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Installing the CrashBox, torch hosepack, and TWIN welding torch

1

Mount the robot flange and CrashBox on the robot

2

Insert the inner liners into the torch hosepack

3

Install the clamp on the CrashBox

4

Insert the torch hosepack into the clamp

5

Connect CrashBox cable

6

Connect torch hosepack to the wirefeeder

7

Insert the inner liners into the TWIN welding torch

8

Install the torch body coupling

9

Check the function of the torch body coupling

10

Install wearing parts on the TWIN welding torch

11

Install TWIN welding torch on the torch hosepack

Connecting the protective gas shield and grounding cable

1

Connect protective gas shield supply to both power sources

2

Connect one grounding cable per power source to the power sources

3

Connect both grounding cables to the workpiece
(see also "Ground connection" on page 

25

)

Preparing the TWIN wirefeeder for operation

1

Connect wirefeeding hoses to the welding wire drums

2

Connect wirefeeding hoses to the TWIN wirefeeder

3

Insert the feed rollers

4

Close all covers

Defining welding lines 1 and 2 on the power sources

1

Switch on power source 2, leave power source 1 switched off

2

Place sticker 2 in a clearly visible location on power source 2

3

Set the parameter to 2 in the Setup menu of power source 2 under Defaults/System/
TWIN Setup

4

Switch on power source 1

5

Place sticker 1 in a clearly visible location on power source 1

6

Check that the parameter is set to 1 in the Setup menu of power source 1 under De-
faults/System/TWIN Setup

Final tasks

1

Carry out an R/L comparison on both power sources

2

Thread the wire electrodes

3

Set the contact pressure

4

Set TWIN characteristics on both power sources
(Welding process/Filler metal/Change material settings... Step 4 - select the charac-
teristic from the characteristics available for each welding process)

5

Set stick out

6

If necessary, carry out system calibration (e.g., if there is a WF REEL unwinding
wirefeeder in the system)

7

Define the lead/trail signal on the robot controls

8

Set TWIN parameters

80

Содержание CMT Twin

Страница 1: ...ine free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy TPS i Robotics welding system TWIN Push TWIN Push Pull TWIN CMT EN US Operating instruct...

Страница 2: ......

Страница 3: ...fety Inspection 16 Disposal 16 Safety symbols 17 Data backup 17 Copyright 17 General information 19 General 21 Application areas 21 Requirements 22 System requirements and minimum equipment TWIN Push...

Страница 4: ...meters 58 TWIN process parameters 58 Pulse synchronization ratio 58 Lead trail phase shift 59 Trail ignition delay 59 Welding parameter standard values for fillet welds 61 Standard values for welding...

Страница 5: ...oning 102 Requirements 102 Commissioning start of welding 102 Installation and commissioning TWIN Push Pull CMT 103 Safety Installation and Commissioning 105 Safety 105 Insulated Guiding of the Wire E...

Страница 6: ...pressure 135 Commissioning 136 Requirements 136 Commissioning start of welding 136 Troubleshooting Maintenance and Disposal 137 Troubleshooting 139 Safety 139 Troubleshooting 139 Displayed Error Codes...

Страница 7: ...e operating company Inefficient operation of the equipment All persons involved in the commissioning operation maintenance and servicing of the device must Be suitably qualified Have knowledge of weld...

Страница 8: ...C to 40 C 14 F to 104 F During transport and storage 20 C to 55 C 4 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 substanc...

Страница 9: ...helmet Cuffless pants Protective clothing involves the following Protecting the face and eyes from UV radiation heat and flying sparks with a face guard featuring a regulation compliant filter Wearin...

Страница 10: ...o welding is taking place close the valve of the shielding gas cylinder or the main gas supply Danger from Fly ing Sparks Flying sparks can cause fires and explosions Never undertake welding near flam...

Страница 11: ...tem with ground conductor contact for proper operation Operation of the device on a grid without a ground conductor and on a socket without a ground conductor contact is only permitted if all national...

Страница 12: ...ce complies with the standard limit values for emis sions it may affect the application area for which it was designed e g when there is sensitive equipment at the same location or if the site where t...

Страница 13: ...rom the body devices with wirefeeder and use suitable protective goggles Do not touch the workpiece during or after welding risk of burns Slag may fly off cooling workpieces Therefore also wear regula...

Страница 14: ...condensation point 20 C Max oil content 25 mg m Use filters if necessary Danger from Shielding Gas Cylinders Shielding gas cylinders contain compressed gas and may explode if damaged Shielding gas cy...

Страница 15: ...nce of 0 5 m 1 ft 7 69 in to allow cooling air to circulate unhindered Take care to ensure that the applicable national and regional guidelines and accident prevention regulations are observed when tr...

Страница 16: ...them or that they satisfy safety requirements Use only original spare and wearing parts also applies to standard parts Do not carry out any modifications alterations etc to the device without the man...

Страница 17: ...U The full text of the EU Declaration of Conformity is available on the follow ing website http www fronius com Devices marked with the CSA test mark satisfy the requirements of the relevant stand ard...

Страница 18: ...18...

Страница 19: ...General information 19...

Страница 20: ...20...

Страница 21: ...t welds and profiles in vehicle manufacturing for lap joints and wheel rim welding in automotive engineering in container construction for butt welds longitudinal seams lap joints and circumfer ential...

Страница 22: ...PowerLiner max 10 m 8 2 x power source TPS 500i 600i Welding Package Pulse firmware official_TPSi_2 2 3 20789 15069 ffw and above 9 Cooling unit CU 2000i Pro MC 2 part 10 TWIN Controller RI FB Pro i T...

Страница 23: ...rmware official_robpro 1 8 0 11 2 x grounding cable System require ments and min imum equipment TWIN CMT 1 TWIN welding torch MTB 2x500 A PA or PB TWIN Basic Kit xx 2 CrashBox 3 TWIN hosepack with TWI...

Страница 24: ...version min 2 2 3 TWIN Push or min 3 2 0 TWIN Push Pull CMT Both power sources must have the same software status The IP addresses must be set correctly on the power sources Dimensioning of the robot...

Страница 25: ...cables Shared grounding cable grounding bridge Grounding cable with bifilar winding Grounding cable coiled Further information on connecting the grounding cable can be found from page 97 Note about th...

Страница 26: ...rail power source In the TWIN welding process the two power sources are referred to as the lead power source and trail power source The lead power source is defined by the welding direction During pul...

Страница 27: ...controls to TWIN welding torch change sta tion 6 Power source 1 TPS 500i 600i WP Pulse RI FB Pro i TWIN Controller cooling unit CU 2000i Part 1 remote control RC Panel Pro TU Podium screwed in place...

Страница 28: ...ystem overview 1 2 1 2 1 2 1 2 1 2 1 2 3 6 18 19 17 15 12 13 11 8 21 22 15 24 4 5 10 7 9 10a 20 16 14 25 23 1 Robot controls 2 Connection cable from robot controls to RI FB Pro i TWIN Controller 3 Con...

Страница 29: ...Welding wire drum 2 Depending on the application two WFi R REEL unwinding wirefeeders can be used additionally for optimal wirefeeding 18 Wirefeeding hose 2 WFi R wire buffer 2 19 Control cable wire b...

Страница 30: ...The balancer mounting Y piece can also be used instead of the robot support Y piece 30...

Страница 31: ...System components 31...

Страница 32: ...32...

Страница 33: ...intended exclusively for wirefeeding in automated MIG MAG welding in combination with Fronius system components Any other use does not constitute proper use The manufacturer accepts no liability for a...

Страница 34: ...in 39 118 ipm 360A 100 450A 60 500A 40 I2 1 2 A I11 U11 60 V U12 I12 0 5 A 24 V IEC 60 974 5 10 Cl A IP 23 www fronius com Ser No Part No Do not use the functions described here until you have fully r...

Страница 35: ...Do not reach into rotating gears of the wire drive or into rotating drive parts Covers and side parts must only be opened removed during maintenance and repair work Gears Feed rollers Wirespools and...

Страница 36: ...lectric 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 that is insulated from the floor and work are...

Страница 37: ...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 protection and wear a shirt col lar with button Use a welding helme...

Страница 38: ...terconnecting hosepack W water cooled interconnecting hosepack The interconnecting hosepacks connect the power sources to the TWIN wirefeeder or the two robot wirefeeders In TWIN welding systems one w...

Страница 39: ...welding torch For TWIN Push Pull and TWIN CMT applications the TWIN drive unit is integrated into the torch hosepack Scope of supply MHP 2x500i R W FSC hosepack TWIN Push MHP 2x450i RD W FSC hosepack...

Страница 40: ...for a low force deflection with large deflection path in the event of a crash The clamp system is used to hold the TWIN welding torch If a 45 torch body is used the clamp system positions the welding...

Страница 41: ...part 4 Bellows 5 Cylinder head screws M4 x 16 mm 6 Magnetic ring Mounted on bellows 4 on delivery NOTE Do not assemble the CrashBox i holder 1 and magnetic ring 6 before installing on the robot It is...

Страница 42: ...robot welding torch transfers the arc power to the workpiece The TWIN welding torches are designed for use with the CrashBox i XXL and are available in two versions PA with contact tips arranged one...

Страница 43: ...red for each angle 4 OPT i MTB TWIN 4 0 sym 4 101 105 CK 8 OPT i MTB TWIN 8 0 sym 4 101 108 CK 11 5 OPT i MTB TWIN 11 5 sym 4 101 102 CK NOTE The tilt angle dependent dimensions of the welding torch c...

Страница 44: ...44...

Страница 45: ...Welding Technology Aspects 45...

Страница 46: ...46...

Страница 47: ...volume 30 l min set power source 1 to 15 l min and power source 2 to 15 l min TWIN welding torch TWIN mode both solenoid valves are switched TWIN welding torch single wire mode both solenoid valves ar...

Страница 48: ...ox 100 115 for aluminum applica tions Stick out SO 1 2 3 4 5 D Stick out SO and distance of the wire electrodes depending on the diameter D of the wire electrode D mm inch SO mm inch 1 0 0 039 15 0 59...

Страница 49: ...cess the trail wire electrode moves away from the workpiece and waits for the start signal of the lead wire electrode welding start delay 4 As soon as the trail wire electrode receives the start signa...

Страница 50: ...al 3833 Steel 1 2 mm M21 Ar 15 20 CO2 TWIN PCS 3834 Steel 1 2 mm M20 Ar 5 10 CO2 TWIN PCS 3837 Steel 1 2 mm M21 Ar 15 20 CO2 TWIN multi arc 3838 Steel 1 2 mm M20 Ar 5 10 CO2 TWIN multi arc 3840 Steel...

Страница 51: ...i arc 4024 CrNi19 1 2 mm M12 Ar 2 5 CO2 TWIN universal 4026 CrNi19 1 2 mm M12 Ar 2 5 CO2 TWIN PCS 4027 CrNi18 1 2 mm M12 Ar 2 5 CO2 TWIN universal 4028 CrNi18 1 2 mm M12 Ar 2 5 CO2 TWIN PCS 4030 NiCrM...

Страница 52: ...C CMT Single wire Pulse Standard PMC LSC CMT activation required IMPORTANT There are no TWIN characteristics available for Pulse or Standard welding processes Welding process combinations using Pulse...

Страница 53: ...process The relative position of the pulses droplet detachment is stored in the characteristic but can also be freely selected Significantly different outputs at lead and trail wire electrode The TPS...

Страница 54: ...d in order to weld with a modified spray arc at the lead wire electrode and a pulsed arc at the trail wire electrode Advantages High penetration by the standard arc of the lead wire electrode Large se...

Страница 55: ...for both welding direc tions CMT TWIN CMT TWIN Schematic representation of the material transition In this process variant different characteristics are used for each of the wire electrodes The arc o...

Страница 56: ...resentation of the material trans ition for the lead power source t s I A IL IT 0 PMC Pulse t s I A IL IT 0 LSC Standard t s I A IL IT 0 CMT Welding current time curves and schematic representation of...

Страница 57: ...N welding torches the solenoid valve for the pausing power source is open The solenoid valve is controlled via the power source PMC Pulse LSC Standard and CMT arcs are possible during single wire weld...

Страница 58: ...t the pulse frequency is adjusted in such a way that it differs between lead and trail by an integral multiple Only every second or every third pulse is then executed for the trail arc for example The...

Страница 59: ...an be set between the two pulses as a percentage of the period duration The adjustment range of 0 95 corresponds to a phase shift of 0 342 0 Synchronous mode no phase shift between the two process lin...

Страница 60: ...on delay of 0 2 seconds can be set The start of the trail arc is synchronized The function can be deactivated In this case the trail arc is ignited immediately and is not synchronized Information on t...

Страница 61: ...haracteristic PMC TWIN Universal 3565 a dimension mm Lead L Trail T Wire speed m min Welding current A Welding voltage V Welding speed cm min Energy input kJ cm Deposition rate kg h Sheet thickness mm...

Страница 62: ...0 8 0 L T 24 6 10 1 451 259 27 6 27 9 60 19 6 17 7 15 8 5 L T 20 0 10 0 369 238 24 9 27 4 45 20 9 15 3 15 9 0 L T 22 5 9 5 429 258 27 0 26 9 40 26 5 16 4 15 Standard values for welding posi tion PB NO...

Страница 63: ...thickness mm Micrograph macro 3 5 L T 18 0 10 0 397 241 23 2 26 2 210 4 4 14 3 3 4 0 L T 20 0 11 0 396 266 27 8 29 7 150 6 8 15 9 6 4 5 L T 23 5 11 2 362 229 24 8 26 5 130 6 8 17 7 6 5 0 L T 20 5 11...

Страница 64: ...64...

Страница 65: ...Operating controls connections and mechanical components 65...

Страница 66: ...66...

Страница 67: ...Air in 1 1 2 2 1 2 2 1 8 10 9 11 12 No Function 1 Welding torch connection 1 For connecting the welding torch 2 Current socket with fine thread 1 For connecting the power cable from the interconnectin...

Страница 68: ...required gas volume on the pressure regulator 3 Wire return button 1 retract the wire electrode without gas or current 4 Wire threading button 1 for threading the wire electrode into the torch hosepac...

Страница 69: ...s retracting the wire electrode if the wire return button is kept pressed down then the speed increases with each further second by 10 m min 393 70 ipm until the preset wire return speed is reached Op...

Страница 70: ...ectrode meets a ground earth connection then the wirefeeding is stopped and the wire electrode is retracted again by 1 mm 0 039 in NOTE If there is a ground earth connection with the contact tip befor...

Страница 71: ...understand all safety rules and user documentation for this equipment and all system components MHP 2x450i RD W FSC incl WF 60i TWIN Drive W mech anical compon ents 1 2 3 4 5 6 7 8 9 Mechanical compon...

Страница 72: ...elected 5 Mode button for selecting the modes 1 2 TWIN External Mode 1 Wire return gas testing and wire threading are only carried out on welding line 1 Mode 2 Wire return gas testing and wire threadi...

Страница 73: ...onnecting Hosepack Con nections 1 2 3 4 1 4 3 1 2 W 1 3 4 1 4 3 2 G W water cooled interconnecting hosepack G gas cooled interconnecting hosepack 1 SpeedNet cable 2 Coolant hoses 3 Protective gas shie...

Страница 74: ...74...

Страница 75: ...Installation and commissioning TWIN Push 75...

Страница 76: ...76...

Страница 77: ...y rules WARNING An electric shock can be fatal Before starting the described work Switch the power switch on the power source to O Disconnect the power source from the grid Ensure that the power sourc...

Страница 78: ...ire electrode that comes into contact with an electrically conductive object during the welding process a lack of insulation between the wire electrode and the grounded housing limit of a robot cell c...

Страница 79: ...its on the upright brackets and correctly positioned and fastened in the welding cell The TWIN Controller is available and fastened close to the power sources e g us ing a corresponding bracket direct...

Страница 80: ...lding wire drums 2 Connect wirefeeding hoses to the TWIN wirefeeder 3 Insert the feed rollers 4 Close all covers Defining welding lines 1 and 2 on the power sources 1 Switch on power source 2 leave po...

Страница 81: ...ons for the wirefeeder holder 1 7x 7 x 6 mm Allen screws Tightening torque 20 Nm 2 6 x 6 mm Allen screws NL wedge lock washers Tightening torque 20 Nm Install hosepack holder 3 2 x 5 mm Allen screws N...

Страница 82: ...Installing the side holders for the in terconnecting hosepacks on the robot 1 2 2 1 Installation of the side holder depends on the robot Follow the Installation Instruc tions 82...

Страница 83: ...T When connecting the interconnecting hosepacks observe marks 1 and 2 on the interconnecting hosepacks and on the wirefeeder 1 water cooled interconnecting hosepack 2 gas cooled interconnecting hosepa...

Страница 84: ...ing hosepack 2 gas cooled interconnecting hosepack NOTE If the interconnecting hosepack is laid incorrectly it can have a significant influ ence on the welding results a stable welding process is not...

Страница 85: ...i 2 power source 2 HP CON 1 interconnecting hosepack 1 HP CON 2 interconnecting hosepack 2 Connecting the TWIN Controller to the robot con trols 1 1 R C 1 R C robot controls NOTE For detailed informat...

Страница 86: ...on the robot 1 Observe the torques when fitting the robot flange Max tightening torque for screws with 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 1...

Страница 87: ...1 Observe the torques when fitting the robot flange Max tightening torque for screws with 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...

Страница 88: ...43 lb ft 2 6 Nm 4 43 lb ft 3 Installing the in ner liner in the torch hosepack NOTE So that the inner liner can be correctly installed lay the hosepack out straight when installing the inner liner 1 1...

Страница 89: ...at the front in the hosepack IMPORTANT The screws for securing the inner liners must not be loosened 1 2 2 2x 5 2x 6 Screw the clamping nipple onto the inner liner up to the stop The inner liner need...

Страница 90: ...connecting the torch hosepack pay attention to marks 1 and 2 on the torch hosepack and on the wirefeeder 1 3 1 1 4 1 2 5 Connect coolant hoses from the welding torch according to the color markings o...

Страница 91: ...Prepare torch body with steel inner liner 1 2 NOTE The coupling area of the torch body must always be free of oil grease and dust and be dry 3 4 5 6 91 EN US...

Страница 92: ...7 8 9 10 11 12 92...

Страница 93: ...Installing wearing parts in the TWIN welding torch 1 6 2 2 4 9 8 3 5 7 1 NOTE For detailed information refer to the In stallation Instructions 42 0410 2487 OPT i TWIN 0 4 8 11 5 93 EN US...

Страница 94: ...all the torch body coupling NOTE The coupling areas between the torch body coupling and torch body must always be free of oil grease and dust and be dry 1 2 3 BY2 0201 4863 1 2 0 N m 2 1 42 0411 1315...

Страница 95: ...and closes correctly check the manual locking of a torch body in the torch body coupling Flawless operation of the interchangeable coupling can only be guaranteed with a vertic al alignment facing do...

Страница 96: ...1 2 4 1 5 96...

Страница 97: ...Connect the grounding cable NOTE If the grounding cables are laid incorrectly it can have a significant influence on the welding results a stable welding process is not guaranteed As far as possible m...

Страница 98: ...ers which match the wire electrode An overview of the available feed rollers and their possible uses can be found in the Spare Parts Lists Inserting chan ging feed rollers CAUTION Danger due to feed r...

Страница 99: ...ct the ground earth connection between the welding system and workpiece CAUTION Danger of damage to the welding torch due to sharp edged end of the wire elec trodes Thoroughly deburr the end of the wi...

Страница 100: ...at the tip of the welding torch points away from the face and body Wear suitable protective goggles Do not point the welding torch at people Ensure that the wire electrodes do not touch any electrical...

Страница 101: ...values on the sticker on the protective cover to adjust the contact pressure Contact pressure standard values steel rollers Steel 4 5 CrNi 4 5 Al 0 5 1 5 Tubular covered electrodes 2 3 Contact pressur...

Страница 102: ...wirefeeder or to the TWIN drive unit Feed rollers corresponding to the wire electrodes to be welded must be inserted in the wirefeeder or the TWIN drive unit Wire electrodes must be threaded in Contac...

Страница 103: ...Installation and commissioning TWIN Push Pull CMT 103...

Страница 104: ...104...

Страница 105: ...y rules WARNING An electric shock can be fatal Before starting the described work Switch the power switch on the power source to O Disconnect the power source from the grid Ensure that the power sourc...

Страница 106: ...re electrode that comes into contact with an electrically conductive object during the welding process a lack of insulation between the wire electrode and the grounded housing limit of a robot cell ch...

Страница 107: ...are stable on a flat and solid surface The system components have been tested according to at least protection class IP 20 This means Protection against the penetration of solid foreign bodies with a...

Страница 108: ...on the Y piece or mount the support Y piece on the robot 2 Mount the side holder on the robot Only for TWIN CMT applications 3 Install wire buffer on the wire buffer holder 4 Install wire buffer with...

Страница 109: ...Connect wirefeeding hoses B to the robot wirefeeders 4 Connect wirefeeding hoses B to the wire buffers 5 Connect control lines to the robot wirefeeders and to the wire buffers 6 Connect wirefeeding h...

Страница 110: ...6 If necessary carry out system calibration e g if there is a WF REEL unwinding wirefeeder in the system 7 Define the lead trail signal on the robot controls 8 Set TWIN parameters 110...

Страница 111: ...nting the balancer mounting on the Y piece Mounting the bal ancer mounting on the Y piece The balancer mounting Y piece is mainly used for TWIN Push Pull systems without wire buffers 1 2 3 4 1 111 EN...

Страница 112: ...Mounting the support Y piece on the robot Mounting the support Y piece on the robot 1 2 2 2 2 1 Installation of the support Y piece depends on the robot Follow the Installation Instructions 112...

Страница 113: ...robot Installing the side holder on the ro bot The side holder is mainly used for TWIN Push Pull systems without wire buffers 1 2 2 1 Installation of the side holder depends on the robot Follow the In...

Страница 114: ...Installing wire buffers on the robot TWIN CMT in stalling wire buf fers on the robot Installation of the side holder depends on the robot Follow the Installation Instructions 1 2 3 114...

Страница 115: ...4 NOTE For detailed information on the wire buffer refer to the Operating Instructions 42 0410 1254 wire buffer 115 EN US...

Страница 116: ...o the wirefeeder IMPORTANT When connecting the interconnecting hosepacks observe marks 1 and 2 on the interconnecting hosepacks and on the wirefeeder 1 water cooled interconnecting hosepack 2 gas cool...

Страница 117: ...hosepack 2 gas cooled interconnecting hosepack NOTE If the interconnecting hosepack is laid incorrectly it can have a significant influ ence on the welding results a stable welding process is not guar...

Страница 118: ...TPSi 2 power source 2 HP CON 1 interconnecting hosepack 1 HP CON 2 interconnecting hosepack 2 Connecting the TWIN Controller to the robot con trols 1 1 R C 1 R C robot controls NOTE For detailed infor...

Страница 119: ...e robot 1 Observe the torques when fitting the robot flange Max tightening torque for screws with 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...

Страница 120: ...he robot 1 Observe the torques when fitting the robot flange Max tightening torque for screws with 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...

Страница 121: ...t is already mounted on the torch hosepack on delivery To make things simpler the TWIN drive unit is shown without the torch hosepack in the following illustrations 1 M6 M8 M6 Tightening torque M6 10...

Страница 122: ...pin 2x Tightening torque 25 Nm 18 44 lb ft 4 5 6 Connect the CrashBox cable to the drive unit and to the CrashBox Mounting the Y piece from the torch hosepack on the robot support Y piece 3 2 1 1 1 2...

Страница 123: ...osepacks during any movement in a robot axis Route hosepacks in a loop Connecting the torch hosepack to the wirefeeder IMPORTANT When connecting the torch hosepack pay attention to marks 1 and 2 on th...

Страница 124: ...gs are mounted in vulnerable areas Bridging of cracks or damaged areas on the corrugated protective hose Connection of Y piece to the corrugated protective hose The anti kink protection rings may only...

Страница 125: ...Prepare torch body with steel inner liner 1 2 NOTE The coupling area of the torch body must always be free of oil grease and dust and be dry 3 4 5 6 125 EN US...

Страница 126: ...7 8 9 10 11 12 126...

Страница 127: ...be free of oil grease and dust and be dry 1 Carry out a visual inspection to check that the springs are present 2 Insert inner liner pieces with a length of 74 mm into the TWIN drive unit The inner l...

Страница 128: ...TWIN drive unit NOTE The coupling areas between the torch body coupling and torch body must always be free of oil grease and dust and be dry 5 1 4 2 1 1 3 6 6 6 3 3 1 The next steps are the same as f...

Страница 129: ...and closes correctly check the manual locking of a torch body in the torch body coupling Flawless operation of the interchangeable coupling can only be guaranteed with a vertic al alignment facing do...

Страница 130: ...1 2 4 1 5 130...

Страница 131: ...eeder press white button 2 Fit the collet 3 Insert the inner liner until it is visible at the sight hole of the drive unit 4 Cut the inner liner flush to length 5 Fit the inlet nozzle to the brass sec...

Страница 132: ...y Connect the grounding cable NOTE If the grounding cables are laid incorrectly it can have a significant influence on the welding results a stable welding process is not guaranteed As far as possible...

Страница 133: ...wire alloy to be welded NOTE Danger due to deficient feed rollers This can result in poor quality weld properties Only use feed rollers which match the wire electrode An overview of the available fee...

Страница 134: ...commissioning Connecting wirefeeding hoses Connect the wirefeeding hoses in the same way as on the TWIN Push system see page 99 The following wirefeeding hoses are required Wire drum robot wirefeeder...

Страница 135: ...re in such a way that the wire electrode is not deformed but nevertheless ensures proper wirefeeding Use the specified standard values on the sticker on the protective cover to adjust the contact pres...

Страница 136: ...wirefeeder or to the TWIN drive unit Feed rollers corresponding to the wire electrodes to be welded must be inserted in the wirefeeder or the TWIN drive unit Wire electrodes must be threaded in Contac...

Страница 137: ...Troubleshooting Maintenance and Disposal 137...

Страница 138: ...138...

Страница 139: ...s and components involved so they cannot be switched back on After opening the device use a suitable measuring instrument to check that electric ally charged components such as capacitors have been di...

Страница 140: ...pack faulty or not connected correctly Check interconnecting hosepack No communication with the robot controls Check the communication with the robot controls Cause Remedy Cause Remedy No welding curr...

Страница 141: ...ck coolant level coolant flow rate coolant contamination etc For more detailed information refer to the Operating Instructions for the cooling unit Cause Remedy Cause Remedy Poor quality weld properti...

Страница 142: ...nected correctly Check the connection between the torch hosepack and the TWIN wirefeed er if the torch hosepack is connected correctly inform the service team Cause Remedy 16768 Welding process does n...

Страница 143: ...Check that power source 1 is connected to port 1 and power source 2 is connected to port 2 on the TWIN Controller Cause Remedy 18232 It is not possible to thread the wire or weld in TWIN mode Single w...

Страница 144: ...ices and components involved so they cannot be switched back on After opening the device use a suitable measuring instrument to check that electric ally charged components such as capacitors have been...

Страница 145: ...air nozzle too close to electronic parts Open covers dismantle device side panels and blow the inside of the device clean with dry reduced compressed air After cleaning restore the system to its origi...

Страница 146: ...146...

Страница 147: ...Technical data 147...

Страница 148: ...148...

Страница 149: ...ing gas 7 bar 101 53 psi Coolant Original Fronius Maximum pressure of coolant 5 bar 72 53 psi Wire speed 1 30 m min 39 37 1181 10 ipm Wire drive 4 roller drive Recommended wire diameter 1 2 1 6 mm 0 0...

Страница 150: ...x Wire electrode distance H Height Angle of curvature L Length 11 5 30 PB PA 45 PB PA SO mm L1 mm s mm x mm L mm H mm L mm H mm 15 60 56 10 44 7 43 327 14 82 00 336 92 136 75 16 61 55 10 44 7 23 328...

Страница 151: ...22 67 89 13 65 10 58 333 49 85 67 342 27 140 42 23 68 89 13 65 10 44 334 35 86 17 344 13 140 92 4 0 30 PB PA 45 PB PA SO mm L1 mm s mm x mm L mm H mm L mm H mm 15 61 24 17 32 16 27 327 73 82 34 337 51...

Страница 152: ...re diameter 0 8 1 2 mm 0 032 0 047 inches MTB 330i W R TX TXM Welding current at 10 min 40 C M21 EN 439 C1 EN 439 100 ED 330 A 100 ED 330 A Wire diameter 0 8 1 6 mm 0 032 0 063 inches MTB 400i W R TX...

Страница 153: ...EN 439 C1 EN 439 100 ED 500 A 100 ED 500 A Wire diameter 1 0 1 6 mm 0 039 0 063 inches 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 diameter...

Страница 154: ...m 5 ft 1 02 in 1 75 m 5 ft 8 90 in 2 3 m 7 ft 6 55 in 3 3 m 10 ft 9 92 in 1200 W 1250 W 1300 W 1400 W 1700 W Minimum coolant flow rate 1 l min 0 26 gal US min Min coolant pressure 3 bar 43 50 psi Max...

Страница 155: ...C1 EN 439 100 ED 2 x 450 A standard 100 ED 2 x 280 A CMT 100 ED 2 x 450 A standard 100 ED 2 x 360 A CMT Wire diameter 0 8 1 6 mm 0 03 0 06 inches Minimum coolant flow Qmin 1 l min 0 26 gal US min Min...

Страница 156: ...D Duty cycle HP 70i HP PC Cable HD 70 Welding current at 10 min 40 C 104 F 60 ED 600 A 100 ED 500 A ED 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 Du...

Страница 157: ...tance diagram Item number 44 0350 3380 Degree of repeatability 1 0 05 mm a Triggering torques in x y direction See table on the next page Maximum displacement in x y direction 45 Weight 1250 g Dimensi...

Страница 158: ...x i 44 0350 3589 CrashBox i PAP 44 0350 3663 distance to the robots flange mm 125 CrashBox i XXL 44 0350 3380 CrashBox 44 0350 3760 The values listed only apply when in a static state x y direction 45...

Страница 159: ...159 EN US...

Страница 160: ...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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