip after 10 mm 0 3...

Page 75: ...anking cover gas test wire threading control panel option A Welding torch end 5 Welding torch connection 6 Coolant hoses to welding torch 7 Blanking cover SpeedNet or external sensor option B Power so...

Page 76: ...cover gas test wire threading control panel option A Welding torch end 5 Welding torch connection 6 Coolant hoses to welding torch 7 Blanking cover SpeedNet or external sensor option B Power source e...

Page 77: ...ld Wire retract button The wire electrode will be retracted 1 mm 0 039 in after the wire re tract button is pressed After a short pause the wirefeeder continues to retract the wire elec trode If the w...

Page 78: ...topped and the wire electrode will be re tracted again by 1 mm 0 039 in Method 2 Threading the wire electrode in 1 mm increments 0 039 in increments always press the wire threading button for less tha...

Page 79: ...ive Wire retract active In applications with a double head wirefeeder when process line 1 is selected 2 and 3 light up on the other process lines but are smaller in size In applications with a double...

Page 80: ...For applications with WireSwitch when process line 1 is active For applications with WireSwitch when process line 2 is active 80...

Page 81: ...i REEL R 2R Controls con nections and mechanical com ponents 1 3 2 Front of WF 25i REEL R 4R G W 1 5 4 Front of WF 30i REEL R 2R G W 6 7 Left side 11 8 9 10 Rear 12 13 100 mm 50 mm 4 x M5 3 9 in 2 0 i...

Page 82: ...ver for optional component 12 M20 thread for connecting QuickConnect option 13 Wire infeed outfeed tube Wire infeed underside Wire outfeed top Control panel 1 2 3 4 Gas test wire threading control pan...

Page 83: ...nts always press the wire retract button for less than one second tap NOTE Do not allow long lengths of wire electrode to be retracted as the wire electrode is not wound onto the wirespool or the weld...

Page 84: ...button for less than one second tap If the wire electrode comes into contact with a ground earth connection the wirefeeding will be stopped and the wire electrode will be retracted again by 1 mm 0 03...

Page 85: ...Assembling system components conventional robot 85...

Page 86: ...86...

Page 87: ...rom the mains until all work has been completed WARNING Risk of serious injury and damage from articles being dropped For all of the screw connections referred to below Check after fitting to ensure t...

Page 88: ...the robot please also note the instructions and information on in stalling the wirefeeder in the User Information Fitting the SB 500i R 7x M6x16 6x 6FSt 6FSt 1x 1x M6x16 1 2x M8 x 20 mm 2 Fitting the...

Page 89: ...t 1 Observe the torques when fitting the robot flange Max tightening torque for screws of strength class 8 8 M4 3 3 Nm 2 43 lb ft M5 5 0 Nm 3 69 lb ft M6 6 0 Nm 4 43 lb ft M8 27 3 Nm 20 14 lb ft M10 5...

Page 90: ...robot 1 Observe the torques when fitting the robot flange Max tightening torque for screws of strength class 8 8 M4 3 3 Nm 2 43 lb ft M5 5 0 Nm 3 69 lb ft M6 6 0 Nm 4 43 lb ft M8 27 3 Nm 20 14 lb ft M...

Page 91: ...3 3 Nm 2 43 lb ft 2 6 Nm 4 43 lb ft 3 91 EN...

Page 92: ...t the drive unit when the power source is switched off CAUTION Danger of property damage due to dirty or wet coupling point Whenever the hosepack is fitted or removed ensure that the coupling point is...

Page 93: ...Fitting the WF Robacta Drive to the robot con ventional 10 Nm 7 38 lb ft M6 x 12 mm 1 2 42 Nm 30 98 lb ft 3 4 93 EN...

Page 94: ...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 CB Fit the extension to the index disc that has alrea...

Page 95: ...Optimum hosep ack arrangement R R R 200 mm R 200 mm 95 EN...

Page 96: ...Fitting the interconnecting hosepack Fitting the Standard inter connecting hosepack to the robot 3 Nm 2 21 lb ft 1 SB 500i 2 96...

Page 97: ...the MHP W hosep ack IMPORTANT Whenever the torch hosepack is fitted or removed ensure that the coupling point is clean and dry Remove any coolant that has escaped from the coupling point 1 1 2 3 Push...

Page 98: ...5 6 IMPORTANT Always route coolant hoses below the hosepack and then guide them to the connection socket WFi R SB 500i SB 60i 7 98...

Page 99: ...1 Coolant return red 2 Coolant flow blue IMPORTANT Connect the coolant hoses to the cooling unit correctly Disconnecting the coolant hoses PUSH 1 2 3 99 EN...

Page 100: ...jury and damage from loose connections All cables leads and hosepacks must be properly secured undamaged insu lated and adequately dimensioned General NOTE Also follow the instructions and information...

Page 101: ...1 2 6 4 5 3 SB 500i R left variant 1 2 NOTE If present lead the coolant hoses from the interconnecting hosepack under the SB 500i R and connect them to the torch hosepack 101 EN...

Page 102: ...102...

Page 103: ...Assembling system components PAP robot 103...

Page 104: ...104...

Page 105: ...he mains until all work has been completed WARNING Risk of serious injury and damage from articles being dropped For all of the screw connections referred to below Check after fitting to ensure they a...

Page 106: ...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 6 Sixth robot axis 200 4 6 Fourth...

Page 107: ...Fitting the SplitBox SB 500i R PAP Fitting the SB 500i R PAP 1 2 107 EN...

Page 108: ...1 Dowel pin in the robot flange Observe the torques when fitting the robot flange Max tightening torque for screws of strength class 8 8 M4 3 3 Nm 2 43 lb ft M5 5 0 Nm 3 69 lb ft M6 6 0 Nm 4 43 lb ft...

Page 109: ...l pin in the robot flange Observe the torques when fitting the robot flange Max tightening torque for screws of strength class 8 8 M4 3 3 Nm 2 43 lb ft M5 5 0 Nm 3 69 lb ft M6 6 0 Nm 4 43 lb ft M8 27...

Page 110: ...4 Nm 2 95 lb ft 2 8 Nm 5 90 lb ft 3 110...

Page 111: ...he drive unit when the power source is switched off CAUTION Danger of property damage due to dirty or wet coupling point Whenever the hosepack is fitted or removed ensure that the coupling point is cl...

Page 112: ...11 Nm 8 11 lb ft 5 Fitting the WF Robacta Drive to the robot PAP 1 1 2 112...

Page 113: ...3 42 0411 1315 BY2 0201 4896 4 18 Nm 13 28 lb ft 5 113 EN...

Page 114: ...6 114...

Page 115: ...ounting of the holder for the interconnecting hosepack depends on the robot manufacturer and robot type Mount the holder for the interconnecting hosepack according to the Installa tion Instructions fo...

Page 116: ...Risk of injury and damage from loose connections All cables leads and hosepacks must be properly secured undamaged insu lated and adequately dimensioned General NOTE Also follow the instructions and i...

Page 117: ...3 4 117 EN...

Page 118: ...118...

Page 119: ...Assembling further system com ponents 119...

Page 120: ...120...

Page 121: ...installation of the SplitBox SB 60i R is illustrated using the right version of the appliance The left version of the appliance should be installed the other way around 1 2 Fitting the SB 60i R to th...

Page 122: ...different fixings are required for fitting the wall bracket The installer is responsible for selecting the correct fixings 10 5 Nm 7 74 lb ft 3 NOTE Use a balancer for hosepacks longer than 1 75 m Po...

Page 123: ...e coupling point is clean and dry Remove any coolant that has escaped from the coupling point The connection of the torch hosepack to the SplitBox SB 60i R is illustrated us ing the right version of t...

Page 124: ...Fitting the TPSi wire buffer Fitting the TPSi wire buffer 4x 3 Nm 4x 2 21 lb ft Fitting to the robot 1 Fitting to a balancer 1 124...

Page 125: ...Connecting the control line to the wire buffer NOTE Carefully place the control line in the strain relief device provided Figure 2 1 2 3 125 EN...

Page 126: ...correct direction The threading direction of the wire elec trode is marked with an arrow The unreeling wirefeeder is designed exclusively for vertical installation on the following mounts WF Mounting...

Page 127: ...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 Only use...

Page 128: ...2 128...

Page 129: ...Fitting the torch body to the WF Robacta Drive Fitting the gas saver nozzle 42 0411 0160 Torx 40 1 2 42 0411 0160 1 Nm 0 74 lb ft 3 42 0411 0160 1 Nm 0 74 lb ft 4 129 EN...

Page 130: ...Fitting the inner liner inside the torch body IMPORTANT For the MTB 330i welding torch the plastic inner liner is fitted from the front Plastic inner liner 1 2 4 3 130...

Page 131: ...Steel inner liner 1 2 3 131 EN...

Page 132: ...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 couplin...

Page 133: ...5kg 1 4kg 1 3kg 1 2kg 1 1kg 1 0kg 0 9kg 0 8kg 0 7kg 0 6kg 0 5kg 0 4kg 0 3kg 0 2kg 0 1kg 0kg 50mm 100mm 150mm 200mm 250mm Safety CAUTION Risk of burns from hot torch body hot torch body coupling and ot...

Page 134: ...Fitting the OPT i camera mount 1 2 3 4 134...

Page 135: ...Fitting the inner liner Fitting the inner liner unreeling wirefeeder SplitBox SB 500i R 1 2 3 4 Fitting the inner liner unreeling wirefeeder WF Robacta Drive with external wirefeeding hose 1 2 135 EN...

Page 136: ...3 Fitting the PowerLiner un reeling wirefeed er WF Robacta Drive with ex ternal wirefeed ing hose 3 2 3 1 Fasten screw only slightly do not tighten 1 3 1 3 2 2 44 0350 3445 3 4 136...

Page 137: ...5 6 Fitting the inner liner unreeling wirefeeder wire buffer 1 2 137 EN...

Page 138: ...3 4 5 Fitting the inner liner SplitBox WF 25i with in ternal inner liner 1 138...

Page 139: ...2 3 4 Fitting the inner liner wire buffer WF Robacta Drive with in ternal wirefeed ing hose 1 2 139 EN...

Page 140: ...3 4 Fitting the inner liner wire buffer WF Robacta Drive with ex ternal wirefeed ing hose 1 2 3 140...

Page 141: ...er liner inside the torch hosepack NOTE Ensure that the hosepack is straight when fitting the inner liner otherwise the liner might not be inserted correctly 1 1 2 3 4 5 Steel inner liner Plastic inne...

Page 142: ...6 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 7 142...

Page 143: ...Start up 143...

Page 144: ...144...

Page 145: ...that match the wire electrode An overview of the feed rollers available and their possible areas of use can be found in the Spare Parts Lists WF 25i Reel 4R inserting repla cing feed rollers for the 4...

Page 146: ...4 2 6 3 4 WF 30i Reel 2R inserting repla cing feed rollers for the 2 roller drive 1 2 CAUTION Risk of crushing due to exposed feed rollers Always fit the protective cover of the 2 roller drive after...

Page 147: ...erting repla cing the WF 25i Robacta Drive feed rollers 1 2 1 2 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 3 4 14...

Page 148: ...5 6 7 8 Torx 40 1 Nm 0 74 lb ft 9 10 148...

Page 149: ...nserting repla cing the WF 60i Robacta Drive CMT feed rollers 1 2 1 2 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: ...5 12 mm 42 0411 0160 6 7 8 12 mm 5 Nm 3 69 lb ft 42 0411 0160 2 9 10 150...

Page 151: ...2 1 11 12 151 EN...

Page 152: ...nt chafing do not route the wirefeeding hoses over sharp edges Use hose holders or hose protectors where necessary Coupling pieces and hoods for welding wire drums are recommended to en sure safe tran...

Page 153: ...properly and re main in place during operation 1 3 2 1 4 2 Setting the con tact pressure for the WF 25i Robacta Drive NOTE Set the contact pressure in such a way that the wire electrode is not deforme...

Page 154: ...nevertheless ensures proper wirefeeding IMPORTANT In the event of a large change in contact pressure a system calib ration must be carried out How to perform the system calibration is explained in th...

Page 155: ...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 All covers cl...

Page 156: ...156...

Page 157: ...Troubleshooting maintenance and disposal 157...

Page 158: ...158...

Page 159: ...all devices and components involved so they cannot be switched back on After opening the device use a suitable measuring instrument to check that electrically charged components such as capacitors hav...

Page 160: ...Replace the welding torch Interconnecting hosepack is faulty or not connected properly Check interconnecting hosepack Cause Remedy Cause Remedy No welding current Mains switch is ON and indicators are...

Page 161: ...itable feed rollers Decrease wire braking force Increase contact pressure on main wirefeeder Acknowledge service code by pressing wire threading button End of wire reached Check whether sufficient wir...

Page 162: ...is leaking Change the welding torch Wrong contact tip or contact tip is worn out Replace the contact tip Wrong wire alloy or wrong wire diameter Check the wire electrode that has been inserted Wrong...

Page 163: ...nd components involved so they cannot be switched back on After opening the device use a suitable measuring instrument to check that electrically charged components such as capacitors have been discha...

Page 164: ...in the third robot axis take the following into account when changing the torch hosepack or interconnecting hosepack CAUTION Risk of damage to the robot wirefeeder or media splitter from escaping cool...

Page 165: ...overed in welding spatter 3 Spatter guard Burned off outside edges notches 4 Contact tips Worn out oval wire entry and wire exit holes Heavily covered in welding spatter Penetration on the tip of the...

Page 166: ...ver nozzle CAUTION Danger of property damage due to dirty or wet coupling point Whenever the welding torch is fitted or removed ensure that the coupling point is clean and dry Remove any coolant that...

Page 167: ...42 0411 0160 1 Nm 0 74 lb ft 5 6 18 Nm 13 28 lb ft 7 Replacing the SB 60i R inner liner Removing the inner liner 1 2 167 EN...

Page 168: ...3 4 Inserting the inner liner 1 2 3 4 168...

Page 169: ...e 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 cont...

Page 170: ...Changing the direction of op eration of the TPSi wire buffer NOTE After conversion make sure the control line is fitted properly in the strain relief device provided 1 2 3 4 5 6 170...

Page 171: ...Replacing the TPSi wire buffer lever NOTE Before fitting the new wire buffer lever turn the locating sleeve into the central position Figure 3 1 2 3 4 5 6 171 EN...

Page 172: ...Fitting wearing parts to the torch body 1 2 3 Fitting wearing parts to the torch body MTW 700 i 1 2 172...

Page 173: ...Removing the CrashBox PAP from the robot 1 BY2 0201 4896 2 3 4 5 1 6 173 EN...

Page 174: ...1 1 7 8 9 10 Disposal Dispose of in accordance with the applicable national and local regulations 174...

Page 175: ...Technical data 175...

Page 176: ...176...

Page 177: ...nt at 10 min 40 C 104 F 40 ED 650 A 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 Ma...

Page 178: ...60 ED 365 A 100 ED 320 A 95 mm 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 I...

Page 179: ...m 15 49 lb ft CrashBox i XL 42 Nm 30 98 lb ft CrashBox i XXL 63 1 Nm 46 54 lb ft CrashBox Drive i PAP 21 Nm 15 49 lb ft CrashBox Drive i PAP XXL 42 Nm 30 98 lb ft Maximum deflection in x y direction C...

Page 180: ...i XL 90 mm x 60 mm b CrashBox i XXL 90 mm x 60 mm b CrashBox Drive i PAP 90 mm x 84 5 mm b CrashBox Drive i PAP XXL 90 mm x 84 5 mm b a At a distance of 300 mm from the robot flange b With bellows 11...

Page 181: ...Triggering torques and weight distance diagram 181 EN...

Page 182: ...0 Deflection at a distance of 300 mm max 1 5275 1 5275 1 5275 0 6684 0 6684 max mm 8 8 8 3 5 3 5 min 0 684 0 684 0 684 0 382 0 382 min mm 3 5 3 5 3 5 2 0 2 0 Weight distance mm kg 400 5 25 10 50 15 78...

Page 183: ...4 7 standard ED Duty cycle MHP 400i RD G PAP Welding current at 10 min 40 C M21 EN 439 C1 EN 439 40 ED 400 A 60 ED 320 A 100 ED 260 A 60 ED 400 A 100 ED 320 A Wire diameter 0 8 1 6 mm 0 030 0 062 inch...

Page 184: ...700 800 850 950 1000 1200 1400 0 935 m 3 07 ft 1 085 m 3 56 ft 1 235 m 4 05 ft 1 435 m 4 71 ft 1 735 m 5 69 ft 1 935 m 6 35 ft 2 235 m 7 33 ft 2 735 m 8 97 ft 3 235 m 10 60 ft 3 735 m 12 25 ft Minimu...

Page 185: ...82 ft 1 175 m 3 86 ft 1 185 m 3 89 ft 1 205 m 3 95 ft 650 W 1 295 m 4 25 ft 1 335 m 4 38 ft 1 355 m 4 45 ft 1 385 m 4 54 ft 700 W 1 415 m 4 64 ft 1 495 m 4 9 ft 1 575 m 5 17 ft 850 W 1 935 m 6 35 ft...

Page 186: ...uirements of the IEC 60974 7 standard D C Duty cycle WF 25i Robacta Drive W Welding current at 10 min 40 C M21 EN 439 C1 EN 439 100 ED 500 A 100 ED 500 A Wire diameter 0 8 1 6 mm 0 032 0 063 inch Mini...

Page 187: ...ically driven welding torches 141 V The product conforms to the requirements of the IEC 60974 7 standard D C Duty cycle WF 60i Robacta Drive W CMT Welding current at 10 min 40 C M21 EN 439 C1 EN 439 1...

Page 188: ...The product conforms to the requirements of the IEC 60974 7 standard ED Duty cycle 188...

Page 189: ...rrent 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 Degree of protection IP 21 Mark of conformity CE CSA Dimensions l x w x h 250 x...

Page 190: ...urrent 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 Degree of protection IP 21 Mark of conformity CE CSA Dimensions l x w x h 250...

Page 191: ...rent at 10 min 40 C M21 EN 439 C1 EN 439 40 ED 320 A 60 ED 260 A 100 ED 210 A 60 ED 320 A 100 ED 260 A Wire diameter 0 8 1 6 mm 0 030 0 062 inch MTB 330i G R TX TXM Welding current at 10 min 40 C M21...

Page 192: ...ed ro bot welding torches MTB 250i W R Welding current at 10 min 40 C M21 EN 439 C1 EN 439 100 ED 250 A 100 ED 250 A Wire diameter 0 8 1 2 mm 0 032 0 047 inch MTB 330i W R TX TXM Welding current at 10...

Page 193: ...M21 EN 439 C1 EN 439 100 ED 500 A 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 C1 EN 439 100 ED 700 A 100 ED 500 A Wire diamete...

Page 194: ...D Duty cycle HP 95i Welding current at 10 min 40 C 104 F 40 ED 500 A 60 ED 450 A 100 ED 360 A ED Duty cycle HP 120i Welding current at 10 min 40 C 104 F 40 ED 600 A 60 ED 530 A 100 ED 430 A ED Duty cy...

Page 195: ...195 EN...

Page 196: ...Froniusstra e 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 spareparts fro...

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