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WireSense

General

If OPT/i WireSense software activation is available on the power source, the sur-
face, edges and weld seams of a workpiece can be measured with the wire elec-
trode.
The wire electrode functions as a sensor that can precisely scan a component by
means of high-frequency reversing wire movement.
Component geometries are recorded and the position of the individual sheets in
relation to each other is precisely determined.

Advantages:

-

Quick and easy reaction to real component deviations

-

No re-training - time and cost savings

-

No additional hardware and a cost-effective alternative to laser sensors or
other optical measuring systems

-

No need to calibrate TCP and sensor

-

Robust and compact measuring system without additional 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 Reel.

The CMT Welding Package is not required for the WireSense function.

How it works

A sensor voltage with limited current is applied to the wire electrode. If the wire
electrode touches the component, a short circuit is created without welding. The
short circuit is broken again by lifting the wire electrode.
The change in position of the wire electrode up to the short circuit is analysed by
the power source and sent as a height measurement signal to the robot control.

The height measurement signal is compared with the current position data of the
robot control.
If there are differences, the robot can correct the Tool Center Point (TCP) or the
respective coordinate system and compensate component position changes ac-
cordingly.

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Содержание Pull

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

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 21: ...System configurations 21...

Страница 22: ...22...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 41: ...System components 41...

Страница 42: ...42...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 68: ...68...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 86: ...86...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 102: ...102...

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

Страница 104: ...104...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

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

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

Страница 114: ...6 114...

Страница 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...

Страница 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...

Страница 117: ...3 4 117 EN...

Страница 118: ...118...

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

Страница 120: ...120...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 128: ...2 128...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

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

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

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

Страница 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...

Страница 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...

Страница 143: ...Start up 143...

Страница 144: ...144...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 151: ...2 1 11 12 151 EN...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 156: ...156...

Страница 157: ...Troubleshooting maintenance and disposal 157...

Страница 158: ...158...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

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

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

Страница 175: ...Technical data 175...

Страница 176: ...176...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 195: ...195 EN...

Страница 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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