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SB 360i LaserHybrid

Fronius LaserHybrid Series, WF 25i LaserHybrid 90, SB 360i LaserHybrid Operating Instructions Manual

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Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Perfect Charging / Perfect Welding / Solar Energy
WF 25i LaserHybrid 90° 10 kW FW SB 360i LaserHybrid
Operating Instructions
LaserHybrid
42,0426,0306,EA 004-11112019
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Table of contents
Safety Instructions ..................................................................................................................................... 7
Explanation of Safety Instructions......................................................................................................... 7
General ................................................................................................................................................. 7
Intended Use......................................................................................................................................... 8
Environmental Conditions ..................................................................................................................... 8
Obligations of the Operating Company................................................................................................. 8
Obligations of Personnel....................................................................................................................... 8
Personal Protective Equipment............................................................................................................. 9
Danger from Toxic Gases and Vapors.................................................................................................. 9
Danger Posed by Shielding Gas Leak .................................................................................................. 9
Danger from Flying Sparks ................................................................................................................... 10
Danger from Welding Current ............................................................................................................... 10
Stray Welding Currents......................................................................................................................... 10
EMC Measures ..................................................................................................................................... 10
Particular Hazard Areas........................................................................................................................ 11
Informal Safety Measures ..................................................................................................................... 12
Safety Measures at the Installation Location ........................................................................................ 13
Safety Measures in Normal Operation.................................................................................................. 13
Safety Inspection .................................................................................................................................. 13
Modifications ......................................................................................................................................... 14
Spare and Wearing Parts...................................................................................................................... 14
Calibrating Power Sources ................................................................................................................... 14
The CE label ......................................................................................................................................... 14
Copyright............................................................................................................................................... 14
General Information 15
General ...................................................................................................................................................... 17
General ................................................................................................................................................. 17
Intended Use......................................................................................................................................... 17
Applications........................................................................................................................................... 17
Scope of Supply.................................................................................................................................... 18
Optional Components ........................................................................................................................... 18
Requirements............................................................................................................................................. 19
Mechanical Requirements .................................................................................................................... 19
Robot Requirements ............................................................................................................................. 19
Ground Connection............................................................................................................................... 19
Alignment .............................................................................................................................................. 20
System Overview ....................................................................................................................................... 21
System Overview .................................................................................................................................. 21
Other LaserHybrid Systems.................................................................................................................. 22
Setup Variants ...................................................................................................................................... 24
Operating controls and connections 27
Product description .................................................................................................................................... 29
Product description ............................................................................................................................... 29
Control Panel WF 25i Robacta Drive / WF 60i Robacta Drive CMT ..................................................... 30
Device Description, SB 360i LaserHybrid ............................................................................................. 31
Connection Specifications.......................................................................................................................... 33
Connection Specifications..................................................................................................................... 33
Compressed Air Diagram...................................................................................................................... 34
Pressure Monitoring in the SplitBox SB 360i LaserHybrid.................................................................... 34
Commissioning 35
General ...................................................................................................................................................... 37
Safety.................................................................................................................................................... 37
Setup Regulations................................................................................................................................. 37
Grid Connection .................................................................................................................................... 37
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Setting Up the LaserHybrid Welding System........................................................................................ 37
Installing the Laser Welding Head on the Robot........................................................................................ 39
Connection Options on the Robot......................................................................................................... 39
Mount WF 25i Robacta Drive on the laser welding head...................................................................... 39
Mounting the Laser Welding Head on the Robot .................................................................................. 40
Installing and Connecting SplitBox SB 360i LaserHybrid ..........................................................................41
Installing SplitBox SB 360i LaserHybrid on Robot ................................................................................41
Connecting SplitBox SB 360i LaserHybrid............................................................................................ 43
Connecting Crossjet................................................................................................................................... 45
Connecting the CrossJet....................................................................................................................... 45
Connecting LaserHybrid Hosepack to Laser Welding Head...................................................................... 47
Mounting the Hosepack on the WF Robacta Drive (Conventional) ...................................................... 47
Connecting/Changing the Wirefeeding Hose on the Laser Welding Head ........................................... 48
Installing/Changing Wirefeed Rollers......................................................................................................... 49
Inserting/Replacing the WF 25i Robacta Drive Feed Rollers................................................................ 49
Connecting Laser Optics and Extra Extraction .......................................................................................... 51
Connecting the Laser Optics................................................................................................................. 51
Connecting the Additional Extraction System ....................................................................................... 54
Preparing Welding Torch ........................................................................................................................... 57
Mounting the Inner Liner in the Torch Body.......................................................................................... 57
Mounting the Welding Torch onto the WF Robacta Drive (Conventional) ............................................ 58
Installing Hosepack on Robot .................................................................................................................... 60
Placing the Hosepack on the Robot...................................................................................................... 60
Adapting the Additional Extraction System ................................................................................................ 62
Safety.................................................................................................................................................... 62
Adapting the Additional Extraction System ........................................................................................... 62
Threading the Wire Electrode .................................................................................................................... 63
Threading the Wire Electrode ............................................................................................................... 63
Setting up Laser Welding Head ................................................................................................................. 65
Stick Out ............................................................................................................................................... 65
Adjustable Axes .................................................................................................................................... 65
Adjustment Device on the Laser Welding Head ................................................................................... 66
Adjusting the x Axis............................................................................................................................... 66
Adjusting the y Axis............................................................................................................................... 67
Adjusting the z Axis............................................................................................................................... 67
Creating Reference Program ..................................................................................................................... 68
Safety.................................................................................................................................................... 68
General ................................................................................................................................................. 68
Creating a Reference Program ............................................................................................................. 68
Signal Sequence for LaserHybrid Welding ................................................................................................ 70
Safety.................................................................................................................................................... 70
Signal Sequence for LaserHybrid Welding ........................................................................................... 70
Measures before Starting Welding............................................................................................................. 72
Measures before Starting Welding........................................................................................................ 72
Operation Recommendations for LaserHybrid Welding System................................................................ 73
Recommendations for the Operation of a LaserHybrid Welding System.............................................. 73
Specifications for the compressed-air supply ....................................................................................... 73
Maintenance 75
Replacing the Welding Torch and Welding Torch Wearing Parts.............................................................. 77
Safety.................................................................................................................................................... 77
Mounting Wearing Parts on the Welding Torch .................................................................................... 77
Replacing the Spatter Guard Plate and Extra Extraction........................................................................... 78
Replacing the Spatter Guard Plate ....................................................................................................... 78
Replacing the Additional Extraction System ......................................................................................... 79
Replacing the Laser Optics........................................................................................................................ 80
Safety.................................................................................................................................................... 80
Preparation ........................................................................................................................................... 80
Removing the Laser Optics................................................................................................................... 81
Installing the Laser Optics..................................................................................................................... 82
Final Tasks............................................................................................................................................ 84
Checking Position of the Wire Electrode in relation to the Laser Focus .................................................... 85
Safety.................................................................................................................................................... 85
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General ................................................................................................................................................. 85
Checking Position of the Wire Electrode in relation to the Laser Focus ............................................... 85
Example: Use of the Reference Program after Welding Torch Replacement....................................... 86
Measures to Reduce Contamination of the Optics .................................................................................... 87
Measures to Reduce Contamination of the Optics ............................................................................... 87
Appendix 89
Technical Data ........................................................................................................................................... 91
WF 25i LaserHybrid 90° 10 kW FW (Laser Welding Head) .................................................................. 91
LaserHybrid hosepack MHP 360i LH.................................................................................................... 91
SB 360i LH............................................................................................................................................ 91
WF 25i Robacta Drive /W ..................................................................................................................... 92
MTB 700 LH /W .................................................................................................................................... 92
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Safety Instructions
Explanation of Safety Instruc­tions
DANGER!
Indicates an immediate danger.
► Death or serious injury may result if appropriate precautions are not taken.
WARNING!
Indicates a possibly dangerous situation.
► Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Indicates a situation where damage or injury could occur.
► Minor injury or damage to property may result if appropriate precautions are not taken.
Indicates the possibility of flawed results and damage to the equipment.
General The LaserHybrid head has been manufactured using state-of-the-art technology and ac-
cording to recognized 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 operating company,
- inefficient operation of the LaserHybrid head.
All persons involved in the commissioning, operation, maintenance, and servicing of the LaserHybrid head must
- be suitably qualified,
- have knowledge of welding and
- have read and implemented carefully these Operating Instructions and the OI for the following system components: Laser Laser optics Power source and associated wirefeeder Robot and its controller
The Operating Instructions must always be at hand wherever the LaserHybrid head is be­ing used. In addition to the Operating Instructions, all applicable local rules and regulations regarding accident prevention and environmental protection must also be followed.
All safety instructions and warning signs on the LaserHybrid head itself must:
- be kept in a legible state
- not be damaged/marked
- not be removed
- not be covered, pasted, or painted over.
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For the location of the safety and danger notices on the LaserHybrid head, refer to the sec­tion headed "General" in the Operating Instructions for the LaserHybrid head. Before switching it on, resolve any faults that could compromise safety.
Your personal safety is at stake!
Intended Use The LaserHybrid head is to be used exclusively for its intended purpose.
The LaserHybrid head is intended exclusively for LaserHybrid welding of aluminum, CrNi and steel materials. Any other use does not constitute proper use. The manufacturer is not responsible for any damage resulting from improper use.
Proper use also means:
- Completely reading and obeying all instructions in the Operating Instructions
- Completely reading and obeying all safety instructions and danger notices
- Carrying out all the specified inspection and servicing work.
Never use the LaserHybrid head or the power source to thaw pipes.
The LaserHybrid head is designed for operation in industry and business. The manufac­turer shall not be liable for any damage resulting from use in a living area. The manufacturer shall not be liable for faulty or incorrect work results either.
Environmental Conditions
Obligations of the Operating Com­pany
Operation or storage of the LaserHybrid head outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer is not responsible for any damage resulting from improper use.
Temperature range of the ambient air:
- 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)
Ambient air: free of dust, acids, corrosive gases or substances, etc. Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)
The operating company must only allow persons to work with the LaserHybrid head if they
- are familiar with the basic occupational safety and accident prevention regulations and are trained in handling the LaserHybrid head
- have read and understood these Operating Instructions, especially the section "Safety Rules," and have confirmed this with their signature
- are trained according to the requirements for the work results.
The safety-conscious work of the personnel must be checked regularly.
Obligations of Personnel
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All persons who are assigned to work with the LaserHybrid head must do the following be­fore beginning work:
- Follow the basic regulations for occupational safety and accident prevention
- Read these Operating Instructions, especially the section "Safety Rules," and confirm that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property damage can occur in one's absence.
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Personal Protec­tive Equipment
Please take the following precautions for your own personal safety:
Persons present in the sealed cell for the LaserHybrid process must
- wear rigid, wet-insulating footwear
- protect hands with appropriate gloves (featuring electrical insulation and thermal pro­tection)
- protect their eyes from laser beams by wearing regulation-compliant safety glasses for lasers. To protect their face and eyes against UV beams, further protection in the form of a protective shield with regulation-compliant filter insert for laser protection class 4 must also be used in front of the safety glasses for lasers and the person's face. Do not look into the laser beam, even with a regulation-compliant filter insert for laser pro­tection class 4.
- Only wear suitable (flame-resistant) clothing
- Wear hearing protection designed for crossjet noise (120 dbA)
If there are persons present in the sealed cell for the LaserHybrid process,
- inform them of all the dangers that may be posed during operation (e.g. potential ac­cumulation of gases hazardous to health, risk of asphyxiation due to lack of oxygen in the breathable air, hazards posed by laser light, etc.)
- provide protective equipment
- construct protective walls or install protective curtains.
Danger from Tox­ic Gases and Va­pors
The fumes produced during welding contain toxic gases and vapors.
Welding fumes contain substances that may cause birth defects and cancer in some cir­cumstances.
Keep your head out of the welding fumes and gases.
Take the following precautionary measures for fumes and harmful gases:
- Do not breathe them in.
- Extract them from the work area using appropriate equipment.
Ensure that there is sufficient fresh air.
Use breathing apparatus with air supply if there is insufficient ventilation.
When no welding is taking place, close the valve of the shielding gas cylinder or the main gas supply.
If there is uncertainty as to whether the extraction capacity is sufficient, compare the mea­sured toxic emission values against the permissible limit values.
The following components are factors that determine how toxic the welding fumes are:
- The metals used for the workpiece
- Electrodes
- Coatings
- Cleaning agents, degreasers, and the like
Danger Posed by Shielding Gas Leak
Consult the corresponding material safety data sheets and manufacturer's instructions for the components listed above.
Keep flammable vapors (such as solvent vapors) out of the laser and arc radiation range.
Risk of asphyxiation due to uncontrolled shielding gas leak
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Shielding gas is colorless and odorless and may suppress the oxygen in the ambient air in the event of leakage.
- Ensure there is a sufficient supply of fresh air with a ventilation flow rate of at least 20 m³ per hour.
- Please observe the safety and maintenance information for the shielding gas cylinder or the main gas supply.
- When no welding is taking place, close the valve of the shielding gas cylinder or the main gas supply.
- Always check the shielding gas cylinder or main gas supply for uncontrolled gas leak­age before each start-up.
Danger from Fly­ing Sparks
Danger from Welding Current
Flying sparks can cause fires and explosions.
Never undertake welding near flammable materials.
Flammable materials must be kept at least 11 meters (35 ft.) from the LaserHybrid welding process or protected with a certified cover.
Keep suitable, tested fire extinguishers on hand.
Sparks and pieces of hot metal may also get into surrounding areas through small cracks and openings. Take appropriate measures to ensure that there is no risk of injury or fire.
Do not undertake welding in areas at risk of fire and explosion, or on sealed tanks, drums, or pipes if these have not been prepared in accordance with corresponding national and international standards.
Do not undertake welding on containers in which gases, fuels, mineral oils, and the like are/ were stored. Residues pose a risk of explosion.
An electric shock can be fatal. Every electric shock poses a risk of death.
All welding power-leads must be secured, undamaged, and insulated. Replace loose con­nections and scorched cables immediately.
Stray Welding Currents
EMC Measures WARNING! Electromagnetic field! Electromagnetic fields may cause health problems
If the following instructions are not observed, stray welding currents may occur, which can result in the destruction of ground conductors, the power source used, the LaserHybrid head, and other electrical equipment.
Ensure that the workpiece terminal is securely connected to the workpiece. If the floor is electrically conductive, set up the power source so that it is insulated wherever possible.
that are not yet known.
The operator is responsible for ensuring that there is no electromagnetic interference with electrical and electronic equipment.
If electromagnetic interference is discovered, the operator is obliged to take action to rectify the situation.
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Check and evaluate possible problems and the interference immunity of equipment in the vicinity according to national and international regulations:
- Safety devices
- Grid power lines, signal lines, and data transfer lines
- EMC and telecommunications equipment
- Devices for measuring and calibrating
- The health of persons close by, e.g., those with pacemakers and hearing aids
Persons with pacemakers must seek advice from their doctor before staying in the imme­diate vicinity of where the welding work is taking place.
Supporting measures to avoid EMC problems: a) Grid power supply
- If electromagnetic interference occurs despite a grid connection that complies
with regulations, take additional measures (e.g., use a suitable grid filter).
b) Welding power-leads
- Keep them as short as possible
- Route them close together (also to avoid EMC problems)
- Route them far from other lines
c) Equipotential bonding d) Workpiece grounding
- If necessary, establish grounding using suitable capacitors
e) Shield, if necessary
- Shield other devices in the vicinity
- Shield the entire welding installation
Particular Hazard Areas
Laser beam poses a risk of injury to the eyes. In addition to using the protective shield with a regulation-compliant UV filter insert, eyes should be protected from laser beams using regulation-compliant safety glasses for lasers. It must still be ensured, however, that no one can accidentally look into the laser beam.
If the workpiece surface is especially bright or highly reflective, reflected laser-scattering radiation poses a further risk. Take suitable precautions so that persons present have ad­equate protection from laser-scattering radiation also.
Keep hands, hair, loose clothing, and tools away from moving parts, such as:
- Ventilators
- Gear wheels
- Rollers
- Shafts
- Wirespools and welding wires
Do not insert body parts into rotating gear wheels on the wire drive or into rotating drive parts.
Covers and side parts must only be opened/removed during maintenance and repair work.
During operation:
- Ensure that all covers are closed and all side parts have been mounted properly.
- Keep all covers and side parts closed.
Welding wire from the welding torch poses a high risk of injury (cuts to the hand, injuries to the face and eyes, etc.).
For this reason, always hold the welding torch away from your body (devices with wirefeed­er) and wear suitable protective goggles.
Do not touch workpieces during or after welding – risk of burns.
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Slag may fly off from workpieces that are cooling down. For this reason, be sure to wear regulation-compliant protective equipment and ensure that other people are sufficiently protected even when reworking workpieces.
Leave the welding torch and other parts with a high operating temperature to cool before working on them.
Special regulations apply in areas where there is a risk of fire or explosion – observe relevant national and international regulations.
Power sources for work in spaces where electrical hazards pose a greater risk (e.g. the boiler room) must be marked with a (Safety) sign. The power source should not be located in these types of spaces, however.
Risk of scalding due to coolant leakage. Before disconnecting connections for the coolant supply hose or return connection, switch off the cooling unit.
When handling coolants, observe the specifications on the safety data sheet. The coolant safety data sheet is available from your service center or from the manufacturer's homep­age.
Only use suitable load-carrying equipment from the manufacturer for transporting devices by crane.
- Attach chains or ropes to all designated suspension points on suitable load-carrying equipment.
- Chains or ropes must be as close to perpendicular as possible.
- Remove the gas cylinder and wirefeeder (MIG/MAG and TIG devices).
Informal Safety Measures
Always use a suitable wirefeeder hoisting attachment with insulation on the crane for hoist­ing the wirefeeder (MIG/MAG and TIG devices).
If the device is fitted with a carrier belt or handle, this should be used exclusively for trans­portation by hand. The carrier belt is not suitable for transportation by crane, counterbal­anced lift truck or other mechanical chain hoists.
All lifting equipment (belts, straps, chains, etc.) used in connection with the device or its components must be checked regularly (e.g., for mechanical damage, corrosion, or chang­es due to other environmental influences). The test interval and scope must, as a minimum, comply with the respective valid national standards and guidelines.
There is a risk of colorless, odorless shielding gas escaping without notice if an adapter is used for the shielding gas connection. Use suitable Teflon tape to seal the thread of the shielding gas connection adapter on the device side before installation.
The Operating Instructions must always be at hand wherever the LaserHybrid head is be­ing used.
In addition to the Operating Instructions, all applicable local rules and regulations regarding accident prevention and environmental protection must also be made available and be fol­lowed.
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All safety and danger notices on the LaserHybrid head must be kept in a legible state.
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Safety Measures at the Installation Location
The cell for the LaserHybrid welding process must meet the following requirements:
- be light-proof in relation to surrounding rooms
- is shielded with at least 1 mm steel plate and/or approved laser protective glass to pro­tect against UV and laser beams
- The laser welding process and the arc welding process must be stopped automatically and immediately as soon as the cell is opened.
A toppling device can be deadly! Set up the device securely on an even, solid surface
- A tilt angle of no more than 10° is permitted
Special regulations apply in areas at risk of fire or explosion
- Follow the appropriate national and international regulations.
Use instructions and checks within the company to ensure that the vicinity of the workplace is always clean and organized.
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 an all-round clearance of 0.5 m (1 ft. 7.69 in.) so that the cooling air can enter and leave unhindered.
Take care to ensure that the applicable national and regional guidelines and accident pre­vention regulations are observed when transporting the device, especially guidelines con­cerning hazards during transport and shipment.
Before transporting the device, always completely drain the coolant and dismantle the fol­lowing components:
- Wirefeeder
- Wirespool
- Shielding gas cylinder
It is essential to conduct a visual inspection of the device to check for damage after it has been transported but before it is commissioned. Have any damage repaired by trained ser­vice technicians before commissioning the device.
Safety Measures in Normal Opera­tion
Safety Inspection The operator is required to have the LaserHybrid head tested by an electrician after every
Only operate the LaserHybrid head if all protective 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 operating company,
- inefficient operation of the device.
Safety devices that are not fully functional must be repaired before the device is switched on.
Never bypass or disable safety devices.
Before conditioning the LaserHybrid head, ensure that no one can be put in danger.
The LaserHybrid head must be examined at least once a week for externally detectable damage and functionality of the safety devices.
alteration, installation or modification, and all repairs and maintenance, and at least every 12 months, to ensure that it is in its correct state.
Regulation Title
IEC (EN) 60 974-1 Equipment for Arc Welding, Part 1: Welding Current Sources
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BGV A2, Section 5 Electrical Plants and Equipment
BGV D1, Sections 33 / 49Welding, Cutting and Related Work Methods
VDE 0701-1 Repairing, Modifying and Testing Electrical Devices;
General Requirements
VDE 0702-1 Repeating Tests on Electrical Devices
Modifications Do not carry out any alterations, installations, or modifications to the LaserHybrid head
without first obtaining the manufacturer’s permission.
Parts that are not in perfect condition must be replaced immediately.
Spare and Wear­ing Parts
Calibrating Power Sources
The CE label The LaserHybrid head meets the basic requirements of the Low Voltage and Electromag-
Copyright Copyright of these operating instructions remains with the manufacturer.
Use only original spare and wearing parts (also applies to standard parts). It is impossible to guarantee that externally procured parts are designed and manufactured to meet the demands made on them, or that they satisfy safety requirements.
When ordering, specify the exact name and part number according to the Spare Parts List as well as the serial number of your device.
Regular calibration of power sources is required in accordance with international stan­dards. The manufacturer recommends a calibration interval of 12 months. Please contact your service center if you require further details.
netic Compatibility Directives and therefore has CE sign.
Text and illustrations are technically correct at the time of going to print. The right to make modifications is reserved. 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 operating in­structions, we will be most grateful for your comments.
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General Information
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General
General
The laser welding head WF 25i LaserHyb­rid 90° 10 kW FW is a development of the 10 kW LaserHybrid head that is used espe­cially for components with fillet welds.
The laser welding head WF 25i LaserHyb­rid 90° 10 kW FW will be referred to in the rest of this OI as the laser welding head.
Additional benefits of the laser welding head:
- High welding speed and great cost-effectiveness
- High process stability combined with a low level of rejects and reworking
- High quality weld seam
- Low heat input, reduced distortion
- High availability of the welding system, high service life of the wearing parts
- Flexible use of the welding system
- High gap tolerance
- Adaptation for fiber, disk, and diode laser possible
Intended Use The WF 25i LaserHybrid 90° 10 kW FW is intended exclusively for automated MIG/MAG
welding in combination with Fronius system components. Any other use does not constitute proper use. The manufacturer is not responsible for any damage resulting from improper use.
Proper use also means:
- Following all the instructions from the OIs for the individual components
- Carrying out all the specified inspection and servicing work
Applications The laser welding head is used for MAG laser applications:
- For all components with fillet welds for plate thicknesses from 1.5 mm
- For penetration welds from one side up to a plate thicknesses of 8 mm
- For lap joints with plate thicknesses of 1.5 - 3 mm steel, aluminum, CrNi, and special steel
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Scope of Supply - 1 laser welding head WF 25i LaserHybrid 90° 10 kW FW
- 1 LaserHybrid hosepack MHP 360i LH/W/FSC/FW/ with external wirefeeding hose
- 1 drive unit WF 25i Robacta Drive
- 1 torch body MTB 700
- 1 optical adjustment gauge
- 1 metal gauge to set the focal point
- 1 extractor tool for register pins
- 1 combination wrench 10 mm
- 1 open-end wrench 10 mm
- 1 wrench 8x10
- 1 bit 1/4" with handle and flexible shaft
- 1 bit 1/4" 840/4 Z.
- 1 TX20 Torx screwdriver
- 1 Allen key, 5 mm
- 1 Allen key, 2.5 mm / laser
- 1 Allen key, 6 mm / laser
- 1 ballpoint Allen wrench, size 3 mm
- 1 ballpoint Allen wrench, size 4 mm
- 1 Operating Instructions
- Miscellaneous screws
Optional Compo­nents
The following components are optionally available for the laser welding head:
- Seam tracking system, e.g. secured at the front on the welding head
- Process monitoring to increase the weld seam quality, e.g. connected to the laser op­tics
- Focus monitoring
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Requirements
Mechanical Re­quirements
Robot Require­ments
Ground Connec­tion
The following mechanical requirements must be met in order to ensure a stable and re­peatable LaserHybrid process:
- Accurate welding torch guidance for robots or single-purpose machines (e.g. longitu­dinal chassis)
- Precise weld seam preparation
- Low component tolerances
- Precise and very fast weld seam management systems with little deviation
The laser welding head weighs around 19 kg. The optics weigh a further 3 kg approximate­ly. A total weight of around 30 kg should be expected for the complete laser welding head when fitted with optics and hosepack. It must therefore be possible for the robot axles to move a weight of 30 kg safely with the accelerations specified.
IMPORTANT! The maximum permitted acceleration for the laser welding head is 3 g at 5– 150 Hz, based on use of the laser optics.
-
Grounding cable with bifilar winding Grounding cable coiled
-
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Alignment
CAUTION!
Danger of serious damage by laser radi­ation reflected directly into the laser op­tics!
This can cause serious damage to the fiber optic. ► Always avoid 90° angles to the work-
piece surface when aligning the Lase­rHybrid head.
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System Overview
System Overview LaserHybrid System with SplitBox SB 360i LaserHybrid Installed on the Robot
(6)
(10)
(4)
(2)
(3)
(1)
(1) Welding wire drum * (2) Unwinding wirefeeder:
WF 25i REEL 4R + OPT/i WF wire straightener (4,100,880,CK) + WF MOUNTING Drum
(3) Control line for unwinding wire-
feeder (4) Remote control (5) Power source TPS 500i
+ robot interface **
+ cooling unit CU 1400i Pro MC or
CU 2000i MC Single
+ upright bracket (screwed on)
(5)
(11)
(8)
(7)
(9)
(6) Wirefeeding hose (7) Interconnecting hosepack (8) Robot (9) SplitBox SB 360i LaserHybrid
+ Mounting SB 360i LH ***
(10) Hosepack LaserHybrid
MHP 360i LH/W/FSC/FW
(11) WF 25i LaserHybrid 90° 10 kW
FW
(12) LaserHybrid cleaning station
(12)
* As an alternative to the welding wire drum, the wirefeeding can also be carried out
via wirespools. The following components are required for this purpose: Unwinding wirefeeder WF 25i REEL 4R + OPT/i WF reel carriage D300
** Example: RI FB Inside/i or RI FB Pro/i
*** Robot support for the SplitBox SB 360i LaserHybrid, depending on type of robot
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Other LaserHy­brid Systems
LaserHybrid System with SplitBox SB 360i LaserHybrid Installed on the Wall
(6)
(4)
(2)
(5)
(3)
(1)
(1) Welding wire drum (2) Unwinding wirefeeder:
WF 25i REEL 4R
+ OPT/i WF wire straightener
(4,100,880,CK)
+ WF MOUNTING Wall (3) Control line for unwinding wire-
feeder (4) Remote control (5) Power source TPS 500i
+ robot interface
+ cooling unit CU 1400i Pro MC or
CU 2000i MC Single
+ upright bracket (screwed on)
(7)
(9)
(8)
(10)
(11)
(12)
(6) Wirefeeding hose (7) Interconnecting hosepack (8) Robot (9) SplitBox SB 360i LaserHybrid
+ wall bracket SB 360i LH
(10) Hosepack LaserHybrid
MHP 360i LH/W/FSC/FW
(11) WF 25i LaserHybrid 90° 10 kW
FW
(12) LaserHybrid cleaning station
22
Page 23
LaserHybrid System with SplitBox SB 360i LaserHybrid Installed on the Power Source
(7)
(8)
(1)
(3)
(5)
(4)
(2)
(1) Remote control (2) Control line for unwinding wire-
feeder (3) Power source TPS 500i
+ robot interface
+ cooling unit CU 1400i Pro MC or
CU 2000i MC Single
+ upright bracket (screwed on)
+ interconnecting hosepack (4) SplitBox SB 360i LaserHybrid
(6)
(9)
(6) Unwinding wirefeeder:
WF 25i REEL 4R + OPT/i WF reel carriage D300
(7) Hosepack LaserHybrid
MHP 360i LH/W/FSC/FW (8) Wirefeeding hose (9) Robot (10) WF 25i LaserHybrid 90° 10 kW
FW (11) LaserHybrid cleaning station
(10)
+ OPT/i TPS Mount SB 360i LH*
(5) Wirespool D300
* Support for the SplitBox SB 360i LaserHybrid, mounted to the power source
(11)
23
Page 24
Setup Variants
Power Source Located in Welding Cell (I)
- TPS 500i – power source
- HP 95i CON W / 1.2 m / 95 mm² – interconnecting hosepack
- SB 360i LaserHybrid – SplitBox, mounted on the power source
- MHP 360i LH/W/FSC/FW 7.5m – LaserHybrid hosepack
- Welding wire drum
- WF 25i REEL 4R – wirefeeder reel
- WF MOUNTING Drum
- Wirefeeding hose L = 10 m
- Laser welding head
Area of application: The robot only makes minor compensatory movements. Robot axles 7 and 8 carry out the majority of the welding feed movements.
Example: Circumferential welds on boilers, axles, etc.
Power Source Located in Welding Cell (II)
- TPS 500i – power source
- HP 95i CON W / 1.2 m / 95 mm² – interconnecting hosepack
- SB 360i LaserHybrid – SplitBox, mounted on the power source
- MHP 360i LH/W/FSC/FW 7.5m – LaserHybrid hosepack
- Wirespool
- WF 25i REEL 4R – wirefeeder reel
- WF reel carriage D300
- Wirefeeding hose L = 10 m
- Laser welding head
Area of application: For test systems only (no wirespool in series production)
Power Source Not Located in Welding Cell (I)
- TPS 500i – power source
- HP 95i CON W / 10 m / 95 mm² – interconnecting hosepack
- SB 360i LaserHybrid – SplitBox, mounted on the robot or the wall
- MHP 360i LH/W/FSC/FW 4.2m – LaserHybrid hosepack
- Welding wire drum
- WF 25i REEL 4R – wirefeeder reel
- WF MOUNTING Drum
- Wirefeeding hose L = 20 m
- Laser welding head
Area of application: Robot axles 1–6 carry out the welding feed movements.
Example: Longitudinal seams on boilers, battery trays, etc.
24
Page 25
Power Source Not Located in Welding Cell (II)
- TPS 500i – power source
- HP 95i CON W / 10 m / 95 mm² – interconnecting hosepack
- SB 360i LaserHybrid – SplitBox, wall mounting
- MHP 360i LH/W/FSC/FW 7.5m – LaserHybrid hosepack
- Welding wire drum
- WF 25i REEL 4R – wirefeeder reel
- WF MOUNTING Drum
- Wirefeeding hose L = 20 m
- Laser welding head
Area of application: Robot axles 1–6 carry out the welding feed movements.
Example: Longitudinal seams on boilers, battery trays, etc.
Power Source Is on a Gantry and Moves Too
- TPS 500i – power source
- HP 95i CON W / 10 m / 95 mm² – interconnecting hosepack
- SB 360i LaserHybrid – SplitBox, mounted on gantry
- MHP 360i LH/W/FSC/FW 4.2 m or 7.5m – LaserHybrid hosepack
- Welding wire drum
- WF 25i REEL 4R – wirefeeder reel
- WF MOUNTING Drum
- Wirefeeding hose L = 20 m
- Laser welding head
Area of application: Robot axles 1–8 carry out the welding feed movements.
Example: Longitudinal seams in rail vehicle construction, large base frames (e.g. press brakes), etc.
25
Page 26
26
Page 27
Operating controls and connections
Page 28
Page 29
Product description
Product descrip­tion
(1)
(11)
(10)
(9)
(8)
(7)
(2)
Item Name
(1) Robot support
(2) Laser optics
(3) Adjustment device
(4) Gas nozzle
(5) MTB torch body
(6) Additional extraction system
(7) Drive unit WF 25i Robacta Drive / W
(8) Support WF 25i Robacta Drive
(9) MHP robot hose pack
(10) CrossJet connection
(11) External wirefeeding hose
(6)
(5)
(4)
(3)
29
Page 30
Control Panel WF 25i Robacta Drive / WF 60i Robacta Drive CMT
(1) (2)
(5)
(4)
No. Function
(2) F1 button
No function at present
(3) Wire-return button
For retracting the wire electrode without gas or current
- Whilst the button is being pressed, the wirefeeder operates at the preset wire-return speed
There are two options available for retracting the wire electrode:
Option 1
Retract the wire electrode at the preset wire-return speed:
- Press and hold the wire-return button
- After pressing the wire-return button, the wire electrode is retracted by
1 mm (0.039 in.)
- After a brief pause, the wirefeeder continues retracting the wire elec-
trode – if the wire-return button is kept pressed down, then the speed in­creases with each further second by 10 m/min (393.70 ipm) until the preset wire-return speed is reached
(3)
No. Function
(1) Gas-test button
To set the required quantity of gas on the gas pressure regulator
- After pressing the gas-test button, gas is released for 30 s. Pressing the button again ends the process early
Option 2
Retract the wire electrode in 1 mm steps (0.039 in. steps) – always press the wire­return button for less than 1 second (tap)
IMPORTANT! Only retract the wire electrode a small amount at a time, to avoid the wire electrode becoming entangled on the wirespool during retraction.
IMPORTANT! If there is a ground earth connection with the contact tip, then be­fore the wire-return button is pressed, the wire electrode is retracted by pressing the wire-return button until the wire electrode is short-circuit-free—however by a maximum of 10 mm (0.39 in.) each time the button is pressed. If the wire electrode is retracted further, press the wire-return button again.
(4) Wire-threading button
For threading the wire electrode into the torch hosepack without gas or current
- Whilst the button is being pressed, the wirefeeder operates at the preset feeder inching speed
There are two options available for the wire threading:
30
Page 31
No. Function
Option 1
Thread the wire electrode at the preset feeder inching speed:
- Press and hold the wire-threading button
- After pressing the wire-threading button, the wire electrode will be
- After a brief pause, the wirefeeder continues threading in the wire elec-
- If the wire electrode meets a ground earth connection, then the wirefeed-
Option 2
Thread the wire electrode in 1 mm steps (0.039 in. steps) – always press the wire­threading button for less than 1 second (tap)
- If the wire electrode meets a ground earth connection, then the wirefeeding is stopped and the wire electrode is retracted again by 1 mm (0.039 in.)
IMPORTANT! If there is a ground earth connection with the contact tip, then be­fore the wire-threading button is pressed, the wire electrode is retracted by press­ing the wire-threading button until the wire electrode is short-circuit-free— however, this must not exceed 10 mm (0.39 in.) each time the button is pressed. If after the 10 mm (0.39 in.) wire retraction there is still a ground earth connection with the contact tip, then when the wire-threading button is pressed again, the wire electrode is retracted again by a maximum of 10 mm (0.39 in.). The process is repeated until there is no longer any ground earth connection with the contact tip.
(5) Display
Status display
threaded in by 1 mm (0.039 in.)
trode – if the wire-threading button is kept pressed down, then the speed increases with each further second by 10 m/min (393.70 ipm) until the preset feeder inching speed is reached
ing is stopped and the wire electrode is retracted again by 1 mm (0.039 in.)
Device Descrip­tion, SB 360i La­serHybrid
(1)
(2)
(3) (4)
(5)
(6) (7)
(8)
Back Front
Item Description
(1) (+) Current socket with fine thread
for connecting the power cable from the interconnecting hosepack
(2) Shielding gas connection socket
(8)
(9)
(10)
(11)
(12)
(13)
(14)
31
Page 32
Item Description
(3) SpeedNet connection
for connecting the SpeedNet cable from the interconnecting hosepack
(4) SpeedNet connection
for connecting system add-ons e.g. the remote control
(5) Gas purging connection
(6) Connection for welding torch cooling – coolant return flow (red)
for connecting the coolant return flow hose from the interconnecting hosepack
(7) Connection for welding torch cooling – coolant supply line (blue)
for connecting the coolant supply line hose from the interconnecting hosepack
(8) SplitBox SB 360i LaserHybrid mount
(9) Welding torch connection (FSC)
for connecting the LaserHybrid hosepack
(10) (11)
(12) Connection crossjet IN
(13) Interconnecting hosepack (for the power source)
(14) Connecting plug for welding torch cooling
Connection crossjet OUT
not included in the SB 300i LaserHybrid in its original state; the interconnecting hosepack is inserted into SB 300i LaserHybrid during the assembly.
for connecting the welding torch cooling on the LaserHybrid hosepack
32
Page 33
Connection Specifications
Connection Spec­ifications
(7)
(1)
(2)
(6)
Item Name
(1) Laser optics water cooling connection
(return opposite)
(2) Fiber optic cable for laser
bending radius > 200 mm
(3) CrossJet extraction connection
for connecting a hose as per the following data:
- Inner diameter Di = 51 mm
- Outer diameter Do = 57 mm
- Max. length = 10 m
(4) CrossJet supply
for connecting a hose as per the following data:
- Inner diameter Di = 12 mm
- Outer diameter Do = 14 mm
- p = 6 bar
- Required filling capacity = 6 bar - 1500 l/min
- Required extraction capacity = 280 m³/h
(3)
(4)
(4)
(5)
33
Page 34
Item Name
(5) Additional extraction connection
for connecting a hose as per the following data:
- Inner diameter Di = 41 mm
- Max. length = 10 m
- Recommended extraction unit: min. fan power = 200 m³/h min. negative pressure = 20,000 Pa
(6) External wirefeeding hose (Fronius)
(7) Radial air supply
for connecting a hose as per the following data:
- Outer diameter Do = 6 mm
Compressed Air Diagram
(1)
(7)
(9)
(4)
(5)
MHP LH = LaserHybrid hosepack
MHP LH
(2)
(7)
(3) (4)
Item Name
(1) Compressed air supply line
(2) Solenoid valve
(8)
(3) Internal pressure measurement
(4) Pressure measurement option
(5) Radial air flow branch
(4)
(6)
(6) CrossJet gas nozzles branch
(7) CrossJet supply
(8) CrossJet extraction
(9) Additional extraction system
(5)
(7)
(8)
(6)
WF 25i LaserHybrid 90° 10 kW FWSB 360i LaserHybrid
Pressure Monitor­ing in the Split­Box SB 360i LaserHybrid
34
The pressure is monitored after the solenoid valve. If the pressure falls below 4.5 bar for longer than two seconds, the "Powersource Ready" bit is withdrawn and error code 16835 (laser crossjet air pressure supply low) issued.
Page 35
Commissioning
Page 36
Page 37
General
Safety
Setup Regula­tions
WARNING!
Work performed incorrectly can cause serious injury and damage to property.
► This setting work must only be carried out by trained and qualified personnel. ► Observe the safety rules in the OI, in particular the "Safety Inspection" section.
The power sources have been tested according to protection class IP 23. This means:
- Protection against solid foreign bodies larger than Ø 12 mm (0.47 in.)
- Protection against spraywater up to an inclined angle of 60°
The welding system can be set up and operated outdoors in accordance with protection class IP 23. However, the effects of direct moisture (e.g. from rain) must be avoided.
WARNING!
Toppling or falling devices can be deadly.
► Securely set up the devices on a level and stable surface.
The ventilation channel of the power sources is an important safety device. When selecting the setup location, ensure that the cooling air can enter and exit unhindered through the vents on the front and back. Any electrically conductive dust (e.g. from grinding work) must not be allowed to be sucked directly into the system.
Grid Connection The device is designed for the grid voltage listed on the rating plate. The fuse protection
required for the grid lead can be found in the "Technical Data" section. If mains cables or mains plugs are not included with your version of the appliance, attach the appropriate mains cable or mains plug in accordance with your country's standards.
CAUTION!
An under-dimensioned electrical installation can lead to serious damage.
► The grid lead and its fuse protection should be designed to suit the existing power sup-
ply.
► The technical data on the rating plate should be followed.
Setting Up the La­serHybrid Weld­ing System
If a power source is connected to the grid during installation, there is a danger of serious injury and damage.
► Please read the "Safety Rules" chapter for the power source in the Operating Instruc-
► All preparation steps must only be performed if: ► The mains cable has been disconnected from the grid ► The power switch of the power source is set to "O"
WARNING!
tions before using it for the first time.
37
Page 38
Initial situation: Robot and robot control are present and ready for operation
Set up welding system:
Mount upright brackets
1
Mount cooling unit on upright bracket
2
Connect power source to cooling unit
3
Set up welding wire drum
4
Mount WF MOUNTING drum onto the welding wire drum
5
Set up and connect unwinding wirefeeder
6
Connect power source with robot control
7
Connect remote control
8
Set up laser welding head:
Mount WF 25i Robacta Drive on the laser welding head
9
Mount laser welding head on the robot
10
Mount and connect SplitBox SB 360i LaserHybrid
11
Connect CrossJet
12
Connect LaserHybrid hosepack to the laser welding head
13
Connect/change wirefeeding hose on the laser welding head
14
Install / replace wirefeed rollers
15
Connect laser optics and additional extraction system
16
Equip welding torch
17
Place LaserHybrid hosepack on the robot
18
Thread the wire electrode
19
Other activities before commissioning:
Adjust the laser welding head
20
Create reference program
21
Signal sequence for LaserHybrid welding
22
Measures before starting welding
23
Establish ground earth connection between workpiece and power source
24
38
Page 39
Installing the Laser Welding Head on the Robot
Connection Op­tions on the Ro­bot
90 mm
Mount WF 25i Ro­bacta Drive on the laser welding head
238 mm
If the drive unit WF 25i Robacta Drive is not mounted to the laser welding head when it is delivered, mount it following the instructions below.
Insert the drive unit WF 25i Robacta
1
Drive into the support
Mount the drive unit using two Allen
2
screws, 5 mm Tightening torque = 10 Nm
1
2
2
39
Page 40
Mounting the La­ser Welding Head on the Robot
The laser welding head does not have any collision protection fitted as standard.
Fronius therefore recommends the use of a commercially available collision protection solution for robotic applications in order to prevent damage to the laser welding head in the event of a crash.
Mount the laser welding head to the ro-
1
bot according to the specifications of the robot manufacturer.
1
40
Page 41
Installing and Connecting SplitBox SB 360i LaserHy­brid
Installing Split­Box SB 360i Lase­rHybrid on Robot
Separate the SplitBox SB 360i LaserHybrid and SplitBox mount
1
Install a suitable holder for the SplitBox mount on your robot
2
IMPORTANT Please observe the robot manufacturer's assembly instructions.
Fit the SplitBox mount on the holder
3
using 4 x Allen screws size 6 mm Tightening torque = 24 Nm
3
3
3
3
Insert the interconnecting hosepack
4
strain-relief device into the opening and push forward
4
41
Page 42
Fix the interconnecting hosepack
5
strain-relief device in place using 2 x
6
5
Allen screws size 4 mm
Open the ear clamps (x 2)
6
Insert the interconnecting hosepack
7
into the ear clamps
7
5
Close the ear clamps
8
10
10
10
8
Insert SplitBox SB 360i LaserHybrid
9
into the SplitBox mount as illustrated
Fix SplitBox in place in the SplitBox
10
8
mount using 3 x screws TX25 at the top and 3 x screws TX25 at the bottom
9
10
Tightening torque = 3.5 Nm
42
10
10
Page 43
Connecting Split­Box SB 360i Lase­rHybrid
Connect interconnecting hosepack to
1
SplitBox:
a) Power cable
a
d
b) Welding torch cooling return flow
(red)
c) Welding torch cooling supply line
f
c
b
e
*
(blue)
d) Protective gas shield e) SpeedNet (from interconnecting
hosepack)
f) SpeedNet (remote control)
* Gas purging connection
Connect LaserHybrid hosepack to wel-
2
ding torch connection (FSC)
Close clamping lever
3
Open cover on LaserHybrid hosepack
3
4
2
4
Connect connecting plug for welding
5
5
torch cooling to the LaserHybrid hose­pack
Connect crossjet air inlet
6
6
43
Page 44
IMPORTANT! When connecting crossjet air outlet hoses, make sure that cutting rings are present!
7
7
8
8
Connect crossjet air outlet (x 2)
7
Fix the hoses in place on the connecti-
8
on using hexagon nuts size 24 mm Tightening torque = 50 Nm
IMPORTANT! Use flat spanner size 22 mm to hold the items in place when fixing the hexagon nuts in place on the connection
Connect hoses for optics cooling
9
(push-in) Blue marking = coolant supply line
9
9
9
9
Connecting Interconnecting Hosepack to Power Source
10
Option:
(1) Data line 3 x 0.5 mm²
(1)
(e.g. for analyzing additional pres­sure monitoring)
44
Page 45
Connecting Crossjet
Connecting the CrossJet
Insert CrossJet exhaust air hose into
1
the opening
Position fixing plate so that it is in a
2
groove of the CrossJet exhaust hose (x2 - also on the opposite side)
1
2
Secure fixing plate with 2 Allen screws,
3
3 mm (x2 - also on the opposite side)
3
3
Depending on the robot movement,
4
determine the required length of the air hoses and cut the air hoses accor-
4
dingly to size
Withdraw protective hose
5
IMPORTANT! When connecting the CrossJet air outlet hoses, ensure that
6
5
the cutting rings are present!
Connect CrossJet air outlet
6
Secure hose to the connection using a
7
hexagonal nut, 24 mm Tightening torque = 50 Nm
IMPORTANT! When securing the he­xagon nut to the 22 mm connection so­cket, counter with a 22 mm wrench.
Repeat process on the other side
8
45
Page 46
Pull protective hoses over the connec-
9
tions
8
8
46
Page 47
Connecting LaserHybrid Hosepack to Laser Welding Head
Mounting the Hosepack on the WF Robacta Drive (Conventional)
IMPORTANT! Only mount the drive unit when the power source is switched off.
CAUTION!
Risk of damage due to dirty or wet coupling points
► When removing or attaching the hosepack, ensure that the coupling point is clean and
dry.
► Remove any coolant that has escaped from the coupling point.
1 2
1
2
3 4
3 4
45,0200,1261
42,0411,1315
47
Page 48
Connecting/ Changing the Wirefeeding Hose on the Laser Welding Head
Place the starting piece on the wirefee-
1
ding hose
Screw the starting piece as far as it will
2
go onto the wirefeeding hose
1
2
Press the green locking button and
6
4
3
hold it
Push the wirefeeding hose into the dri-
4
ve unit until the tension on the locking
3
5
button is released
Let go of the locking button
5
Push the wirefeeding hose onwards
6
until the lock engages and the locking button pops out
48
Removal:
Press the locking button and hold it
1
Pull the wirefeeding hose from the dri-
2
ve unit
Page 49
Installing/Changing Wirefeed Rollers
Inserting/Replac­ing the WF 25i Ro­bacta Drive Feed Rollers
1 2
1
2
2
1
3
3 4
0 mm *
* If the roller mount is opened as far as it will go with the slight resistance, the roller mount stays in this po­sition.
5 6
5
4
6
42,0411,0160
49
Page 50
7 8
7 8
9 10
9
42,0411,0160
Torx 40 1 Nm
10
2
11 12
11 12
1
2
50
Page 51
Connecting Laser Optics and Extra Extraction
Connecting the Laser Optics
CAUTION!
Risk of damage to the laser welding head as a result of contamination from above.
► Observe the OI, specifications, and safety instructions from the manufacturer of the la-
ser optics
► Before connecting, position the laser welding head so that the longitudinal axis of the
laser welding head is outside of the horizontal (> 90°). This will ensure that no dirt can get into the laser optics from above.
Remove 5 x Allen screws size 6 mm
5x
1
1
1
1
For assembly: the 3 x shorter screws are located one be­low the other; the 2 x longer screws opposi-
1
1
te each other.
Remove 2 x register pins:
2
a) Position and connect extractor
tool for register pins
c
b) Knock the striking weight of the
extractor tool backwards, thereby
c
a
a
b
removing the register pins
c) Remove bracket for robot connec-
tion
51
Page 52
Position the laser welding head so that
3
the longitudinal axis on the laser wel­ding head is outside of the horizontal (> 90°)
Clean connection area using compres-
4
sed air
Remove the protective cover from the
5
fiber optic cable connection
5
4
Clean connector of the fiber optic cable
6
using compressed air
Remove protective cover from the
7
connector of the fiber optic cable
7
6
52
Page 53
IMPORTANT! When connecting the fiber optic cable, pay attention to the position of the register pin on the connector!
Connect fiber optic cable:
a
8
a) Press the button
b
b) Withdraw the rubber sleeve in the
direction of the optics
c
b
c) Connect the fiber optic cable
connector
Check whether the rubber sleeve is
9
cleanly sealed all around the fiber optic cable connector
IMPORTANT! The picture opposite shows an incorrectly positioned rubber sleeve! The rubber sleeve shown has a kink in the area indicated by the arrows, and therefore it is not fully sealed.
INCORRECTLY positioned rubber sleeve! The rubber sleeve does not seal fully.
10
10
Connect the optics cooling using the
10
Allen screws, size 2.5 mm Tightening torque = 4 Nm
53
Page 54
11
11
12
Connect the optics cooling supply
11
(blue marking)
Connect the optics cooling return
12
Connecting the Additional Ex­traction System
12
12
Position laser welding head in the vertical line
13
1
2
Push hose over the connection
1
Secure hose with hose clamp
2
54
Page 55
Apply robot connection bracket
3
Push slot nut upwards, so that the top
4
hole of the slot nut is positioned under
3
the top hole of the robot connection
bracket.
4
Use a short Allen screw (6 mm) to
5
lightly fix the slot nut and robot connec­tion bracket
5
5
Insert register pins (x2)
6
Position and connect extractor tool for
6
7
register pins
Knock the striking weight of the extrac-
8
tor tool forwards, thereby positioning
7
7
8
the register pins
55
Page 56
5x
10
9
9
9
For assembly: the 3 x shorter screws are located one be­low the other; the 2 x longer screws opposi­te each other.
Insert the remaining 4 Allen screws,
9
size 6 mm
Fix the bracket for the robot connection
10
in place using 5 x Allen screws, size 6 mm Tightening torque = 24 Nm
56
Page 57
Preparing Welding Torch
Mounting the In­ner Liner in the Torch Body
Plastic inner liner:
1 2
1
3
3
2
57
Page 58
Steel inner liner:
1 1
1
1
3
2
Mounting the Welding Torch onto the WF Ro­bacta Drive (Con­ventional)
IMPORTANT! When removing or attaching the welding torch, ensure that the coupling
point is clean and dry. Remove any coolant that has escaped from the coupling point.
1 2
1
2
58
Page 59
3
3
59
Page 60
Installing Hosepack on Robot
Placing the Hose­pack on the Ro­bot
IMPORTANT! The optional LaserHybrid hosepack holder is not included in the scope of
supply for the laser welding head.
6 x 5 Nm
44,0360,0099
(11)
(13)
8 Nm
(14)
2,9 Nm
(12)
27 Nm
2,9 Nm
(12)
(8) (5) (7)
(6)
(6) (9)
(10)
(11)
(6)
(6)
(7) (4)
(4)
44,0350,0254
(1) Robot arm (2) Mounting HP LH xx
(3) Item profile 10 50 x 50 mm, 2 m
(4) Optional extension arm
(5) Opening for extraction hose (6) Opening for wirefeeding hose (7) Opening for fiber optic cable (8) Opening for LaserHybrid hose-
M10 45 Nm
Mounting plate depending on ro­bot
(42,1000,0112)
(44,0350,0254)
pack
42,1000,0112
(3)
(2)
(1)
(9) Adapter insert for extraction hose
set, diameter 41/51 mm
(42,0411,9036) (10) Lower sheet metal part (11) Slot nut (12) Allen screw
M4 x 60 mm (13) Allen screw
M8 x 20 mm (14) Allen screw
M6 x 25 mm
60
Page 61
Installation
Mount the mounting plate (2) to the robot arm (1) according to the instructions of the
1
robot manufacturer
Cut the profile 10 50 x 50 mm (3) to length according to the robot arm
2
Mount the profile 10 50 x 50 mm (3) using slot nuts and 4 hexagonal bolts, size 17 mm,
3
to the mounting plate (2) Tightening torque = 10 Nm
Remove Allen screw, size 3 mm (12), and dismantle the lower sheet metal part (10)
4
of the LaserHybrid hosepack holder
Loosen the 2 Allen screws, size 6 mm (13), between the lower sheet metal part (10)
5
and the slot nut (11) so that the slot nut (11) can be pushed into the top slot on the profile 10 50 x 50 mm (3)
Push the slot nut (11) with the lower sheet metal part (10) into the top slot on the profile
6
10 50 x 50 mm (3)
Tighten 2 Allen screws, size 6 mm (13), and secure the lower sheet metal part (10)
7
with the slot nut (11) to the profile 10 50 x 50 mm (3) Tightening torque = 27 Nm
Repeat steps 4 - 7 for all LaserHybrid hosepack holders
8
Using the Allen screw, size 3 mm (12), attach the components of the LaserHybrid
9
hosepack holder(s) back onto the lower sheet metal part (10) Tightening torque = 2.9 Nm
For all LaserHybrid hosepack holders, remove the top and side plastic parts
10
6 Allen screws, size 5 mm (14)
Position hoses, cables, and LaserHybrid hosepack into the openings of the LaserHy-
11
brid hosepack holders
For all LaserHybrid hosepack holders, fit the top plastic part and secure to the side
12
plastic parts 6 Allen screws, size 5 mm (14), tightening torque = 4 Nm
61
Page 62
Adapting the Additional Extraction System
Safety
Adapting the Ad­ditional Ex­traction System
WARNING!
Work performed incorrectly can cause serious injury and damage to property.
► This setting work must only be carried out by trained and qualified personnel. ► Observe the safety rules in the OI, in particular the "Safety Inspection" section.
To make components more accessible, the position of the additional extraction system can be adapted to the existing available space.
The additional extraction system is factory-set for the LaserHybrid welding process.
Every change in position of the additional extraction system can affect the extraction per­formance.
Loosen 4 Allen screws
1
size 2.5 mm
4x
1
1
1
1
2
2
When adapting the position of the addi­tional extraction system, ensure that the gas shield remains intact and that no shielding gas is extracted from the wel­ding area.
Adapt the position of the additional ex-
2
traction system according to the appli­cation and accessibility
Tighten screws
3
62
Page 63
Threading the Wire Electrode
1
Threading the Wire Electrode
IMPORTANT! Before threading the wire electrode, carefully deburr the end of the wire
electrode!
Requirement:
- Wirefeeding hose connected
- Wire electrode is threaded into the unwinding wirefeeder
- Correct wirefeed rollers and inlet nozzles available in the laser welding head
1 2
1
2
1
2
3 4
3
4
Press the wire threading button until the wire electrode comes out of the welding torch
63
Page 64
64
Page 65
Setting up Laser Welding Head
Stick Out
(1)
(2)
(3)
15 - 20 mm
Adjustable Axes The spatial position of the arc process to the laser beam can be adjusted in all three Car-
tesian coordinate axes.
When setting the spatial position of the welding torch, pay attention to a general stick out of 15-20 mm.
Standard stick out = 20 mm
► Using an adjustment device, compen-
sate for a stick out < 20 mm in the x, y, and z axis according to the focal length of the laser optics.
► Observe the specifications on the laser
optics!
(1) Welding torch (2) Contact tip (3) Stick out
CAUTION!
Risk of damage to the optical fiber due to the laser beam being vertical to the work­piece surface.
If the laser beam is at 90° to the workpiece surface, then the laser beam is reflected directly into the laser optics. This may cause serious damage to the optical fiber.
z (± 5 mm)
90°
y
(± 5 mm)
x (± 5 mm)
65
Page 66
Adjustment De­vice on the Laser Welding Head
The laser welding head is equipped with an adjustment device, which allow for precise po­sitioning in the x, y, and z coordinate axes.
(1) Scale for the x axis
(2) Adjustment screw with graduati-
(1)
(6)
on for the x axis
Adjustment range +/- 5 mm Allen screw, 5 mm
¼-turn corresponds to an adjust­ment path of 0.25 mm
(2) (3) (4) (5)
(3) Scale for the z axis
(4) Adjustment screw with graduation for the y axis
Adjustment range +/- 5 mm Allen screw, 5 mm
Adjusting the x Axis
¼-turn corresponds to an adjustment path of 0.25 mm
(5) Scale for the y axis
(6) Adjustment screw with graduation for the z axis
Adjustment range +/- 5 mm Allen screw, 5 mm
¼-turn corresponds to an adjustment path of 0.25 mm
Loosen threaded pin on the adjustment
1
device size 2.5 mm
Adjust x axis by turning the adjustment
2
screw:
1
3
Allen key, size 5 mm ¼-turn corresponds to 0.25 mm
2
After adjusting the x axis, re-tighten the
3
threaded pin on the adjustment device
2
66
Page 67
Adjusting the y Axis
Loosen 2 Allen screws by 1 turn res-
1
pectively
1
1
size 4 mm
Adjust y axis by turning the adjustment
2
screw (3): Allen key, size 5 mm ¼-turn corresponds to 0.25 mm
After adjusting the y axis, re-tighten the
3
2 Allen screws
Adjusting the z Axis
2
2
Loosen threaded pin on the adjustment
1
device size 2.5 mm
Adjust z axis by turning the adjustment
2
2
screw: Allen key, size 5 mm
2
¼-turn corresponds to 0.25 mm
After adjusting the z axis, re-tighten the
3
threaded pin on the adjustment device
1
3
67
Page 68
Creating Reference Program
Safety
Work performed incorrectly can cause serious injury and damage to property.
► This setting work must only be carried out by trained and qualified personnel. ► Observe the safety rules in the OI, in particular the "Safety Inspection" section.
General A pilot laser with low power is required for the described adjustment work.
A reference program will also need to be created:
- After the laser welding head is installed for the first time
- When programming a new part, if the x-, y- and z-values have changed on the adjust-
Creating a Refer­ence Program
The scope of supply for the laser welding head includes a metal gauge for the exact ad­justment of the wire electrode position with respect to the laser focus. This gauge is mounted in the working area of the robot and is used to create a reference program for the series components.
Create a reference program before welding the first series component
WARNING!
ment units.
Requirement:
- The laser welding head must be set up and fully connected.
- The wire electrode must be threaded in.
- With the wire electrode, the stick out must be adjusted for the relevant application
- Observe the focal width specification on the laser optics
Mount gauge (1) in the working area of the robot
1
Switch on pilot laser
2
Position laser welding head via robot so that the pilot laser beam hits the gauge at an
3
angle of 90°
Default setting for the parameter finding of the component to be welded:
Using the robot, approach the gauge
4
so that the laser focus is in the cross hairs of the gauge
Using the robot, lower the laser wel-
5
(1)
r
(1)
ding head until the wire electrode tou­ches the gauge
Using the x and y adjustment units on
6
the laser welding head, position the wire electrode with respect to the laser focus
Standard value: r = 4 mm (with a stick out of 20 mm and in accor­dance with the focal length indicated on the laser optics)
68
Page 69
Document the distance of the wire electrode to the laser focus in the x and y axis in
7
accordance with the scaling on the gauge
Save the settings in the robot as the reference program
8
Carry out a test weld
9
The best welding result is used as the basis for the reference program.
If changes are required to the mechanical x, y, and z settings on the basis of the test
10
weld, overwrite the reference program that was initially created
69
Page 70
Signal Sequence for LaserHybrid Welding
Safety
WARNING!
Work performed incorrectly can cause serious injury and damage to property.
► The welding process may only be programmed by trained personnel. ► Observe the safety rules in the OI, in particular the "Safety Inspection" section
CAUTION!
Risk of damage to the optical fiber due to the laser welding head being perpendicu­lar to the workpiece surface during welding.
If the laser optics unit is at 90° to the workpiece surface, then the laser beam is reflected directly into the laser optics. This may cause serious damage to the optical fiber. ► Always guide the laser welding head to be trailing or leading!
When welding lots of short weld seams in direct succession, only switch off the CrossJet flow and external extraction system at the end of the entire process.
This will avoid contamination of the protective glass due to welding fumes.
Signal Sequence for LaserHybrid Welding
Robot start position:
Set signal "Extraction on"
1
Set signal "Crossjet on"
2
If preheating is not required, continue from "LaserHybrid welding start position."
Preheating start position:
Requirement: The laser must be ready for beam release.
Set signal "Gas test"
1
Set signal "Laser on"
2
The following factors determine the preheating temperature: Travel speed Laser output Distance to the workpiece surface
Preheating end position:
Reset signal "Laser on"
1
Reset signal "Gas test"
2
70
LaserHybrid welding start position:
Requirement: The laser must be ready for beam release.
Set signal "Arc on"
1
Wait for the current flow signal ("arc standing")
2
Page 71
Set signal "Laser on"
3
Set signal "Start robot"
4
LaserHybrid welding end position:
Stop robot movement
1
Reset signal "Laser on"
2
Reset signal "Welding on"
3
Wait until the current flow signal = zero
4
Robot end position:
IMPORTANT! The robot end position is not the end of the weld seam.
Reset signal "Crossjet on"
1
Reset signal "Extraction on"
2
71
Page 72
Measures before Starting Welding
Measures before Starting Welding
Check the coolant flow on the laser optics cooling system
1
Check the coolant flow on the welding torch cooling system
2
(visual inspection in the coolant tank of the cooling unit)
Check whether a protective glass is present in the laser optics
3
Check whether all covers are correctly mounted on the laser welding head
4
Test CrossJet
5
Test extraction
6
Test shielding gas
7
72
Page 73
Operation Recommendations for LaserHybrid Weld­ing System
Recommenda­tions for the Op­eration of a LaserHybrid Welding System
For smooth operation, the following items should always be available when using a Lase­rHybrid welding system:
LaserHybrid service station
Compressed-air gun supplied with 6 bar
Mobile tool trolley with the following tools and spare parts:
- 20 x contact tips, for each diameter
- 10 x gas distributors
- 4 x gas nozzles
- One drive roller set incl. compression lever with axles
- Allen key set
- Side cutter
- Release spray
- Optics cleaning set from the respective optics manufacturer
- 1 x protective glass tray, packed to be dust-proof (as reserve)
- Min. 10 x protective glasses, packed to be dust-proof
IMPORTANT! Always have a reserve laser welding head incl. optics in stock!
- Delivery time for a new laser welding head:
- Delivery time for laser optics:
- Repair of laser optics:
min. 8 weeks! min. 8 weeks! min. 8 weeks!
Specifications for the compressed­air supply
IMPORTANT! Throughout all servicing on the laser welding head, the external extraction
system must be switched on.
To ensure the proper functioning of the device, fulfill the following specifications for the compressed air supply:
- compressed air supply at least 7 bar constant
- compressed air free of oil
- compressed air free of water
- compressed air free of dust - no contaminants larger than 5μm
73
Page 74
74
Page 75
Maintenance
Page 76
Page 77
Replacing the Welding Torch and Welding Torch Wearing Parts
Safety
Mounting Wear­ing Parts on the Welding Torch
CAUTION!
Risk of burns due to the intensely heated welding torch during operation.
► The welding torch may only be cleaned, and its components checked, once it has
cooled down.
1
2
4
5
6
7
8
3
2x
6x
2x
77
Page 78
Replacing the Spatter Guard Plate and Extra Ex­traction
Replacing the Spatter Guard Plate
Remove 4 Allen screws
1
size 2.5 mm
Replace the spatter guard plate
2
Assemble in reverse order
1
1
1
1
2
IMPORTANT! When assembling the spatter guard plate, ensure that it is sealed flush with the outer edges of the laser welding head marked in the figure.
78
Page 79
Replacing the Ad­ditional Ex­traction System
Loosen 4 Allen screws
1
size 2.5 mm
Replace the extraction system
4x
1
1
1
1
2
2
2
79
Page 80
Replacing the Laser Optics
Safety
Preparation
WARNING!
Work performed incorrectly can cause serious injury and damage to property.
► This assembly work must only be carried out by trained and qualified personnel. ► Observe the safety rules in the OI, in particular the "Safety Inspection" section.
CAUTION!
Risk of damage to the laser welding head as a result of contamination from above.
► Observe the OI, specifications, and safety instructions from the manufacturer of the la-
ser optics
► Prior to removing the laser optics, position the laser welding head so that the longitu-
dinal axis on the laser welding head is outside of the horizontal (> 90°). This will ensure that no dirt can get into the laser optics from above.
For better accessibility, before the laser optics unit is removed, the robot connec­tion bracket can be removed.
The following steps are shown when the robot connection bracket is removed.
Remove the robot connection bracket in accordance with page 51, step 1 and 2.
IMPORTANT! Only disconnect the coolant hose at the laser optics end, never from the fiber optic cable.
1
2
Loosen Allen screw and disconnect
1
coolant hose from the laser optics SW 2.5 mm
Disconnecting the Fiber Optic Cable
2
from the Laser Optics
The fiber optic cable is disconnected from the laser optics in reverse order to its connection, see page 52, as from step 4:
- Clean the fiber optic cable and connection area with compressed air
- Withdraw the rubber sleeve in the direction of the optics
- Press the button on the underside
- Remove the fiber optic cable
- Apply the protective covers to the
connector of the fiber optic cable and to the fiber optic cable connection socket
80
Page 81
Disconnect the hose for the radial air
3
flow
3
Removing the La­ser Optics
Loosen the Allen screws
2
3
1
1
M5 x 20 mm, size 4 mm
Do not remove the screws. It must be possible to move the clamp.
4
Loosen the Allen screws
2
3
1
2
M5 x 25 mm, size 4 mm
Remove the screws
3
Remove the bracket
4
CAUTION!
If dropped, the laser optics unit can be damaged to such an extent that it is rendered unusable.
► Remove and handle the laser optics carefully.
Remove the Allen screws
5
M5 x 20 mm, size 4 mm
The screws are needed again when the new laser optics unit is installed.
Remove laser optics from the laser
6
welding head
4
5
4
81
Page 82
Installing the La­ser Optics
CAUTION!
If dropped, the laser optics unit can be damaged to such an extent that it is rendered unusable.
► Insert and handle laser optics carefully.
(1)
(a)
(a)
(c)
(c)
(b)
(d)
(2)
1
2
(2) Positioning area on the laser op-
tics with
(c) Holes for register pins
(b)
(d)
(1) Optical adjustment gauge
with (a) Register pins (b) Holes for screw fixing
(d) Threaded holes
Place the optical adjustment gauge onto the laser optics so that the register pins en-
1
gage in the holes for the register pins on the laser optics
Secure the optical adjustment gauge with 2 Allen screws
2
M5 x 16 mm, size 4 mm
On both robot connection brackets:
Loosen 3 Allen screws
5
5
3
3
3
3
size 6 mm
Remove 2 register pins
4
2
82
4
4
If necessary, move the profile until the
5
laser optics unit with the mounted opti­cal adjustment gauge has space
Page 83
Place the laser optics with the optical
6
adjustment gauge onto the laser wel-
8
ding head
Push the laser optics with the optical
7
adjustment gauge forward as far as it will go onto the mounting bracket
6
Push the slot nuts under the holes of
8
the optical adjustment gauge
Secure the optical adjustment gauge
9
with 2 Allen screws to the slot nuts M8 x 16 mm, size 6 mm
9
0 mm
7
9
IMPORTANT! Secure the laser optics only with the existing 2 Allen screws M5 x 20 mm, size 4 mm. Do not use the screws M5 x 16 mm out of the scope of supply of the laser optics!
Position 2 Allen screws M5 x 20 mm
10
and tighten them size 4 mm Tightening torque = 5.7 Nm
10
10
CAUTION!
Risk of damage to the laser optics due to stresses!
Incorrect assembly can cause that stresses that result in the failure of the laser optics ► The sequence of the following steps must be observed!
Fit the bracket
11
Secure the bracket with 2 Allen screws
12
13
12
M5 x 25 mm size 5 mm Tightening torque = 5.7 Nm
11
Tighten 2 Allen screws M5 x 20 mm
13
size 4 mm
13
12
Tightening torque = 5.7 Nm
83
Page 84
Remove 2 Allen screws M5 x 16 mm,
14
size 4 mm
Remove 2 Allen screws M8 x 16 mm,
15
size 6 mm
14
14
16
15
15
Insert register pins on both robot connection brackets
17
Tighten the screws on both robot connection brackets
18
Remove the optical adjustment gauge
16
Tightening torque = 24 Nm
Check the position of the laser focus using the reference program
19
Final Tasks Connect up all connection sockets on the laser optics according to the OI of the laser
1
optics manufacturer:
- Fiber optic cable
- Cooling hoses
- Air hose for radial air flow
84
Page 85
Checking Position of the Wire Electrode in relation to the Laser Focus
Safety
Work performed incorrectly can cause serious injury and damage to property.
► This setting work must only be carried out by trained and qualified personnel. ► Observe the safety rules in the OI, in particular the "Safety Inspection" section.
General A pilot laser with low power is required for the described adjustment work.
Check the position of the wire electrode in relation to the laser focus:
- Each time the laser welding head is replaced
- Each time the laser optics are replaced
- Each time the welding torch is changed
Checking Posi­tion of the Wire Electrode in rela­tion to the Laser Focus
1
2
3
WARNING!
Switch off MIG/MAG power source
Replace components
Switch on MIG/MAG power source
(1)
r
(1)
Using the robot, move to the reference
4
point on the gauge (1): the laser focus is in the cross hair on the gauge
Thread in wire electrode up to the gau-
5
ge
Check the position of the wire electro-
6
de in relation to the laser focus: the position of the wire electrode must match the values documented on the gauge using scaling.
If necessary, correct the position of the
7
wire electrode in relation to the laser focus using the x, y, and z adjustment devices
85
Page 86
Example: Use of the Reference Program after Welding Torch Replacement
Switch off power source
1
Change welding torch
2
Welding torch replacement is complete, wearing parts have been fitted:
3
switch on power source
Adjust stick out to 15 - 20 mm according to application
4
Upload the reference program and slowly approach the reference position on the ad-
5
justment gauge
Thread in wire electrode until this touches the adjustment gauge
6
Check the position of the wire electrode to the laser focus
7
Only if the position is incorrect:
8
correct the x/y/z axis position on the mechanical setting devices of the laser welding head – NOT on the robot
IMPORTANT! Do not under any circumstances overwrite the reference program of the robot!
Start production
9
86
Page 87
Measures to Reduce Contamination of the Optics
Measures to Re­duce Contamina­tion of the Optics
Crossjet and Extraction
1. Please observe the values for the crossjet and extraction specified in these Operating Instructions.
2. Switch on the crossjet and extraction at least five seconds before the start of welding.
3. Do not switch off the crossjet and extraction until the laser welding head is safely in the smoke-free zone.
Protective Glass (including Replacement)
IMPORTANT! Before changing the protective glass drawer, clean the area around it with
a cleaning cloth.
The environment must be clean when the protective glass drawer is being replaced.
4. To prevent dust from penetrating the focusing lens, the laser welding head must be vertical when the protective glass is being changed (welding torch pointing toward the floor).
5. Before changing the protective glass: – Switch on the extraction and crossjet – Clean the welding head with compressed air as best as you can
IMPORTANT Do not blast the protective glass with the air current directly.
– Switch off crossjet – Replace protective glass
IMPORTANT When replacing the protective glass, the extraction must be switched on and crossjet switched off.
6. Keep the amount of time the protective glass drawer is open to the minimum neces­sary.
7. If there are welding fumes on the protective glass, replace the protective glass with a new pane of glass.
The contaminated protective glass can be used again: – Pre-clean the protective glass with a cloth – Finish cleaning the protective glass with a cotton swab soaked in methanol – Store the protective glass in a dust-free area
8. If there is welding spatter on the protective glass, the protective glass must be re­placed with a new pane of glass immediately. Dispose of the protective glass that has welding spatter.
9. Check the protective glass from time to time at the start of production in order to de­termine a change interval specific to the application.
Automated Torch Cleaning Device
10. When using an automatic torch cleaning device: Switch on the crossjet and extraction during the cleaning process.
87
Page 88
Changing the Fiber Optic Cable
11. The laser welding head must be in a horizontal position when you are changing the fiber optic cable so that no dust can fall into the optics from above.
IMPORTANT! Clean with compressed air before changing.
88
Page 89
Appendix
Page 90
Page 91
Technical Data
WF 25i LaserHy­brid 90° 10 kW FW (Laser Welding Head)
LaserHybrid hosepack MHP 360i LH
Weight (without laser optics) 19 kg
Laser optics Trumpf BEO D70/F300
Max. laser performance on the workpiece 10 kW
Max. current carrying capacity of the welding torch (100% D.C. at 40°C) M21 (EN439) C1 (EN439)
Max. welding current (100% DC at 40°C) 360 A
Wire diameter 1.0–1.6 mm
Voltage rating (V-Peak) 141 V
Cooling system Liquid cooling
Coolant Original Fronius coolant
Hosepack length 4.2 m/7.5 m
Minimum cooling capacity in accordance with IEC 60974­2, subject to hosepack length
Coolant pressure min./max. 3.0/5.0 bar
Minimum flow of coolant 1.0 l/min
1400/1500 W
360 A 360 A
SB 360i LH
This product meets the requirements set out in standard IEC 60974-7/-10 CI.A.
Supply voltage 24 V DC/60 V DC
Nominal current 0.5 A / 0.8 A
Welding current at 10 min / 40 °C (104 °F) 40% D.C.* 500 A
60% D.C.* 450 A
100% D.C.* 360 A
Maximum pressure of shielding gas 7 bar
101.53 psi.
Coolant Original Fronius
Maximum pressure of coolant 5 bar
72.53 psi
Protection class IP 20
Marks of conformity CE
Dimensions L × W × H 560.4 x 334.93 x 113 mm
22.06 x 13.19 x 4.45 in.
Weight 9.6 kg
21.16 Ib.
*) D.C. = duty cycle
91
Page 92
WF 25i Robacta Drive /W
X / I
(10 min/40°C)
max
M21 (EN 439)
X / I
(10 min/40°C)
max
C1 (EN 439)
Ø
[mm] [in.]
100% D.C.*, 500 A
100% D.C.*, 500 A
0.8-1.6
0.032-0.063
MTB 700 LH /W
Q
p
p
min
min
max
[L/min] [gal./min]
[bar] [psi]
[bar] [psi]
0.26
43
72
Supply voltage [V DC] 60
Nominal current [A] 3
Wire speed
[m/min] [ipm]
39.37 - 984.25
1 - 25
* D.C. = duty cycle
X / I
(10 min/40°C)
max
100% D.C.*, 700 A
M21 (EN 439)
X / I
(10 min/40°C)
max
100% D.C.*, 700 A
C1 (EN 439)
Ø
[mm] [in.]
1.0-1.6
0.039-0.063
1
3
5
* D.C. = duty cycle
92
Page 93
93
Page 94
94
Page 95
95
Page 96
FRONIUS INTERNATIONAL GMBH
Froniusstraße 1, A-4643 Pettenbach, Austria
E-Mail: sales@fronius.com
www.fronius.com
Under www.fronius.com/contact you will find the addresses
of all Fronius Sales & Service Partners and locations
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