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Technical data

LaserHybrid Ul-
tracompact Twin
(laser welding
head)

LaserHybrid Ul-
tracompact Twin
hosepack

The product conforms to the requirements of the IEC 60974-7 standard.

Weight (without laser optics system)

8 kg

Laser optics

Trumpf BEO D35 / F300

Duty cycle of the laser optics 100% at 4 kW and per minute
*60% at 6 kW and per minute
Dimensions

360 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 °C)
M21 (EN439)
C1 (EN439)

2 x 300 A
2 x 300 A

Wire diameter

1.0 - 1.6 mm

Voltage measurement (V-Peak)

141 V

Hosepack length

7.5 m

Cooling system

Liquid cooling

Coolant

Original Fronius coolant

Lowest cooling capacity in accordance with IEC 60974-2,
depending on the length of the hosepack

1800 W

Min./max. coolant pressure

3.0 / 5.5 bar

Min. coolant flow

1.0 l/min

Содержание LaserHybrid Ultracompact Twin

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

Страница 2: ...2...

Страница 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...

Страница 4: ...4...

Страница 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...

Страница 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...

Страница 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...

Страница 8: ...8...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 18: ...18...

Страница 19: ...General information...

Страница 20: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 34: ...34...

Страница 35: ...Control elements and connections...

Страница 36: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 41: ...Start up...

Страница 42: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 76: ...76...

Страница 77: ...Maintenance...

Страница 78: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 110: ...110...

Страница 111: ...Appendix...

Страница 112: ......

Страница 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...

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

Страница 115: ...115...

Страница 116: ...116...

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Страница 118: ...118...

Страница 119: ...119...

Страница 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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