Fronius LaserHybrid Ultracompact Twin Operating Instructions Manual

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LaserHybrid Ultracompact Twin

Operating Instructions

LaserHybrid

42,0426,0255,EN 003-16082017

Dear reader,

Introduction Thank you for the trust you have placed in our company and congratulations on buying this

high-quality Fronius product. These instructions will help you familiarise yourself with 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 safety rules to ensure greater safety when using the product. Careful handling of the product will repay you with years of safe and reliable operation. These are essential prerequisites for excellent results.

Contents

Safety rules ................................................................................................................................................ 9

Explanation of safety symbols .............................................................................................................. 9

General ................................................................................................................................................. 9

Proper use ............................................................................................................................................ 10

Environmental conditions...................................................................................................................... 10

Obligations of the operator.................................................................................................................... 10

Obligations of personnel ....................................................................................................................... 11

Personal protective equipment ............................................................................................................. 11

Danger from toxic gases and vapours .................................................................................................. 11

Danger from escaping shielding gas..................................................................................................... 12

Danger from flying sparks ..................................................................................................................... 12

Hazards from welding current ............................................................................................................... 12

Vagrant welding currents ...................................................................................................................... 13

EMC measures ..................................................................................................................................... 13

Specific hazards.................................................................................................................................... 14

Informal safety measures...................................................................................................................... 15

Safety measures at the installation location.......................................................................................... 15

Safety measures in normal operation ................................................................................................... 16

Safety inspection................................................................................................................................... 16

Alterations ............................................................................................................................................. 16

Replacement and wearing parts ........................................................................................................... 17

Calibration of power sources ................................................................................................................ 17

CE marking ........................................................................................................................................... 17

Copyright............................................................................................................................................... 17

General information 19

General ...................................................................................................................................................... 21

General ................................................................................................................................................. 21

Proper use/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 required for the laser-twin welding process ............... 24

Power source synchronisation .............................................................................................................. 24

Software activation................................................................................................................................ 24

Mechanical requirements...................................................................................................................... 25

Dimensioning of the robot ..................................................................................................................... 25

Functional principle .................................................................................................................................... 26

Functional principle ............................................................................................................................... 26

Lead power source and trail power source ........................................................................................... 26

Welding technology aspects ...................................................................................................................... 27

Welding technology aspects ................................................................................................................. 27

Earth connection ................................................................................................................................... 27

Welding circuit inductivity L, welding circuit resistance r....................................................................... 27

Tilt angle of the welding torch ............................................................................................................... 28

Possible arc combinations .................................................................................................................... 28

Pulse/Pulse ........................................................................................................................................... 28

Connecting to the robot control.................................................................................................................. 30

Robot interfaces for the laser-twin welding process ............................................................................. 30

Standard robot interfaces...................................................................................................................... 31

Twin fieldbus systems .......................................................................................................................... 32

Standard fieldbus systems.................................................................................................................... 33

Control elements and connections 35

Description of the device............................................................................................................................ 37

Description of the device....................................................................................................................... 37

Connection specifications .......................................................................................................................... 39

Connection specifications ..................................................................................................................... 39

Compressed air diagram....................................................................................................................... 40

Start-up 41

General ...................................................................................................................................................... 43

Safety.................................................................................................................................................... 43

Setup regulations .................................................................................................................................. 43

Mains connection .................................................................................................................................. 43

Assembling a laser-twin system............................................................................................................ 43

Commissioning (overview).................................................................................................................... 45

Fitting the laser welding head to the robot ................................................................................................. 46

Requirements for the robot ................................................................................................................... 46

Fitting the laser welding head to the robot ............................................................................................ 46

Connecting the LaserHybrid Ultracompact Twin hosepack to the laser welding head .............................. 47

Preparatory work................................................................................................................................... 47

Connecting the LaserHybrid Ultracompact Twin hosepack to the laser welding head ......................... 48

Connect/replace the external wirefeeding hoses on the laser welding head ........................................ 52

And finally... .......................................................................................................................................... 53

Connecting the laser optics system, Crossjet and additional extractor...................................................... 54

Connecting the laser optics system ...................................................................................................... 54

Connecting the Crossjet and additional extractor ................................................................................. 56

Laying the hosepack on the robot.............................................................................................................. 57

Laying the hosepack on the robot......................................................................................................... 57

Threading the wire electrode ..................................................................................................................... 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 radial air flow....................................................................................................................... 64

Adjusting the laser welding head ............................................................................................................... 67

Stick out ................................................................................................................................................ 67

Adjustable axes..................................................................................................................................... 67

Adjusting device on the laser welding head.......................................................................................... 68

Adjusting the x-axis............................................................................................................................... 68

Adjusting the y-axis............................................................................................................................... 69

Creating a reference program.................................................................................................................... 70

Safety.................................................................................................................................................... 70

General ................................................................................................................................................. 70

Creating a reference program............................................................................................................... 70

Signal sequence for LaserHybrid welding.................................................................................................. 72

Safety.................................................................................................................................................... 72

Signal sequence for LaserHybrid welding............................................................................................. 72

Measures to be taken before the start of welding ...................................................................................... 74

Measures to be taken before the start of welding ................................................................................. 74

Parameter settings on the power source .............................................................................................. 74

Recommendations for operating a laser-twin welding system................................................................... 75

Recommendations for operating a laser-twin welding system.............................................................. 75

Maintenance 77

Changing the wire electrode ...................................................................................................................... 79

Preparatory work................................................................................................................................... 79

Unthreading the wire electrode ............................................................................................................. 80

Changing the wire electrode ................................................................................................................. 82

Replacing wearing parts ............................................................................................................................ 83

Preparatory work................................................................................................................................... 83

Removing the feed rollers ..................................................................................................................... 83

Replacing the inlet nozzles ................................................................................................................... 86

Replacing and installing the feed rollers ............................................................................................... 86

Replacing the welding torch and welding torch inner liners ....................................................................... 88

Safety.................................................................................................................................................... 88

Preparatory work................................................................................................................................... 88

Replace the welding torch..................................................................................................................... 89

Replacing the welding torch inner liners ............................................................................................... 90

Replacing welding torch wearing parts ...................................................................................................... 91

Safety.................................................................................................................................................... 91

Welding torch spare parts ..................................................................................................................... 91

Removing the welding torch wearing parts ........................................................................................... 91

Fitting the welding torch wearing parts ................................................................................................. 93

Replacing the spatter guard sheet ............................................................................................................. 95

Removing the spatter guard plate......................................................................................................... 95

Fitting the spatter guard plate ............................................................................................................... 95

Replacing the laser optics system ............................................................................................................. 97

Safety.................................................................................................................................................... 97

Preparatory work................................................................................................................................... 97

Removing the laser optics system ........................................................................................................ 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 setting the position of the wire electrode in relation to the focus point

of the laser .................................................................................................................................................

Safety.................................................................................................................................................... 106

General ................................................................................................................................................. 106

Checking the position of the wire electrode in relation to the focal spot of the laser ............................ 106

Example: Using the reference program after changing the welding torch ............................................ 107

Measures to reduce optics contamination ................................................................................................. 108

Measures to reduce optics contamination ............................................................................................ 108

106

Appendix 111

Technical data............................................................................................................................................ 113

LaserHybrid Ultracompact Twin(laser welding head) ........................................................................... 113

LaserHybrid Ultracompact Twin hosepack ........................................................................................... 113

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

Safety rules

Explanation of safety symbols

General

DANGER! Indicates immediate and real danger. If it is not avoided, death or se-

rious injury will result.

WARNING! Indicates a potentially dangerous situation. Death or serious injury may result if appropriate precautions are not taken.

CAUTION! Indicates a situation where damage or injury could occur. If it is not avoided, minor injury and/or damage to property may result.

NOTE! Indicates a risk of flawed results and possible damage to the equipment.

IMPORTANT! Indicates tips for correct operation and other particularly useful information.

It does not indicate a potentially damaging or dangerous situation.

If you see any of the symbols depicted in the "Safety rules" chapter, special care is required.

The LaserHybrid head is manufactured using state-of-the-art technology and according to recognised safety standards. If used incorrectly or misused, however, it can cause:

- injury or death to the operator or a third party,

- damage to the LaserHybrid head 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 suitably qualified,

- have sufficient knowledge of welding and

- carefully observe these operating instructions as well as the operating instructions for the following system components: the laser the laser optics system the power source and its wirefeeder the robot and its control system

The operating instructions must always be at hand wherever the LaserHybrid head is being used. In addition to the operating instructions, attention must also be paid to any generally applicable and local regulations regarding accident prevention and environmental protection.

All safety and danger notices on the LaserHybrid head

- must be in a legible state,

- must not be damaged,

- must not be removed,

- must not be covered, pasted or painted over.

For the location of the safety and danger notices on the LaserHybrid head, refer to the "General" section in the operating instructions for your LaserHybrid head. Before switching on the device, rectify any faults that could compromise safety.

This is for your personal safety!

Proper use

The LaserHybrid head is to be used exclusively for its intended purpose. The LaserHybrid head is intended solely for use in LaserHybrid welding of aluminium, CrNi and steel materials. Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage.

Proper use also includes:

- carefully reading and following all the instructions given in the operating instructions

- studying and obeying all safety and danger notices carefully

- performing all stipulated inspection and servicing work.

Never attempt to use the LaserHybrid head or the power source being used for thawing frozen pipes.

The LaserHybrid head is designed for use in industry and the workshop. The manufacturer accepts no responsibility for any damage caused through use in a domestic setting. The manufacturer likewise accepts no liability for inadequate or incorrect work results.

Environmental conditions

Obligations of the operator

Operation or storage of the LaserHybrid head outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage.

Ambient air temperature range:

- during operation: -10 °C to + 40 °C (14 °F to 104 °F)

- during transport and storage: -25 °C to + 55 °C (-13 °F to 131 °F)

Relative humidity:

- up to 50% at 40 °C (104 °F)

- up to 90% at 20 °C (68 °F)

The ambient air must be free from dust, acids, corrosive gases or substances, etc. Can be used at altitudes up to 2000 m (6561 ft. 8.16 in.)

The operator must only allow persons to work with the LaserHybrid head who:

- are familiar with the fundamental instructions regarding safety at work and accident prevention and have been instructed in how to use the LaserHybrid head

- have read and understood these operating instructions, especially the "Safety rules" section, and have confirmed as much with their signatures

- are trained to produce the required results.

Checks must be carried out at regular intervals to ensure that operators are working in a safety-conscious manner.

Obligations of personnel

Before starting work, all persons using the LaserHybrid head undertake:

- to observe the basic instructions regarding safety at work and accident prevention

- to read these operating instructions, especially the "Safety rules" section and sign to confirm that they have understood them and will follow them.

Before leaving the workplace, ensure that people or property cannot come to any harm in your absence.

Personal protective equipment

For your personal safety, take the following precautions:

Persons in the closed cell for the LaserHybrid process must:

wear solid footwear that provides insulation even in wet conditions

protect their hands by wearing suitable gloves (electrically insulated and heatproof)

protect their eyes from laser beams by wearing regulation-compliant laser safety goggles. In addition, they must protect their faces and eyes from UV rays 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 protection class 4, they should not look into the laser beam.

only wear suitable (i.e. flame-retardant) clothing

Danger from toxic gases and vapours

use ear protectors to protect them from the cross-jet noise (120 dbA)

If other persons are in the closed cell for the LaserHybrid process, you must:

- make them aware of all the dangers that may occur during operation (e.g. risk of a build-up of gases that are detrimental to health, possible risk of suffocation due to lack of oxygen in the air, danger from laser light, etc.)

- provide them with protective equipment

- erect safety screens or curtains

The fumes produced during welding contain harmful gases and vapours.

Welding fumes contain substances that may, under certain circumstances, cause birth defects or cancer.

Keep your face away from welding fumes and gases.

Fumes and hazardous gases

- must not be breathed in

- must be extracted from the working area using appropriate methods.

Ensure an adequate supply of fresh air.

Otherwise, a protective mask with an air supply must be worn.

Close the shielding gas cylinder valve or main gas supply if no welding is taking place.

If there is any doubt about whether the extraction capacity is sufficient, the measured toxic emission values should be compared with the permissible limit values.

The following components are responsible, amongst other things, for the degree of toxicity of welding fumes:

- Metals used for the workpiece

- Electrodes

- Coatings

- Cleaners, degreasers, etc.

The relevant material safety data sheets and manufacturer's specifications for the listed components should therefore be studied carefully.

Flammable vapours (e.g. solvent fumes) should be kept away from the radiation area of the laser and the arc.

Danger from escaping shielding gas

Danger from flying sparks

Risk of suffocation from the uncontrolled escape of shielding gas

Shielding gas is colourless and odourless and, in the event of a leak, can displace the oxygen in the ambient air.

- Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/hour.

- Observe safety and maintenance instructions on the shielding gas cylinder 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 main gas supply for uncontrolled gas leakage before every start-up.

Flying sparks may cause fires or explosions.

Never weld close to flammable materials.

Flammable materials must be at least 11 m (35 ft.) away from the LaserHybrid welding process, or alternatively covered with an approved cover.

A suitable, tested fire extinguisher must be available and ready for use.

Sparks and pieces of hot metal may also get into adjacent areas through small gaps or openings. Take appropriate precautions to prevent any danger of injury or fire.

Welding must not be performed in areas that are subject to fire or explosion or near sealed tanks, vessels or pipes unless these have been prepared in accordance with the relevant national and international standards.

Do not carry out welding on containers that are being or have been used to store gases, propellants, mineral oils or similar products. Residues pose an explosive hazard.

Hazards from welding current

An electric shock can be fatal. Every electric shock is hazardous to life.

All welding cables must be firmly attached, undamaged and properly insulated. Replace any loose connections and scorched cables immediately.

Vagrant welding currents

If the following instructions are ignored, vagrant welding currents may occur. These can destroy earthed conductor terminals, the power source being used, the LaserHybrid welding head and other electrical equipment.

Ensure the workpiece clamp is connected tightly to the workpiece. On electrically conductive floors, the power source must be set up in such a way as to be insulated from the floor, wherever possible.

EMC measures

Warning, electromagnetic field. Electromagnetic fields may cause as yet

unknown damage to health.

It is the operator's responsibility to ensure that no electromagnetic interference occurs in electrical and electronic devices.

If electromagnetic interference is found to be occurring, the owner/operator is obliged to take all necessary measures to prevent this interference.

Check for possible problems, and check and evaluate neighbouring devices' resistance to interference according to national and international requirements:

- Safety devices

- Power, signal and data transfer lines

- IT and telecommunications devices

- Measuring and calibrating devices

- The health of persons in the vicinity, e.g. users of pacemakers and hearing aids

Individuals with pacemakers must seek advice from their doctor before approaching the welding work area.

Supporting measures for avoidance of EMC problems: a) Mains supply

- If electromagnetic interference arises despite the correct mains con-

nection, additional measures are necessary (e.g. use of a suitable line filter)

b) Welding power-leads

- must be kept as short as possible

- must be laid close together (also to avoid EMC problems)

- must be laid apart from other leads

c) Equipotential bonding d) Earthing of the workpiece

- If necessary, establish an earth connection using suitable capacitors.

e) Shielding, if necessary

- Shield off other nearby devices

- Shield off entire welding installation

Specific hazards

Risk of injury to the eyes from the laser beam. In addition to the protective visor with regulation UV filter element, ensure that all persons wear regulation laser safety goggles to protect their eyes from laser beams. You should still ensure that nobody can accidentally look into the laser beam.

With highly shiny, reflective workpiece surfaces, there is a further danger caused by reflected and scattered laser radiation. Suitable precautions must be taken to ensure that all persons in the area are sufficiently protected from scattered laser radiation.

Keep hands, hair, clothing and tools away from moving parts. For example:

- Fans

- Cogs

- Rollers

- Shafts

- Wirespools and welding wires

Do not reach into the rotating cogs of the wire drive or into rotating drive components.

Covers and side panels may only be opened or removed for as long as 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 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 with wire-feed unit) and wear suitable protective goggles.

Never touch the workpiece during or after welding - risk of burns.

Slag can jump off cooling workpieces. The specified protective equipment must therefore also be worn when reworking workpieces, and steps must be taken to ensure that other people are also adequately protected.

Welding torches and other parts with a high operating temperature must be allowed to cool down before handling.

Special provisions apply in areas at risk of fire or explosion

- observe relevant national and international regulations.

Power sources for work in areas with increased electric risk (e.g. near boilers) must carry the "Safety" sign. However, the power source must not be located in such areas.

Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting coolant flow or return lines.

Observe the information on the coolant safety data sheet when handling coolant. The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer's website.

Use only suitable load-carrying equipment supplied by the manufacturer when transporting devices by crane.

- Hook chains or ropes onto all suspension points provided on the load-carrying equipment.

- Chains and ropes must be at the smallest angle possible to the vertical.

- Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).

If the wirefeeder is attached to a crane holder during welding, always use a suitable, insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).

If the device has a carrying strap or handle, this is intended solely for carrying by hand. The carrying strap is not to be used if transporting with a crane, counterbalanced lift truck or other mechanical hoist.

All lifting accessories (straps, handles, chains, etc.) used in connection with the device or its components must be tested regularly (e.g. for mechanical damage, corrosion or changes caused by other environmental factors). The testing interval and scope of testing must comply with applicable national standards and directives as a minimum.

Odourless and colourless shielding gas may escape unnoticed if an adapter is used for the shielding gas connection. Prior to assembly, seal the deviceside thread of the adapter for the shielding gas connection using suitable Teflon tape.

Informal safety measures

Safety measures at the installation location

The operating instructions must always be at hand wherever the LaserHybrid head is being used.

In addition to the operating instructions, any generally applicable and local regulations regarding accident prevention and environmental protection must be provided and followed.

All safety and danger notices on the LaserHybrid head must be kept in a legible condition.

The cell for the LaserHybrid welding process must meet the following requirements:

- be sealed off from adjoining rooms to make it lightproof

- be screened with min. 1 mm thick steel plate and/or approved laser protective glass to prevent any UV or laser radiation escaping

- both the laser welding process and the arc welding process must stop automatically as soon as the cell is opened

A device that topples over can easily kill someone. Place the device on a solid, level surface.

- The maximum permissible tilt angle is 10°.

Special regulations apply in rooms at risk of fire or explosion

- Observe relevant national and international regulations.

Use internal directives and checks to ensure that the workplace environment is always clean and clearly laid out.

Only set up and operate the device in accordance with the degree of protection shown on the rating plate.

When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft. 7.69 in.) to ensure that cooling air can flow in and out freely.

When transporting the device, observe the relevant national and local guidelines and accident prevention regulations. This applies especially to guidelines regarding the risks arising during transport.

Before transporting the device, allow coolant to drain completely and detach the following components:

- Wire feed speed

- Wirespool

- Shielding gas cylinder

After transporting the device, the device must be visually inspected for damage before commissioning. Any damage must be repaired by trained service technicians before commissioning the device.

Safety measures in normal operation

Safety inspection

Only operate the LaserHybrid head if all protection and safety devices are fully functional. If the safety devices are not fully functional, there is a risk of

- injury or death to the operator or a third party,

- damage to the device and other material assets belonging to the operator,

- inefficient operation 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, ensure that no one is likely to be endangered.

Check the LaserHybrid head at least once a week for obvious damage and proper functioning of the safety devices.

The operator is obliged to have the LaserHybrid head checked by a qualified

electrician to ensure it is safe for use after any modifications, alterations, re-

pairs, care and maintenance, and in any case at least every twelve months.

Regulation Title

IEC (EN) 60 974-1 Arc welding equipment - Part 1: Power sources

BGV A2, §5 Electrical plant and equipment

BGV D1, §33 / §49 Welding, cutting and associated processes

VDE 0701-1 Repair, modification and inspection of electrical ap-

pliances; general requirements

VDE 0702-1 Repeat tests on electrical equipment

Alterations

Do not carry out any modifications, alterations, etc. to the LaserHybrid head without the manufacturer's consent.

Components that are not in perfect condition must be replaced immediately.

Replacement and wearing parts

Use only original spare and wearing parts (also applies to standard parts). It is impossible to guarantee that parts sourced from third parties are designed and manufactured to meet the demands made of them, or that they satisfy safety requirements.

When ordering, please give the exact designation and part number as shown in the spare parts list, as well as the serial number of your device.

Calibration of power sources

CE marking

In view of international standards, regular calibration of power sources is necessary. Fronius recommends a 12-month calibration interval. For more information, please contact your service centre.

The LaserHybrid head fulfils the fundamental requirements of the Low Voltage Directive and the Electromagnetic Compatibility Directive and is thus CEmarked.

The text and illustrations are all technically correct at the time of printing. We reserve the right to make changes. The contents of the operating instructions shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for improvement, or can point out any mistakes that you have found in the instructions, we will be most grateful for your comments.

General information

General

Proper use/intended purpose

The LaserHybrid Ultracompact Twin is a further development of the LaserHybrid Ultracompact head. The LaserHybrid Ultracompact Twin head is used specifically for components requiring high welding speeds.

Throughout the rest of these Operating Instructions, the LaserHybrid Ultracompact Twin head is referred to as the laser welding head.

Alongside the laser welding head, the lasertwin welding process is also described in these Operating Instructions.

The LaserHybrid ultracompact Twin is intended exclusively for MAG tandem (Twin) welding. Utilisation for any other purpose, or in any other manner, shall be deemed to be not in accordance with the intended purpose. The manufacturer shall not be held liable 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 stipulated inspection and maintenance work

Advantages Advantages of the laser welding head:

- High welding speed and therefore highly cost-effective

- High process stability combined with low reject numbers and little need for rework

- High weld seam quality

- Low heat input, low distortion

- High availability of welding system, long service life for wearing parts

- Flexibility

- Good gap tolerance

- Can be adapted for fibre, disc and diode lasers

- No slip in the hosepack, resulting in a stable arc

- Few wearing parts - low maintenance costs

- Simple layout

Advantages of the laser-twin welding process:

- Arc can be controlled selectively

- Minimal arc blow during pulsed arc

- Small weld pool due to short arc, which results in a high welding speed

- Same menu navigation as the TPS 4000/5000

Application areas The LaserHybrid Ultracompact Twin laser welding head is primarily used in laser-MAG ap-

plications:

- For axle and bodywork production with sheet thicknesses of 1 - 4 mm in the motor vehicle industry

- For tank and boiler manufacturing

Other application areas:

- In rolling stock manufacturing for longitudinal seams and profiles

- In shipbuilding for fillet welds and profiles

- In vehicle manufacturing for lap joints and welding of wheel rims

- In container construction for lap joints and circumferential welds

- For edge welds on lifting gear

System overview

(4)

(2)

(1)

(1) Welding wire drum (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 activation + Software update from the Fronius database + Drive Easy Twin control box + FK 9000 R cooling unit / part 1 + RCU 5000i remote control + Upright console (secured)

(4) Wirefeeding hoses

(1)

(3)

(5)

(6)

(7)

(12)

(11)

(8)

(9)

(10)

(5) LHSB cable connection between

the power sources

(6) Trail power source

+ LHSB connection option + Software activation + Software update from the Fronius database + FK 9000 R cooling unit / part 2 + RCU 5000i remote control + Upright console (secured)

(7) LaserHybrid Ultracompact Twin

hosepack (8) Fieldbus (9) Robot control (10) Robot (11) CrashBox (12) LaserHybrid Ultracompact Twin

laser welding head

Laser welding head scope of supply

- 1 LaserHybrid Ultracompact Twin laser welding head (complete)

- 1 LaserHybrid Ultracompact Twin hosepack

- 1 metal gauge for adjusting the focal spot

- 1 flat spanner (8/10 mm)

- 1 slotted screwdriver, 2.5 mm

- 1 Allen key, 2.5 mm

- 1 ball-ended hex 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 Instructions

- Wirefeeder accessories and feed rollers, depending on the configuration

Optional components

The following components are available as options for the "LaserHybrid Ultracompact Twin" laser welding head:

- Focus monitoring

- Various laser beam sources

- Temperature sensor

- CrashBox

Requirements

System requirements and minimum equipment required for the laser-twin welding process

(1) LaserHybrid Ultracompact Twin welding head

(2) LaserHybrid Ultracompact Twin hosepack

(3) Two unreeling wirefeeders

WF 25i REEL R /SA/2R/G/W (stand-alone) + OPT/i WF wire straightening section option (4,100,880,CK)

(4) Two power sources

TPS 5000 (+ variants) + Official UST V3.10.33 firmware and higher + LHSB connection option + "TimeTwin Digital" software activation + Software update from the Fronius database + Standard I/O robot interface or fieldbus

The options are required on both power sources.

(5) Drive Easy Twin control box

(6) Cooling unit

FK 9000 R (2-part)

Power source synchronisation

Software activation

The power sources are synchronised with one another during the laser-twin welding process via:

- The LHSB connection option on the power sources

- 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

- Level 2.

Possible settings: On / oFF

NOTE! For the laser-twin welding process, the P-C parameter must be set to "On" on both power sources.

Activation of the "TimeTwin Digital" software (item number 4,061,110) is required on both power sources for the laser-twin welding process. The t-C (Twin-Control) parameter is available following successful activation and establishment of an active LHSB connection. The t-C parameter defines the lead power source. This power source specifies the frequency for the trail power source.

IMPORTANT! Software activation on the power sources is monitored via the LHSB connection. If the software is not activated on a power source and the t-C parameter is therefore not available, the t-C parameter is also not displayed on the other power source.

Possible settings: On / oFF

Display/setting:

- No robot interface available... the t-C parameter is displayed and configured on the power source under Setup menu - Level 2.

- Robot interface available ... the t-C parameter is controlled by the robot control in such a way that either the first or second power source functions as the lead power source, depending on the welding direction. The t-C parameter must be set to "On" on the lead power source via the robot control. This can be checked on the t-C parameter display on the power source under Setup Menu - Level 2.

Mechanical requirements

Dimensioning of the robot

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 carriage)

- Exact joint preparation

- Low component tolerances

- Seam guidance systems with low deviation

Please note the following when dimensioning the robot:

- The torch holder on the robot must be stable. A LaserHybrid Ultracompact Twin welding head weighs roughly 10.4 kg.

- The CrashBox must be designed for the weight of the laser welding head.

- The LaserHybrid Ultracompact Twin hosepack must be considered when dimensioning the robot. The robot hosepacks and wirefeeding hoses must be routed via a balancer in the robot cell.

Functional principle

(5)

(4)

(7)

(3)

(2) (2)

(8)

(6)

(1) (1)

(9)

- Two wire electrodes (5) and (11) are welded by a laser beam (6) in a weld pool under a gas shroud.

- The welding process is performed using two independent power sources (4) and (10).

- The power sources (4) and (10) are synchronised (7).

- The wire is fed via two unreeling wirefeeders (2) and a shared frontpull drive (8).

- The frontpull drive (8) is controlled by a control unit (3).

- Both wire electrodes are brought together in the welding torch in such a way that two independent welding potentials (9) are available.

(11)

(10)

Lead power source and trail power source

IMPORTANT! The laser-twin welding process only works when used with filler metal from

welding wire drums (1).

The two power sources are referred to as the lead power source and the trail power source in the laser-twin welding process.

- The lead power source is determined by the welding direction.

- The t-C (Twin-Control) parameter must be set to "On" on the lead power source. (See also "System requirements" chapter, "Software activation" section).

- The lead power source specifies the frequency for the trail power source.

- The wire electrode of the lead power source is the front wire electrode, in terms of the welding direction.

Welding technology aspects

Shielding gas

ArO2 ... for unalloyed and low-alloy steels

Gas flow

total gas flow rate approx. 15 - 20 l/min

TPS 5000 welding characteristics (database 02-0043)

Material Gas 1.2 (L) 1.0 (T)

G3Si1-Twin M22 - 96% Ar, rest O

G3Si1-Twin M21 - 90% Ar, rest O

* ... Recommended by Fronius for the laser-twin welding process L ... Lead wire electrode T ... Trail wire electrode

02-1922 02-1919 *

02-1921 02-1918 *

02-1920 02-1917

Earth connection Use a separate grounding (earthing) cable for each power source:

Welding circuit inductivity L, welding circuit resistance r

Separate grounding (earthing) cable Shared grounding (earthing) cable, earth socket

Grounding (earthing) cable laid in a loop Grounding (earthing) cable coiled

IMPORTANT! The welding circuit inductivity L and the welding circuit resistance r must be calibrated separately for each power source and for each twin welding process.

Tilt angle of the welding torch

Select the welding torch tilt angle so that the lead wire electrode (= the electrode of the lead power source) is positioned neutrally or slightly forward.

90 - 100°

Welding torch tilt angle neutral to slightly forward

Possible arc combinations

Pulse/Pulse

The LHSB connection on the power sources means that various arc types can be combined in the laser-twin welding process.

The welding direction is defined by the wire pairing (Ø 1.2 mm lead power source / Ø 1.0 trail power source) and the design of the welding torch.

Lead wire electrode

(=lead power source)

Trail wire electrode

(= trail power source)

Pulse Pulse

I (A)

t (s)

IL > I

Welding current/time curve and schematic representation of the material transfer

Trail wire electrode

Lead wire electrode

Active pulsed arc with droplet transfer

Inactive pulsed arc (no droplet transfer)

Welding current of lead power source

Welding current of trail power source

Welding direction

A "Master selection signal" is output by the robot control. This signal defines the lead power source.

Synchronisation of both power sources: The welding current pulses of the trail power source are placed precisely between the two welding current pulses of the lead power source (180° phase shift). This results in:

- Optimal material transfer (one droplet of material per welding current pulse)

- Minimal arc blow during pulsed arc

- Stable arc across the entire power range

- Reproducible process

- Excellent 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

- Good melting of the cold base material

- Precise root pass formation

- Trail wire electrode fills the weld pool

- Longer degassing time (reduced proneness to porosity)

- High welding speed

NOTE! The Pulse/Pulse arc combination should be used for all general welding applications.

Connecting to the robot control

Robot interfaces for the laser-twin welding process

There are two special robot interfaces available for the laser-twin welding process, for connecting to the robot control:

- Twin Standard I/O Job (0-24 V digital)

- Twin Standard I/O Synergic / Job (0-24 V digital, 0-10 V analogue)

Each of these "Twin interfaces" features an integral programmable logic controller (PLC). The signals are connected logically by the PLC. Both power sources are therefore triggered simultaneously by a signal from the robot control. Only one "Twin interface" is required for two power sources. The "Twin interface" in installed in the switch cabinet.

Application example:

No. Part/device No. Part/device

(1) LocalNet connection (5) Twin interface

(2) LocalNet connection (6) Connection to robot control

(3) Power source (7) Robot control

(4) Power source

(1)

(2)

(3)

(4)

(5)

(6)

(7)

Standard robot interfaces

The following standard robot interfaces can be used to connect to the robot control for Twin processes:

- ROB 3000 (0-24 V digital)

- ROB 4000 (0-24 V digital, 0-10 V analogue)

- ROB 5000 (0-24 V digital, 0-10 V analogue)

Signals must be connected logically by the robot control when standard robot interfaces are used. Two identical robot interfaces are required for two power sources. The two standard robot interfaces are installed in the switch cabinet. Robot interfaces "1" and "2" are connected to power sources "1" and "2" via LocalNet.

Application example:

No. Part/device No. Part/device

(1) Standard interface (5) Power source

(2) Standard interface (6) Power source

(3) LocalNet connection (7) Connection to robot control

(4) LocalNet connection (8) Robot control

(1) (3)

(2) (4)

(8)

(5)

(6)

(7)

Twin fieldbus systems

The following Twin fieldbus systems can be used to connect to the robot control for Twin processes:

- Twin DeviceNet fieldbus robot interface

- Twin CANopen fieldbus robot interface

- Twin Interbus CU fieldbus robot interface

- Twin Profibus fieldbus robot interface

An integral PLC is also a feature of the "Twin fieldbus systems" as well as the "Twin interfaces". The 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 system" is required for two power sources. The "Twin fieldbus system" is fitted to one of the power sources. The connection to the second power source is established via LocalNet and the connection to the robot control via the fieldbus.

Application example:

No. Part/device No. Part/device

(1) Robot control (5) Power source

(2) Fieldbus connection (6) LHSB-HUB

(3) Twin fieldbus system (7) Power source

(4) LocalNet connection

(1)

(2) (3) (4)

(5)(7) (6)

Standard fieldbus systems

The following standard fieldbus systems can be used to connect to the robot control for Twin processes:

- DeviceNet fieldbus robot interface

- CanOpen fieldbus robot interface

- Interbus CU fieldbus robot interface

- Interbus LWL fieldbus robot interface

- Profibus 1.5 MB fieldbus robot interface

Signals 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 are fitted to the power sources. The robot control is connected to the power sources via the fieldbus.

Application example:

No. Part/device No. Part/device

(1) Fieldbus connection (5) Power source

(2) Standard fieldbus system (6) LHSB-HUB

(3) Fieldbus connection (7) Power source

(4) Standard fieldbus system (8) Robot control

(1) (2) (3) (4)

(5)(7) (6)(8)

Control elements and connections

Description of the device

(1)

(16)

(15)

(14)

(17)

(3a)

(2)

(3)

(4)

(5)

(13)

(12)

(11)

(10)

(9)

(8)

(7)

(6)

Item Designation

(1) Crossjet outlet air connection

(2) Protective cover/fibre optic cable connection

(3)

(3a)

(4) Laser optics

(5) Radial air flow

(6) Gas nozzle

(7) LaserHybrid Ultracompact Twin welding torch

(8) Adjusting device

(9) Drive roller cover

(10) Motor cover

(11) Robot connection flange

Additional extractor

Optional additional extractor (with corresponding spatter guard sheet)

One of the two extractors is fitted prior to delivery depending on the configuration.

Item Designation

(12) Controls

(a)

(b)

(c)

(a) (b) (c)

(13) Robot holder

(14) Laser optics system water cooling connection

(15) Wirefeeding hose connections

(16) LaserHybrid Ultracompact Twin hosepack

(17) CrashBox (option)

Wire retract button Wire threading button Gas-test button

Connection specifications

(7)

(6)

(1) (2)

(3)

(4)

(5)

Item Designation

(1) Fibre optic cable for laser

Bending radius > 100 mm

IMPORTANT! Only use a fibre optic cable with fibres of </= 0.3 mm. Larger fibres can affect the welding result and cause damage to the laser welding head.

(2) Crossjet outlet air connection

For connecting a hose matching the following specifications:

- Internal diameter Di = 50 mm

- Max. length = 10 m

- Crossjet outlet air 170 m³/h

(3) Additional extractor connection,

for connecting a hose matching the following specifications:

- Internal diameter Di = 40 mm

- Max. length = 10 m

- Required extraction capacity 60 m³/h

(4) Crossjet compressed air connection

(of LaserHybrid interconnecting hosepack)

- Operate at 6 bar with and with a volumetric flow of 60 m³/h

Compressed air diagram

Item Designation

(5) Laser optics system water cooling connection

(of LaserHybrid interconnecting hosepack)

(6) External wirefeeding hose (Fronius)

(7) LaserHybrid interconnecting hosepack (Fronius)

Hosepack incl. compressed air for Crossjet and radial air flow, water cooling for laser optics system and media coupling

(3)

(2)

(4)

(5)

(3)

(2)

1000 l/min

Item Designation

(1) Compressor supply

(min. 6 bar)

(2) Crossjet inlet air connection

(3) Radial air flow branch connection

(4) Crossjet outlet air

(5) Extractor

(1)

Start-up

General

Safety

Setup regulations The power sources are tested to protection class IP23, meaning:

- Protection against penetration by solid foreign bodies with diameters > 12 mm (0.47

- Protection against spraywater at any angle up to 60° to the vertical

In accordance with protection class IP23, the welding system can be set up and operated outdoors. However, direct wetting (e.g. from rain) should be avoided.

The venting duct is a very important safety device on the power source. When choosing the device location, ensure that the cooling air can enter and exit unhindered through the air ducts on the front and back of the device. Electrically conductive metallic dust (from grinding work, for example) must not be allowed to get sucked into the machine.

WARNING! Work that is carried out incorrectly can cause serious injury and damage. Set up work must only be performed by trained and qualified personnel. Observe the safety regulations in the operating instructions, paying particular attention to the section entitled "Safety inspection".

in.)

WARNING! Toppling or falling devices can cause life-threatening injuries. Place devices on a solid, level surface so that they remain stable.

Mains connection The device is designed to run at the mains voltage indicated on the rating plate. The re-

quired fuse protection for the mains supply can be found in the "Technical data" section. If there is no mains cable or mains plug on your device, fit one that conforms to national standards.

NOTE! Inadequately dimensioned electrical installations can cause serious damage. The incoming mains lead and its fuse must be dimensioned to suit the local power supply. The technical data shown on the rating plate applies.

Assembling a laser-twin system

Starting situation: Robot and robot control are available and ready to use

WARNING! If a power source is connected to the mains during installation, there is a risk of serious injury and damage. Before using for the first time, read the "Safety rules" section in the Operating Instructions of the power source. Only carry out these preparations if:

- The mains switch on both power sources is in the "O" position

- Both mains cables are unplugged from the mains

Fit the laser 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 consoles (FK 9000 R/part 1 = lead power source, FK 9000 R/part 2 = trail power source)

Connect the power sources to the cooling unit parts

NOTE! The control unit must only be fitted to the power source using the optional holder from Fronius (item no. 4,100,719).

Fit the Drive Easy Twin control box to the lead power source:

Establish an LHSB connection between the power sources

Connect the lead power source to the robot control

Connect power source "1" to power source "2"

Set up the welding wire drums

Assemble the unreeling wirefeeders

Connect the laser-twin hosepack to the laser welding head

Lay the laser-twin hosepack on the robot

Connect the laser-twin hosepack to the power sources and the Drive Easy Twin con-

trol box:

(1)

(2)

(3)

Rear Front

(4)

(5)

(6)

(7)

(1) AIR OUT

For connecting 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 hosepack

(3) GAS OUT

For connecting the shielding gas line from the laser-twin hosepack

(4) LocalNet

For connecting the power source

(5) GAS IN

For connecting the shielding gas infeed

(6) LocalNet

Connection socket for system extension

(7) AIR IN

For connecting the compressed air line

Route and connect the wirefeeding hoses from the unreeling wirefeeders to the laser

welding head

Connect the remote controls

Establish grounding (earthing) connections between the workpiece and power sourc-

es "1" and "2"

IMPORTANT!

- Use a separate grounding cable

- Lay the grounding cable in a loop

Commissioning (overview)

Commissioning the laser welding head comprises the following sections:

- Fitting the laser 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 the robot

- Threading the wire

- Setting up the laser welding head

- Setting the radial air flow

- Creating a reference program and checking the position of the wire electrode in relation to the focal point of the laser

- Signal sequence for LaserHybrid welding

- Measures to be taken before the start of welding

Fitting the laser welding head to the robot

Requirements for the robot

Fitting the laser welding head to the robot

The laser welding head weighs approx. 8 kg. The optics weigh an additional 2 kg. The total weight of the laser welding head with the optics system and hosepack fitted is approx. 10 kg. The axis accelerations specified for the robot must therefore permit a mass of 10 kg to be moved safely.

IMPORTANT! The maximum permitted acceleration of the laser welding head is 3 g at 5 150 Hz, based on the laser optics.

NOTE! The laser welding head does not have collision protection as standard. Fronius therefore recommends using a commercial collision protection device for robot applications to prevent the laser welding head being damaged in the event of a crash.

Refer to the Spare Parts List for collision protection devices and flanges for each robot (see page )

Fit the laser welding head to the robot as specified by the robot manufacturer.

Connecting the LaserHybrid Ultracompact Twin hosepack to the laser welding head

Preparatory work 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 side (3 mm)

Pull the drive roller cover towards the

rear and remove it

Remove the Allen screw

(3 mm)

Pull the motor cover towards the rear

and remove it

Connecting the LaserHybrid Ultracompact Twin hosepack to the laser welding head

Feed in the hosepack

Push the hexagon nut over the media

Lightly tighten the hexagon nut

(1)

(2)

(3)

IMPORTANT! Before tightening the hexagon nut, ensure the correct positioning of the media as shown in the illustration: a) The hoses (4) for cooling the laser op-

tics are 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 compressed air supply (1)

(4)

Tighten the hexagon nut

(46 mm)

Remove the six Allen screws

(4 mm)

Remove the robot connection flange

(without control elements)

Fitting the strain-relief device

View from the robot to the laser welding head

Remove the Allen screw

(3 mm)

Position strain-relief device for the mo-

tor line from the hosepack

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)

Connecting the hose for the Crossjet compressed air supply

Insert the hose for the Crossjet com-

pressed air supply as far as it will go

Connecting the media couplings

(3)

(2)

Connecting the motor line

IMPORTANT! Grease the screws before

connecting the media couplings.

Fit the two media couplings using 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)

Plug in the connector on the motor

Secure the cables to the motor using

cable ties

Connecting the cooling system for the laser optics

Connect the flow and return hose for

the laser optics water cooling system as shown

Hose with blue markings (= water flow): top

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 wirefeeding hoses on the laser welding head

Undo the hexagon nuts

(24 mm)

Feed the external wirefeeding hoses

up to the wirefeeding hose holders

Tighten the hexagon nuts until the sea-

ling lip protrudes (24 mm)

And finally...

(1)

NOTE! When fitting the covers ensure that cables are not trapped,

crushed or damaged in any way.

Insert the motor cover into the side recesses

Secure the motor cover using an Allen

screw (3 mm)

Position the drive roller cover

IMPORTANT! The drive roller cover must be positioned without gaps between it and the mounting plate (1).

Secure the drive roller cover using two

Allen screws (3 mm)

Position the media cover

Secure the media cover using two Al-

len screws

(4 mm)

Connecting the laser optics system, Crossjet and additional extractor

Connecting the laser optics system

CAUTION! Risk of damage to the laser welding head due to contamination from

above.

- Observe the Operating Instructions, specifications and safety instructions set out by the laser optics system manufacturer

- Before connecting, position the laser welding head in relation to the horizontal so that no contaminants can enter the laser optics from above.

Position the laser welding head in rela-

tion to the horizontal

Clean the fibre optic cable connector

and connection area using compressed air

Remove the protective cover from the

fibre optic cable connector

Remove the protective cover from the

fibre optic cable connection socket

Connect the fibre optic cable:

Press the button on the underside

b) Retract the rubber sleeve in the direction of the optics

c) 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 positioned rubber sleeve The rubber sleeve shown is kinked (see arrows) and therefore does not

form a complete seal.

INCORRECTLY positioned rubber sleeve. The rubber sleeve does not form a complete seal.

Check that the coolant hoses for the la-

ser optics are connected correctly

Connecting the Crossjet and additional extractor

IMPORTANT! Confusing the Crossjet outlet air and additional extractor connections will

impair 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-

(1)

(2)

let air and additional extractor to the relevant connections indicated in the connection specifications (e.g. using a hose clamp)

(1) Crossjet outlet air

(2) Additional extractor

Laying the hosepack on the robot

IMPORTANT! The optional LaserHybrid hosepack holder is not included in the scope of

supply of the laser welding head.

(7) (4) (6)

(5)

(5) (8)

(5)

(6)

(4)

(3)

44,0360,0099

6 x 4 Nm

4 Nm

(3)

(2)

(1)

(1) Robot arm (2) Profile support (3) LaserHybrid hosepack holder (4) Opening for extractor hose (5) Opening for wirefeeding hose

Assembly

Fit the profile support (2) to the robot arm (1)

Assemble the bottom part of the LaserHybrid hosepack (3) as shown (without the up-

per part and side parts of the hose clamp)

Secure 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 the hose clamp and secure using the side parts

(6) Opening for fibre optic cable (7) Opening for LaserHybrid hose-

pack

(8) Adapter insert for extractor hose

kit ø 41/51 mm (42,0411,9036)

Threading the wire electrode

Preparatory work

Remove the two Allen screws

(4 mm)

Remove the media cover

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

Removing the welding torch wearing parts

Remove the gas nozzle (2.5 mm Allen key)

Unscrew the contact tips (7 mm flat spanner)

3 4

Threading the wire electrode

Unscrew the contact tip adapter using an 8 mm box spanner

Remove the gas distributor

IMPORTANT!

- The lead and trail wire electrodes must be threaded in before using the system for the first time.

- Depending on the circumstances, the lead or trail electrodes can be changed individually or at the same time.

- Read and observe the safety rules, safety instructions and all documentation relating to the unreeling wirefeeders.

Requirement:

- 2 x wire electrodes 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, Installation Instructions, etc.

- The power source must be switched on and the coolant supply must be switched off.

Thread the wire electrode into the unreeling wirefeeder

Close the feed rollers on the unreeling wirefeeder

Set the wire threading mode on the unreeling wirefeeder

Thread in the wire electrode until it reaches the feed rollers on the laser welding head

Open the feed rollers on the unreeling wirefeeder

* Fully open

Fully open the adjusting screw on the

laser welding head

Pull the pressure 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

Set the contact pressure:

three rings must be visible (*)

Press the wire threading button on the

laser welding head until the wire electrodes protrude out of the welding torch

Pull the pressure lever upwards

Swivel the feed rollers 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 torque so that only the frictional forces in the system are overcome: The wire electrode must exit very slowly. It must be possible to easily stop the wire electrode movement at any time using two fingers.

Swing in the feed rollers

Push the pressure lever downwards

Fitting the welding torch wearing parts

IMPORTANT! The wire electrode must be threaded in when fitting the welding torch wear-

ing parts.

Fit the gas distributor

Screw in the contact tip adapter (8 mm box spanner) Tightening torque = 5 Nm

* IMPORTANT! When fitting the gas distributor, ensure that the recess on the gas

distributor is positioned above the raised element on the welding torch.

3 4

Screw in the contact tips (7 mm flat spanner) Tightening torque = 4 Nm

Position the gas nozzle and secure using a 2.5 mm Allen key Tightening torque = 1 Nm

Setting the radial air flow

Requirements IMPORTANT! The radial air flow must be set before switching on the laser welding head.

The flow rate meter from the laser welding head scope of supply is required to set the radial air flow.

Setting the radial air flow

Remove the two Allen screws

(3 mm)

Swivel the additional extractor to one

side

Disconnect the air hose

Connect the hose and adapter from the

laser welding head scope of supply

Connect the hose

Fit 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 screwdriver

Remove the flow rate meter

Disconnect the hose and adapter

Connect the air hose

Swing in the additional extractor

Fit the additional extractor using two

Allen screws (3 mm)

Adjusting the laser welding head

Stick out

(1)

(1) Welding torch (2) Contact tip

(2)

(3)

18 mm

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 only be carried out by collimating the laser optics system.

(4)

(3) Stick out of lead electrode

(4) Stick out of trail electrode (deter-

NOTE! When setting the physical position of the welding torch, ensure that the stick out is always 18 mm.

18 mm (relative to the focal length of the laser optics)

mined by the torch settings)

y (± 3 mm)

x (± 2 mm)

Adjusting device

on the laser welding head

The laser welding head is fitted with an adjusting device that enables precise positioning in the x and y coordinate axes.

The adjusting device comprises:

(1) Adjusting screw with pitch

Allen screw (3 mm), quarter turn corresponds to an adjustment of 0.25 mm

(2) Scale denoting adjustment range

Adjusting the xaxis

(1)

(2)

Illustration of both adjusting devices without covers

(1)

Undo the grub screw (1)

(3 mm)

Use the adjusting screw (2) and the 3

mm Allen key to adjust the x-axis: 1 rotation corresponds to 1.0 mm

(1)(2)

Once the x-axis has been adjusted, re-

tighten the grub screw (1)

Illustration of both adjusting devices without covers

Adjusting the yaxis

(1)

2 0

+ 3 mm- 3 mm

(1) (2)

NOTE! The y setting range of ± 3 mm starts from the second graduation mark on the y scale. In position 0, both the laser and wire electrode would fall on the same exact location.

(1) Laser beam

Undo the grub screw (1)

(3 mm)

Use the adjusting screw (2) and the 3

mm Allen key to adjust the y-axis: 1 rotation corresponds to 1.0 mm

Once the y-axis has been adjusted, re-

tighten the grub screw (1)

Illustration of both adjusting devices without covers

Standard distance values

Laser - lead wire electrode 3 - 5 mm

Lead wire electrode - trail wire electrode 7 - 8 mm*

* determined by the welding torch geometry

Creating a reference program

Safety

General A low-power pilot laser is required for this work.

A reference program must be created:

- After fitting the laser welding head for the first time

- When programming a new component, provided that the x and y values on the adjust-

Creating a reference program

A metal gauge for precise positioning of the wire electrode relative to the focal spot of the laser is included as part of the laser welding head scope of supply. This gauge is fitted within the operating range of the robot and is used to create a reference program for series components.

Create a reference program before welding the first series component

Requirement:

- The laser welding head must be assembled and fully connected.

- The wire electrodes must be threaded in.

- A stick out of 18 mm must be set for the lead electrode.

ment units have changed.

Fit the gauge (1) within the operating range 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 component to the welded:

Move the robot towards the gauge so

that the focal spot of the laser is within the crosshairs on the gauge

Lower the laser welding head using the

(1)

robot so that the lead electrode is touching the gauge

Use the x and y adjustment units on the

laser welding head to position the lead wire electrode in relation to the focal spot of the laser

Standard value: r = 3 mm

Both wire electrodes should be touching the gauge.

Document the gap between the lead wire electrode and the focal spot of the laser

along both the x- and y-axes as per the scale marked on the gauge

Save the settings as a reference program in 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-

write the reference program initially created

Signal sequence for LaserHybrid welding

Safety

Signal sequence for LaserHybrid welding

WARNING! Work that is carried out incorrectly can cause serious injury or dam-

age. The welding sequence must only be programmed by trained specialist personnel. Observe the safety rules in the operating instructions, paying particular attention to the section entitled "Safety inspection".

CAUTION! Risk of damage to optical fibre if laser welding head is positioned perpendicular to the surface of the workpiece during welding. If the laser optics system is placed at a right angle to the surface of the workpiece, the laser will be reflected directly into the laser optics system. The optical fibre can be seriously damaged if this occurs. Always set the laser welding head at a forwards or backwards tilt angle.

NOTE! When welding a number of short weld seams one after the other, do not switch off the crossjet flow and external extraction until the end of the entire sequence. This will prevent welding smoke from making the protective glass dirty.

Robot start position:

Set the "extraction on" signal

Set the "crossjet on" signal

Select the mode

e.g. mode "3" (internal parameter selection for adjustment purposes): set mode bit "0" to "1" set mode bit "1" to "1" set mode bit "2" to "0"

If "Job" mode is selected, see the operating instructions for the MIG/MAG power source for more detailed information about this mode.

If preheating is not required, continue from "LaserHybrid welding start position".

Preheating start position:

Requirement: the laser must be ready to enable the beam.

Set the "gas test" signal

Set the "laser on" signal

The preheating temperature comes from the following factors: travel speed, laser power, distance to the surface of the workpiece

Preheating end position:

Reset the "laser on" signal

Reset the "gas test" signal

LaserHybrid welding start position:

Requirement: the laser must be ready to enable the beam.

Set the "arc on" signal

Wait for the current flow signal ("arc on")

Set the "laser on" signal

Set the "robot start" signal

The distance 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 start" signal

Wait until the current flow signal = zero

Robot end position:

IMPORTANT! The robot end position is not the end of the weld seam.

Reset the "crossjet on" signal

Reset the "extraction on" signal

Measures to be taken before the start of welding

Parameter settings on the power source

Check the coolant flow on the laser optics cooling system

Check the coolant flow on the welding torch cooling system

(visual inspection in the coolant tank on the cooling unit)

Check whether protective 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

CAUTION! To prevent damage to the weldpiece, the same parameter settings must be used on the lead- and trail power source (see below):

- Burn-back time (bbc)

- Gas pre-flow time (GPr)

- Gas post-flow time (GPo)

- Starting current duration (t-S)

- Final current duration (t-E)

- Slope 1 (SL 1)

- Slope 2 (SL 2)

Recommendations for operating a laser-twin welding system

To ensure smooth operation, the following items must always be available for a laser-twin welding system:

Laser-twin service station

Compressed-air gun supply at 6 bar

Portable tool trolley with the following tools and spare parts:

- 20 x 1.0 mm contact tips

- 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 key, 7 mm

- Diagonal cutting pliers

- Flat spanner, 7 mm (for removing fixing sleeves)

- Parting agent

- Optics cleaning kit from the respective optics manufacturer

- 1 x protective glass drawer in dust-proof packaging (as a spare)

- Min. 10 x protective glass in dust-proof packaging

IMPORTANT! Always have a spare laser welding head incl. optics in stock!

- Delivery time for a new laser welding head:

- Delivery time for laser optics:

- Laser optics repair:

IMPORTANT! The external extractor must remain switched on during servicing of the laser welding head.

min. eight weeks min. eight weeks min. eight weeks

Maintenance

Changing the wire electrode

Preparatory work

Remove the two Allen screws

(4 mm)

Remove the media cover

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

Unthreading the wire electrode

IMPORTANT!

- Depending on the circumstances, the lead or trail electrodes can be changed individually or at the same time.

- Read and observe the safety rules, safety instructions and all documentation relating to 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, Installation Instructions, etc.

- The power source must be switched on and the coolant supply must be switched off.

Cut off the wire electrodes in front of

the gas nozzle

Remove the gas nozzle

(2.5 mm Allen key)

Unscrew the contact tips

(7 mm flat spanner)

Unscrew the contact tip adapter

Remove the gas distributor

Set the wire threading mode on the unreeling wirefeeder

Open the feed rollers on the unreeling wirefeeder

Fully open the adjusting screw

* Fully open

Pull the pressure lever upwards

Swivel the feed rollers downwards

Manually remove the wire electrode on the unreeling wirefeeder

Changing the wire electrode

IMPORTANT! When performing any activities on unreeling wirefeeders, read and observe

the safety rules, safety instructions and all documentation relating to the unreeling wirefeeders.

Remove the unreeling wirefeeder from the empty welding wire drum

Replace the welding wire drum

Fit the unreeling wirefeeder to the new welding wire drum

Thread the wire electrode into the laser welding head

(see "Threading in the wire electrode" section, page 58)

Replacing wearing parts

Preparatory work

Remove the two Allen screws

(4 mm)

Remove the media cover

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

Removing the feed rollers

Fully open the adjusting screw

* Fully open

Swivel 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

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

Position the slotted screwdriver bet-

ween the top feed rollers and the side wall

Press out the top feed rollers using the

slotted screwdriver

Remove the top feed rollers

Replacing the inlet nozzles

Replacing and installing the feed rollers

1 2

Removal:

Remove the inlet nozzles using need-

le-nosed pliers

Installation:

Insert the inlet nozzles using needle-

nosed pliers

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).

Replacing the welding torch and welding torch inner liners

Safety

Preparatory work

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

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

Remove the two Allen screws

(4 mm)

Remove the media cover

Remove the three Allen screws

(2.5 mm)

Remove the current interface cover

Replace the welding torch

Remove the two Allen screws

(5 mm)

Disconnect the two media couplings

L = Lead electrode T = Trail electrode

CAUTION! Risk of damage due to falling parts! Ensure that the welding torch does not fall when undoing the screws.

Cut off the wire electrodes in front of

the gas nozzle

Remove the three Allen screws from

the underside of the welding torch (3 mm)

Tightening torque 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 the welding torch inner liners must be

threaded in

- Ensure that the O-rings are present on the current interface and in a suitable condition

Replacing the welding torch inner liners

IMPORTANT! The welding torch inner liners can only be replaced when the welding torch

has been 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 inserting the inner liners into the welding torch, both inner liners must protrude out of the welding torch by the same amount.

Replacing welding torch wearing parts

Safety

Welding torch spare parts

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

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

Removing the welding torch wearing parts

Remove the gas nozzle (2.5 mm Allen key)

Unscrew the contact tips (7 mm flat spanner)

3 4

Unscrew the contact tip adapter using an 8 mm box spanner

Unscrew the nozzle fittings using an 11 mm box spanner

Remove the gas distributor

Fitting the welding torch wearing parts

IMPORTANT! The wire electrode must be threaded in when fitting the welding torch wear-

ing parts.

Screw in the nozzle fittings (11 mm box spanner) Tightening torque = 6 Nm

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 the welding torch.

3 4

Screw in the contact tip adapter (8 mm box spanner) Tightening torque = 5 Nm

Screw in the contact tips (7 mm box spanner) Tightening torque = 4 Nm

Position the gas nozzle and secure using a 2.5 mm Allen key Tightening torque = 1 Nm

Replacing the spatter guard 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 push

it forwards

Fit the spatter guard plate using two Al-

len screws (3 mm)

Replacing the laser optics system

Safety

Preparatory work

WARNING! Work that is carried out incorrectly can cause serious injury and dam-

age. Installation must only be carried out by trained and qualified personnel. Observe the safety regulations in the operating instructions, paying particular attention to the section entitled "Safety inspection".

CAUTION! Risk of damage to the laser welding head due to contamination from above.

- Observe the Operating Instructions, specifications and safety instructions set out by the laser optics system manufacturer

- Before removing, position the welding head from the horizontal so that no contaminants can enter the laser optics from above.

Position the laser welding head in relation to the horizontal

Clean the fibre optic cable and connection area using compressed air

IMPORTANT! Only connect the coolant hose to the laser optics; never connect it to the fibre optic cable.

Undo the Allen screw and disconnect the coolant hose (1) from the laser optics (2.5 mm)

(1)

The procedure for disconnecting the fibre optic cable from the laser optics is carried out in the reverse order to the connection procedure, see page 55, step 5 onwards:

Retract the rubber sleeve in the direction of the optics

Press the button on the underside

Remove the fibre optic cable

Position the protective covers on the fibre optic 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 outlet air hose

Clean the area around the Crossjet outlet connection using compressed air

Removing the laser optics system

Note: The numbering of the arrows in the illustrations may differ from the work steps.

Remove the two Allen screws

(4 mm)

Remove the media cover

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 Allen screws

(3 mm)

Swivel the additional extractor to one

side

Disconnect the air hose

Remove the two Allen screws

(3 mm)

Pull the Crossjet forwards

Remove the four Allen screws from the

underside of the laser welding head (2.5 mm)

Disconnect the coolant hose

100

Fronius LaserHybrid Ultracompact Twin Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual