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/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0219,EN 009-13072018
TPS/i Robotics Pull welding system
TPS/i Robotics PushPull CMT
welding system
Operating Instructions
EN
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EN
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.
Explanation of
safety symbols
If you see any of the symbols depicted in the "Safety rules" chapter, special care is required.
DANGER! Indicates immediate and real danger. If it is not avoided, death or serious 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.
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Contents
Safety rules ................................................................................................................................................ 9
General ................................................................................................................................................. 9
Proper use ............................................................................................................................................ 9
Environmental conditions...................................................................................................................... 10
Obligations of the operator.................................................................................................................... 10
Obligations of personnel ....................................................................................................................... 10
Mains connection .................................................................................................................................. 10
Protecting yourself and others .............................................................................................................. 11
Danger from toxic gases and vapours .................................................................................................. 11
Danger from flying sparks ..................................................................................................................... 12
Risks from mains current and welding current...................................................................................... 12
Meandering welding currents................................................................................................................ 13
EMC Device Classifications .................................................................................................................. 13
EMC measures ..................................................................................................................................... 13
EMF measures...................................................................................................................................... 14
Specific hazards.................................................................................................................................... 14
Factors affecting welding results........................................................................................................... 15
Danger from shielding gas cylinders..................................................................................................... 15
Danger from escaping shielding gas..................................................................................................... 16
Safety measures at the installation location and during transport ........................................................ 16
Safety measures in normal operation ................................................................................................... 16
Commissioning, maintenance and repair.............................................................................................. 17
Safety inspection................................................................................................................................... 17
Disposal ................................................................................................................................................ 18
Safety symbols...................................................................................................................................... 18
Data protection...................................................................................................................................... 18
Copyright............................................................................................................................................... 18
General information 19
General ...................................................................................................................................................... 21
Overview of the conventional TPS /i welding system with internal wirefeeding hose ........................... 21
Overview of the conventional TPS /i welding system with external wirefeeding hose .......................... 22
Overview of the TPS/i PAP welding system ......................................................................................... 23
Overview of the conventional TPS /i CMT welding system................................................................... 24
Overview of the TPS /i PAP CMT welding system................................................................................ 25
Interconnecting hosepack .......................................................................................................................... 26
General remarks ................................................................................................................................... 26
General ................................................................................................................................................. 26
PowerLiner................................................................................................................................................. 27
General ................................................................................................................................................. 27
WF 25i REEL R /4R, WF 30i REEL R /2R ................................................................................................. 28
Safety.................................................................................................................................................... 28
Device concept ..................................................................................................................................... 28
Application area .................................................................................................................................... 28
Proper use ............................................................................................................................................ 28
Warning notices on the device.............................................................................................................. 29
SplitBox SB 500i R..................................................................................................................................... 31
Device concept ..................................................................................................................................... 31
Proper use ............................................................................................................................................ 31
Safety.................................................................................................................................................... 31
Warning notices on the device.............................................................................................................. 32
SplitBox SB 60i R....................................................................................................................................... 33
Device concept ..................................................................................................................................... 33
Proper use ............................................................................................................................................ 33
Safety.................................................................................................................................................... 33
Warning notices on the device.............................................................................................................. 34
PushPull hosepack .................................................................................................................................... 35
General ................................................................................................................................................. 35
Scope of supply .................................................................................................................................... 35
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WF Robacta Drive...................................................................................................................................... 36
General ................................................................................................................................................. 36
Warning notices on the device.............................................................................................................. 36
CrashBox /i ................................................................................................................................................ 37
General ................................................................................................................................................. 37
Also required for fitting to robot arm...................................................................................................... 37
Device concept ..................................................................................................................................... 37
Areas of utilisation................................................................................................................................. 38
Scope of supply .................................................................................................................................... 38
Robot welding torch ................................................................................................................................... 39
Safety.................................................................................................................................................... 39
General ................................................................................................................................................. 39
TPSi wire buffer ......................................................................................................................................... 40
General ................................................................................................................................................. 40
Controls, connections and mechanical components 41
SplitBox...................................................................................................................................................... 43
Safety.................................................................................................................................................... 43
General remarks ................................................................................................................................... 43
Gas test/wire threading control panel (optional) ................................................................................... 43
Control elements, connections and mechanical components of the SplitBox............................................ 45
Safety.................................................................................................................................................... 45
Control elements, connections and mechanical components............................................................... 45
SB 60i R:control elements, connections and mechanical components ................................................ 46
SB 60i R /L:control elements, connections and mechanical components ............................................ 47
SB 500i R PAP control elements, connections and mechanical components ........................................... 49
Safety.................................................................................................................................................... 49
Control elements, connections and mechanical components............................................................... 49
WF 25i Robacta Drive control panel / WF 60i Robacta Drive CMT ........................................................... 51
WF 25i Robacta Drive control panel / WF 60i Robacta Drive CMT ...................................................... 51
WF 25i REEL R /4R, WF 30i REEL R /2R ................................................................................................. 53
Safety.................................................................................................................................................... 53
Controls, connections and mechanical components............................................................................. 53
Control panel......................................................................................................................................... 55
Installation - conventional robot 57
Fitting the welding system to a conventional robot .................................................................................... 59
Safety.................................................................................................................................................... 59
Fitting the TPS/i welding system to a conventional robot ..................................................................... 59
Optimum hosepack arrangement.......................................................................................................... 59
Fitting the SplitBox ..................................................................................................................................... 61
Fitting the wirefeeder holder ................................................................................................................. 61
Fitting the SB 500i R ............................................................................................................................. 61
Fitting the SB 500i R (left variant) ......................................................................................................... 61
Fitting the SB 60i R to the robot............................................................................................................ 62
Fitting the SB 60i R to the balancer ...................................................................................................... 62
Mounting the SB 60i R on the wall........................................................................................................ 63
Fitting the TPSi wire buffer......................................................................................................................... 64
Fitting the TPSi wire buffer.................................................................................................................... 64
Installing the CrashBox Drive /i on the robot.............................................................................................. 65
Installing the CrashBox on the robot (conventional) ............................................................................. 65
Installing the CrashBox/i Dummy on the robot...................................................................................... 66
Preparing the WF Robacta Drive and fitting to a conventional robot ......................................................... 67
Fitting the gas-saver nozzle .................................................................................................................. 67
Fitting the hosepack to the WF Robacta Drive (conventional).............................................................. 68
Fitting the WF Robacta Drive to the CrashBox (conventional) ............................................................. 69
Fitting the inner liner inside the torch body ........................................................................................... 69
Fitting the welding torch to the WF Robacta Drive (conventional) ........................................................ 71
Fitting the interconnecting hosepack ......................................................................................................... 72
Fitting the standard interconnecting hosepack to the robot .................................................................. 72
Connecting the extension hosepack ..................................................................................................... 72
Connecting the SplitBox to the system components.................................................................................. 74
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Safety.................................................................................................................................................... 74
General ................................................................................................................................................. 74
Connecting the SplitBox to the system components............................................................................. 74
Fitting the inner liner (unreeling wirefeeder - SplitBox SB 500i R)........................................................ 75
Fitting the inner liner (SplitBox - WF 25i with internal inner liner) ......................................................... 76
Fitting the inner liner (unreeling wirefeeder- WF Robacta Drive with external wirefeeding hose) ........ 77
Fitting the inner liner (wire buffer - WF Robacta Drive with external wirefeeding hose) ....................... 77
Fitting the inner liner (unreeling wirefeeder - wire buffer) ..................................................................... 78
Fitting the inner liner (unreeling wirefeeder - SplitBox SB60i) .............................................................. 79
Fitting the inner liner inside the torch hosepack.................................................................................... 80
Connecting the torch hosepack to the SplitBox SB 60i R ..................................................................... 81
Connecting the control line to the wire buffer........................................................................................ 82
Fitting the unreeling wirefeeder.................................................................................................................. 83
Fitting the unreeling wirefeeder............................................................................................................. 83
Installation - PAP 85
Fitting the welding system to a PAP robot ................................................................................................. 87
Safety.................................................................................................................................................... 87
Fitting the TPS/i welding system to a PAP robot .................................................................................. 87
Maximum axis rotation .......................................................................................................................... 87
Fitting the SplitBox ..................................................................................................................................... 88
Fitting the SB 500i R PAP..................................................................................................................... 88
Fitting the TPSi wire buffer......................................................................................................................... 89
Fitting the TPSi wire buffer.................................................................................................................... 89
Installing the CrashBox Drive /i PAP on the robot ..................................................................................... 90
Installing the CrashBox on the robot..................................................................................................... 90
Installing the CrashBox/i Dummy on the robot...................................................................................... 91
WF Robacta Drive...................................................................................................................................... 92
Fitting the gas-saver nozzle .................................................................................................................. 92
Fitting the hosepack to the WF 25i Robacta Drive................................................................................ 92
Fitting the WF Robacta Drive to the robot............................................................................................. 93
Fitting the inner liner inside the torch body ........................................................................................... 94
Fitting the welding torch to the WF Robacta Drive................................................................................ 96
Fitting the interconnecting hosepack ......................................................................................................... 97
Fitting the PAP interconnecting hosepack to the robot ......................................................................... 97
Connecting the extension hosepack ..................................................................................................... 97
Connecting the SplitBox to the system components..................................................................................
99
Safety.................................................................................................................................................... 99
General ................................................................................................................................................. 99
Connecting the SplitBox to the system components............................................................................. 99
Fitting the inner liner (unreeling wirefeeder - SplitBox SB 500i R)........................................................ 100
Fitting the inner liner (SplitBox - WF 25i with internal inner liner) ......................................................... 100
Fitting the inner liner (unreeling wirefeeder - wire buffer) ..................................................................... 101
Fitting the inner liner (wire buffer - WF Robacta Drive with internal wirefeeding hose) ........................ 102
Connecting the control line to the wire buffer........................................................................................ 103
Start-up 105
Inserting/replacing feed rollers................................................................................................................... 107
General ................................................................................................................................................. 107
4-roller drive: inserting/replacing feed rollers ........................................................................................ 107
2-roller drive: inserting/replacing feed rollers ........................................................................................ 108
Inserting/replacing the WF 25i Robacta Drive feed rollers.................................................................... 109
Inserting/replacing the WF 60i Robacta Drive CMT feed rollers........................................................... 111
Feeding in the wire electrode..................................................................................................................... 113
Insulated routing of wire electrode to wirefeeder .................................................................................. 113
Feeding in the wire electrode................................................................................................................ 113
Setting the contact pressure for the WF 25i Robacta Drive.................................................................. 114
Setting the contact pressure for the WF 60i Robacta Drive CMT ......................................................... 115
Start-up ...................................................................................................................................................... 116
Requirements........................................................................................................................................ 116
General ................................................................................................................................................. 116
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Troubleshooting, maintenance and disposal 117
Troubleshooting ......................................................................................................................................... 119
Safety.................................................................................................................................................... 119
Fault diagnosis...................................................................................................................................... 119
Care, maintenance and disposal ............................................................................................................... 123
General ................................................................................................................................................. 123
Safety.................................................................................................................................................... 123
Every start-up........................................................................................................................................ 123
Whenever the welding torch or torch hosepack is changed ................................................................. 123
Changing the torch hosepack, changing the interconnecting hosepack............................................... 124
Every 6 months ..................................................................................................................................... 124
Recognising faulty wearing parts .......................................................................................................... 124
Replacing the WF 25i Robacta Drive clamping lever............................................................................ 125
Replacing the WF 60i Robacta Drive CMT clamping lever................................................................... 125
Replacing the WF Robacta Drive gas-saver nozzle ............................................................................. 126
Replacing the SB 60i R inner liner ........................................................................................................ 127
Replacing the TPSi wire buffer wire guide ............................................................................................ 129
Changing the direction of operation of the TPSi wire buffer ................................................................. 130
Replacing the TPSi wire buffer lever..................................................................................................... 131
Fitting wearing parts to the torch body.................................................................................................. 132
Fitting wearing parts to the torch body - MTW 700 i ............................................................................. 132
Removing the CrashBox PAP from the robot ....................................................................................... 133
Disposal ................................................................................................................................................ 134
Technical data 135
SB 500i R, R left variant, PAP ................................................................................................................... 137
SB 500i R, R left variant, PAP .............................................................................................................. 137
SB 60i R..................................................................................................................................................... 138
SB 60i R................................................................................................................................................ 138
CrashBox /i ................................................................................................................................................ 139
CrashBox /i ........................................................................................................................................... 139
PushPull hosepack .................................................................................................................................... 141
General ................................................................................................................................................. 141
WF 25i Robacta Drive................................................................................................................................ 142
WF 60i Robacta Drive CMT ...................................................................................................................... 143
Robot welding torch ................................................................................................................................... 144
Interconnecting hosepacks ........................................................................................................................ 145
HP 70i ................................................................................................................................................... 145
HP 95i ................................................................................................................................................... 145
HP 120i ................................................................................................................................................. 145
HP 70i, HP PC Cable HD 70................................................................................................................. 145
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Safety rules
General
Proper use The device is to be used exclusively for its intended purpose.
The device is intended solely for the welding processes specified on the rating plate.
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 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 maintenance work.
Never use the device for the following purposes:
- Thawing out pipes
- Charging batteries
- Starting engines
The device 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 results.
The device 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 device and other material assets belonging to the operating company,
- inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing
the device must:
- be suitably qualified,
- have sufficient knowledge of automated welding, and
- read and carefully follow these operating instructions as well as the operating instructions for all system components.
The operating instructions must always be at hand wherever the device 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 device
- 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 device, refer to the
section headed "General" in the operating instructions for the device.
Before commissioning the device, rectify any faults that could compromise
safety.
This is for your personal safety!
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Environmental
conditions
Operation or storage of the device 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 temperature range:
- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
Relative humidity:
- up to 50% at 40 °C (104 °F)
- up to 90% at 20 °C (68 °F)
The surrounding air must be free from dust, acids, corrosive gases or substances, etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)
Obligations of the
operator
The operator must only allow persons to work with the device who:
- are familiar with the fundamental instructions regarding safety at work and accident
prevention and have been instructed in how to use the device
- have read and understood these operating instructions, especially the section "safety
rules", 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 using the device, all persons instructed to do so 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.
Mains connection Devices with a higher rating may affect the energy quality of the mains due to their current
consumption.
This may affect a number of types of device in terms of:
- connection restrictions
- criteria with regard to the maximum permissible mains impedance
*)
- criteria with regard to the minimum short-circuit power requirement
*)
*)
at the interface with the public grid
see Technical Data
In this case, the plant operator or the person using the device should check whether the
device may be connected, where appropriate by discussing the matter with the power supply company.
NOTE! Ensure that the mains connection is earthed properly
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Protecting yourself and others
Anyone working with the device exposes themselves to numerous risks, e.g.
- flying sparks and hot pieces of metal
- Arc radiation, which can damage eyes and skin
- Hazardous electromagnetic fields, which can endanger the lives of those using cardiac pacemakers
- Risk of electrocution from mains current and welding current
- Greater noise pollution
- Harmful welding fumes and gases
Suitable protective clothing must be worn when working with the device. The protective
clothing must have the following properties:
- Flame-resistant
- Insulating and dry
- Covers the whole body, is undamaged and in good condition
- Safety helmet
- Trousers with no turn-ups
Protective clothing refers to a variety of different items. Operators should:
- Protect eyes and face from UV rays, heat and sparks using a protective visor and regulation filter
- Wear regulation protective goggles with side protection behind the protective visor
- Wear stout footwear that provides insulation even in wet conditions
- Protect the hands with suitable gloves (electrically insulated and providing protection
against heat)
- Wear ear protection to reduce the harmful effects of noise and to prevent injury
Keep all persons, especially children, out of the working area while any devices are in operation or welding is in progress. If, however, there are people in the vicinity:
- Make them aware of all the dangers (risk of dazzling by the arc, injury from flying
sparks, harmful welding fumes, noise, possible risks from mains current and welding
current, etc.)
- Provide suitable protective equipment
- Alternatively, erect suitable safety screens/curtains.
Danger from toxic
gases and vapours
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 with a ventilation rate of at least 20 m³/hour.
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.
Amongst others, the following components are responsible 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 arc's radiation area.
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Danger from flying sparks
Flying sparks may cause fires or explosions.
Never weld close to flammable materials.
Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the arc, 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.
Risks from mains
current and welding current
An electric shock is potentially life threatening and can be fatal.
Do not touch live parts either inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed rollers
and all pieces of metal that are in contact with the welding wire are live.
Always set the wirefeeder up on a sufficiently insulated surface or use a suitable, insulated
wirefeeder holder.
Make sure that you and others are protected with an adequately insulated, dry temporary
backing or cover for the earth or ground potential. This temporary backing or cover must
extend over the entire area between the body and the earth or ground potential.
All cables and leads must be secured, undamaged, insulated and adequately dimensioned. Replace loose connections and scorched, damaged or inadequately dimensioned
cables and leads immediately.
Use the handle to ensure the power connections are tight before every use.
In the case of power cables with a bayonet connector, rotate the power cable around the
longitudinal axis by at least 180° and pre-load.
Do not wrap cables or leads around the body or parts of the body.
The electrode (rod electrode, tungsten electrode, welding wire, etc.) must
- never be immersed in liquid for cooling
- Never touch the electrode when the power source is switched on.
Double the open circuit voltage of a power source can occur between the welding electrodes of two power sources. Touching the potentials of both electrodes at the same time
may be fatal under certain circumstances.
Arrange for the mains cable to be checked regularly by a qualified electrician to ensure the
ground conductor is functioning properly.
The device must only be operated on a mains supply with a ground conductor and a socket
with a ground conductor contact.
Operating the device on a grid without a ground conductor and in a socket without a ground
conductor contact will be deemed gross negligence. The manufacturer shall not be held
liable for any damage arising from such usage.
If necessary, provide an adequate earth connection for the workpiece.
Switch off unused devices.
Wear a safety harness if working at height.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to prevent anyone from plugging the mains plug back in and switching it on again.
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After opening the device:
- Discharge all live components
- Ensure that all components in the device are de-energised
If work on live parts is required, appoint a second person to switch off the main switch at
the right moment.
Meandering welding currents
If the following instructions are ignored, meandering welding currents can develop with the
following consequences:
- Fire hazard
- Overheating of parts connected to the workpiece
- Irreparable damage to ground conductors
- Damage to device and other electrical equipment
Ensure that the workpiece is held securely by the workpiece clamp.
Attach the workpiece clamp as close as possible to the area that is to be welded.
If the floor is electrically conductive, the device must be set up with sufficient insulating material to insulate it from the floor.
If distribution boards, twin-head mounts, etc., are being used, note the following: The electrode of the welding torch / electrode holder that is not used is also live. Make sure that the
welding torch / electrode holder that is not used is kept sufficiently insulated.
In the case of automated MIG/MAG applications, ensure that only an insulated wire electrode is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeed unit.
EMC Device Classifications
Devices in emission class A:
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:
- Satisfy the emissions criteria for residential and industrial areas. This is also true for
residential areas in which the energy is supplied from the public low-voltage mains.
EMC device classification as per the rating plate or technical data.
EMC measures In certain cases, even though a device complies with the standard limit values for emis-
sions, it may affect the application area for which it was designed (e.g. when there is sensitive equipment at the same location, or if the site where the device is installed is close to
either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rectify the situation.
Check and evaluate the immunity to interference of nearby devices according to national
and international regulations. Examples of equipment that may be susceptible to interference from the device include:
- Safety devices
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
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Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite correct mains connection, addition-
al measures are necessary (e.g. use a suitable line filter).
2. Welding power leads
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
5. Shielding, if necessary
- Shield off other nearby devices
- Shield off entire welding installation
EMF measures Electromagnetic fields may pose as yet unknown risks to health:
- effects on the health of others in the vicinity, e.g. wearers of pacemakers and hearing
aids
- wearers of pacemakers must seek advice from their doctor before approaching the device or any welding that is in progress
- for safety reasons, keep distances between the welding cables and the welder's head/
torso as large as possible
- do not carry welding cables and hosepacks over the shoulders or wind them around
any part of the body
Specific hazards 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/removed while maintenance or repair work is
being carried out.
During operation
- Ensure that all covers are closed and all side panels are fitted properly.
- Keep all covers and side panels closed.
The welding wire 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.
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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 and/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 wire-feed unit (MIG/MAG and TIG devices).
If the wire-feed unit 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 device-side thread of the adapter for
the shielding gas connection using suitable Teflon tape.
Factors affecting
welding results
The following requirements with regard to shielding gas quality must be met if the welding
system is to operate in a correct and safe manner:
- Size of solid matter particles < 40 μm
- Pressure dew point < -20 °C
- Max. oil content < 25 mg/m³
Filters must be used if necessary.
NOTE! There is an increased risk of soiling if ring mains are being used
Danger from
shielding gas cylinders
Shielding gas cylinders contain gas under pressure and can explode if damaged. As the
shielding gas cylinders are part of the welding equipment, they must be handled with the
greatest of care.
Protect shielding gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instructions to prevent
them falling over.
Keep the shielding gas cylinders well away from any welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.
Only use shielding gas cylinders suitable for the application in hand, along with the correct
and appropriate accessories (regulator, hoses and fittings). Only use shielding gas cylinders and accessories that are in good condition.
Turn your face to one side when opening the valve of a shielding gas cylinder.
Page 16
16
Close the shielding gas cylinder valve if no welding is taking place.
If the shielding gas cylinder is not connected, leave the valve cap in place on the cylinder.
The manufacturer's instructions must be observed as well as applicable national and international regulations for shielding gas cylinders and accessories.
Danger from escaping shielding
gas
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.
Safety measures
at the installation
location and during transport
A device toppling over could easily kill someone. Place the device on a solid, level surface
such that it remains stable
- The maximum permissible tilt angle is 10°.
Special regulations apply in rooms at risk of fire 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.
Do not lift or transport operational devices. Switch off devices before transport or lifting.
Before transporting the device, allow coolant to drain completely and detach the following
components:
- Wirefeeder
- 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
Only operate the device when all 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 switching on the device, ensure that no one is likely to be endangered.
Page 17
17
EN
Check the device at least once a week for obvious damage and proper functioning of safety
devices.
Always fasten the shielding gas cylinder securely and remove it beforehand if the device
is to be transported by crane.
Only the manufacturer's original coolant is suitable for use with our devices due to its properties (electrical conductibility, anti-freeze agent, material compatibility, flammability, etc.).
Only use suitable original coolant from the manufacturer.
Do not mix the manufacturer's original coolant with other coolants.
Only connect the manufacturer's system components to the cooling circuit.
The manufacturer accepts no liability for damage resulting from use of other system components or a different coolant. In addition, all warranty claims will be forfeited.
Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under certain conditions. Transport the coolant only in its original, sealed containers and keep well
away from any sources of ignition.
Used coolant must be disposed of properly in accordance with the relevant national and
international regulations. The coolant safety data sheet may be obtained from your service
centre or downloaded from the manufacturer's website.
Check the coolant level before starting to weld, while the system is still cool.
Commissioning,
maintenance and
repair
It is impossible to guarantee that bought-in parts are designed and manufactured to meet
the demands made of them, or that they satisfy safety requirements.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without the manufacturer's consent.
- Components that are not in perfect condition must be replaced immediately.
- 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.
The housing screws provide the ground conductor connection for earthing the housing
parts.
Only use original housing screws in the correct number and tightened to the specified
torque.
Safety inspection The manufacturer recommends that a safety inspection of the device is performed at least
once every 12 months.
The manufacturer recommends that the power source be calibrated during the same 12month period.
A safety inspection should be carried out by a qualified electrician
- after any changes are made
- after any additional parts are installed, or after any conversions
- after repair, care and maintenance has been carried out
- at least every twelve months.
For safety inspections, follow the appropriate national and international standards and directives.
Further details on safety inspection and calibration can be obtained from your service centre. They will provide you on request with any documents you may require.
Page 18
18
Disposal Do not dispose of this device with normal domestic waste! To comply with the European
Directive on Waste Electrical and Electronic Equipment and its implementation as national
law, electrical equipment that has reached the end of its life must be collected separately
and returned to an approved recycling facility. Any device that you no longer require must
either be returned to your dealer or given to one of the approved collection and recycling
facilities in your area. Ignoring this European Directive may have potentially adverse affects on the environment and your health!
Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage and elec-
tromagnetic compatibility directives (e.g. relevant product standards of the EN 60 974 series).
Fronius International GmbH hereby declares that the device is compliant with Directive
2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following
address: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant standards
for Canada and the USA.
Data protection The user is responsible for the safekeeping of any changes made to the factory settings.
The manufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these operating instructions remains with the manufacturer.
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.
Page 19
General information
Page 20
Page 21
21
EN
General
Overview of the
conventional TPS
/i welding system
with internal wirefeeding hose
The conventional TPS/i welding system with internal wirefeeding hose is available in two
different variants:
- Variant A: with an unreeling wirefeeder (4)
- Variant B: with an unreeling wirefeeder (2)
- Variant C: with two unreeling wirefeeders (2) and (4)
The variants differ in terms of the possible wirefeeding distance.
(1) Wire drum
(2) Unreeling wirefeeder, for example WF 30 R REEL 2R
(3) Wirefeeding hose
(4) B only: Unreeling wirefeeder, for example WF 30 R REEL 2R
(5) Interconnecting hosepack
(6) Media splitter, for example SB 500i R
"QuickConnect" option
(7) Torch hosepack
(8) CrashBox and robot flange
(9) WF 25i Robacta Drive
(10) Robot welding torch
(11) Service station, for example Robacta TX/i
(12) Trolley or upright console
(13) Cooling unit, for example CU 1400i Pro
(14) Power source, for example TPS 320i
A
BC
max.
15 m
max.
8 m
max. 15 m
max. 15 m
max. 15 m
(1)
(12)
(13)
(14)
(3)
(2)
(8)
(9)
(10)
(11)
(5)(4)(4) (6) (7)
Page 22
22
Overview of the
conventional TPS
/i welding system
with external
wirefeeding hose
The conventional TPS/i welding system with external wirefeeding hose is available in three
different variants:
- Variant A: without an unreeling wirefeeder
- Variant B: with an unreeling wirefeeder (2)
- Variant C: with two unreeling wirefeeders (2) and (5)
The variants differ in terms of the possible wirefeeding distance.
(1) Wire drum
(2) B and C only: Unreeling wirefeeder, for example WF 30 R REEL 2R
(3) PowerLiner (max. 10 m) or wirefeeding hose (max. 8 m)
(4) Wirefeeding hose
(5) C only: Unreeling wirefeeder, for example WF 30 R REEL 2R
(6) Interconnecting hosepack
(7) Media splitter, for example SB 500i R
"QuickConnect" option
(8) Torch hosepack
(9) CrashBox and robot flange
(10) WF 25i Robacta Drive
(11) Robot welding torch
(12) Service station, for example Robacta TX/i
(13) Trolley or upright console
(14) Cooling unit, for example CU 1400i Pro
(15) Power source, for example TPS 320i
A
BC
(1)
(13)
(14)
(15)
(3)
(4)
(2)
(9)
(10)
(11)
(12)
(6) (7)(5)
(8)
max.
15 m
max.15m
max.15m
Page 23
23
EN
Overview of the
TPS/i PAP welding system
The TPS/i PAP welding system is available in three different variants:
- Variant A: with PowerLiner (3)
- Variant B: with an unreeling wirefeeder (2)
- Variant C: with two unreeling wirefeeders (2) and (5)
The variants differ in terms of the possible wirefeeding distance.
(1) Wire drum
(2) B and C only: Unreeling wirefeeder, for example WF 30 R REEL 2R
(3) A only: PowerLiner (max. 8 m) or wirefeeding hose (max. 6 m)
(4) B and C only: Wirefeeding hose
(5) C only: Unreeling wirefeeder, for example WF 30 R REEL 2R
(6) Interconnecting hosepack
(7) Media splitter, for example SB 500i R PAP
"QuickConnect" option
(8) Torch hosepack
(9) CrashBox and robot flange
(10) WF 25i Robacta Drive
(11) Robot welding torch
(12) Service station, for example Robacta TX/i
(13) Trolley or upright console
(14) Cooling unit, for example CU 1400i Pro
(15) Power source, for example TPS 320i
A
B
C
max.
15 m
max.15mmax.15m
(1)
(13)
(14)
(15)
(3)
(4)
(2)
(9)
(10)
(11)
(12)
(5) (4) (6) (7) (8)
Page 24
24
Overview of the
conventional TPS
/i CMT welding
system
(1) Wire drum
(2) Unreeling wirefeeder, for example WF 30i REEL 2R
(3) Wirefeeding hose or PowerLiner
(4) Interconnecting hosepack
(5) Media splitter, for example SB 500i R
"QuickConnect" option
(6) Torch hosepack
(7) CrashBox and robot flange
(8) WF 60i Robacta Drive CMT
(9) Robot welding torch
(10) Wire buffer
(11) Service station, for example Robacta TX/i
(12) Trolley or upright console
(13) Cooling unit, for example CU 1400i Pro
(14) Power source, for example TPS 320i
(15) SpeedNet Cable CON
A
max. 6 m
(1)
(12)
(13)
(14)
(15)
(3)
(2)
(7)
(8)
(9)
(11)
(10)
(4) (4)(3) (5) (6)
max. 4 m
0 - max. 8 m
Page 25
25
EN
Overview of the
TPS /i PAP CMT
welding system
(1) Wire drum
(2) Unreeling wirefeeder, for example WF 30i REEL 2R
(3) Wirefeeding hose
(4) Interconnecting hosepack
(5) Media splitter, for example SB 500i R
"QuickConnect" option
(6) Torch hosepack
(7) CrashBox and robot flange
(8) WF 60i Robacta Drive CMT
(9) Robot welding torch
(10) Wire buffer
(11) Service station, for example Robacta TX/i
(12) Trolley or upright console
(13) Cooling unit, for example CU 1400i Pro
(14) Power source, for example TPS 320i
(15) SpeedNet Cable CON
A
max. 6 m
max.
4 m
(1)
(12)
(13)
(14)
(3)
(2)
(7)
(8)
(9)
(11)
(10)
(4) (4)(3) (5) (6)
(15)
0 - max. 8 m
Page 26
26
Interconnecting hosepack
General remarks
The interconnecting hosepack connects the power source to the wirefeeder. With the TPS/
i welding system the interconnecting hosepack is available in two versions - one split and
one continuous variant.
- 3 / 5 / 10 / 15 m (extension - split variant)
- 4 / 8 m (connection - continuous variant)
General
The interconnecting hosepack connects the power source to the SplitBox SB 60i R.
The interconnecting hosepack is fixed in position on the SplitBox SB 60i R and is available
in the following preconfigured lengths:
- 3 m (extension - split variant)
- 4 / 8 m (connection - continuous variant)
Page 27
27
EN
PowerLiner
General
The PowerLiner is a wirefeeder system for all standard wire types. Wire diameters of 0.6
mm to 1.6 mm may be used.
The PowerLiner does not need an inner liner. The wire electrode is guided by rollers set at
an angle of 90 degrees. Seventy-six rollers are used for each metre of wirefeeding hose.
As a result, rolling friction rather than slip friction occurs while the wire is being transported.
The PowerLiner can be prepared to any length. For Robacta Drive applications, lengths of
up to 10 m can be realised. For CMT applications, lengths of up to 6 m can be realised
between the unreeling wirefeeder and wire buffer and 4 m between the wire buffer and
drive unit.
A connection can be established to large spool systems, wire drums, welding torches or
wirefeeders using QuickConnect.
Pay attention to the wirefeeding direction when fitting the PowerLiner.
Page 28
28
WF 25i REEL R /4R, WF 30i REEL R /2R
Safety
Device concept The unreeling wirefeeder is an extra drive unit for ensuring constant and precision wire-
feeding over large wirefeeding distances between the welding wire drum and the robot
wirefeeder.
While in operation, the unreeling wirefeeder is synchronised with the power source.
It is supplied with power and controlled by the power source in the welding system.
The unreeling wirefeeder is available in two versions:
- WF 25i REEL R /4R
Integrated version with 4-roller drive
- WF 30i REEL R /2R
Integrated version with 2-roller drive - not permitted in conjunction with a basket-type
spool
Application area All indoor and automated MIG/MAG applications.
Proper use The device is designed exclusively for wirefeeding in automated MIG/MAG welding appli-
cations in conjunction with Fronius system components. Any use above and beyond this
purpose is deemed improper. The manufacturer shall not be held liable for any damage
arising from such usage.
Utilisation in accordance with the intended purpose also comprises:
- carefully reading these operating instructions
- following all the instructions and safety rules in these operating instructions
- performing all stipulated inspection and maintenance work
WARNING! Incorrect operation or shoddy workmanship can cause serious injury
and damage. The following documents must be completely read and understood
before commissioning the unreeling wire-feed unit:
- these operating instructions
- the operating instructions of the power source in use
- the operating instructions of all other system components
- especially the safety rules and safety instructions in the above mentioned
documents
CAUTION! Risk of injury from rotating drive parts if covers are open.
When performing maintenance or set-up work, make sure that the drive components of the unreeling wire-feed unit cannot be started by the power source, by a
wire-feed unit or by any other system add-ons.
Page 29
29
EN
Warning notices
on the device
The device is fitted with safety symbols and a rating plate. The safety symbols and rating
plate must not be removed or painted over. The safety symbols warn against operating the
equipment incorrectly, as this may result in serious injury and damage.
e.g.: WF 30i REEL R /2R/G/W
Do not dispose of used devices with domestic waste. Dispose of them according to the safety rules.
Welding is dangerous. The following basic requirements must be met to ensure
the equipment is used properly:
- Anyone performing automated welding must be sufficiently qualified
- Suitable protective equipment must be used
- All persons not involved must be kept at a safe distance from the wire-feed
unit and the welding process
Do not use the functions described here until you have thoroughly read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the
safety rules
40,0006,3035
Page 30
30
Keep hands, hair, clothing and tools away from moving parts. For example:
- Cogs
- Feed rollers
- 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/removed while maintenance or repair work is being carried out.
Wear eye protection
Page 31
31
EN
SplitBox SB 500i R
Device concept The SplitBox (SB) 500i R, SB 500i R / L and SB 500i R PAP devices bring together the
welding media for automated MIG/MAG welding and have been specially designed for
mounting onto the robot. Two versions of the devices are available:
- R = for applications in which the hosepack is externally mounted on the robot
- PAP = for applications in which the hosepack is mounted in the robot arm
Proper use The device is designed exclusively for bringing together the welding media in automated
MIG/MAG welding applications in conjunction with Fronius system components. Any use
above and beyond this purpose is deemed improper. The manufacturer shall not be held
liable for any damage arising from such usage.
Utilisation in accordance with the intended purpose also comprises:
- carefully reading these operating instructions
- following all the instructions and safety rules in these operating instructions
- performing all the stipulated inspection and maintenance work
Safety
WARNING! Incorrect operation or shoddy workmanship can cause serious injury
or damage. All work described in this document must only be carried out by
trained and qualified personnel. All functions described in this document must
only be used by trained and qualified personnel. Do not carry out any of the work
or use any of the functions described until you have fully read and understood the
following documents:
- this document
- all the operating instructions for the system components, especially the safety rules
Page 32
32
Warning notices
on the device
The device is fitted with safety symbols and a rating plate. The safety symbols and rating
plate must not be removed or painted over. The safety symbols warn against operating the
equipment incorrectly, as this may result in serious injury and damage.
Welding is dangerous. The following
basic requirements must be met to ensure the equipment is used properly:
- Welders must be sufficiently qualified
- Suitable protective equipment
must be used
- All persons not involved must be
kept at a safe distance from the
wirefeeder and the welding process
Do not use the functions described here
until you have fully read and understood the following documents:
- These operating instructions
- all the operating instructions for the
system components, especially
the safety rules
Do not dispose of used devices with domestic waste. Dispose of them according to the safety rules.
Keep hands, hair, clothing and tools away from moving parts. For example:
- cogs
- feed rollers
- wirespools and welding wires
Do not reach 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.
40,0006,3035
Caution:
Attention:
Parts may be at welding
voltage
Les pièces peuvent être
à la tension de soudage
500 A/100% 600 A/60% 650A/40%
I2
0.8 AI
11
U11
60 V
U
12 I12 0.5 A24 V
IEC 60 974-1/-10 Cl.A IP 43
www.fronius.com
Ser.No.:
Part No.:
XXXXXXXXXX
4,040,080
SB 500i R /G/W/FSC
Page 33
33
EN
SplitBox SB 60i R
Device concept The SB 60i R and SB 60i R/L are devices for bringing together the welding media in auto-
mated MIG/MAG welding and are specially designed for mounting on robots.
Proper use The device is designed exclusively for bringing together the welding media in automated
MIG/MAG welding applications in conjunction with Fronius system components. Any use
above and beyond this purpose is deemed improper. The manufacturer shall not be held
liable for any damage arising from such usage.
Utilisation in accordance with the intended purpose also comprises:
- carefully reading these operating instructions
- following all the instructions and safety rules in these operating instructions
- performing all the stipulated inspection and maintenance work
Safety
SB 60i R .... Right version of the appliance, for fitting to the right side of the robot
SB 60i R /L .... Left version of the appliance, for fitting to the left side of the robot
WARNING! Incorrect operation or shoddy workmanship can cause serious injury
or damage. All work described in this document must only be carried out by
trained and qualified personnel. All functions described in this document must
only be used by trained and qualified personnel. Do not carry out any of the work
or use any of the functions described until you have fully read and understood the
following documents:
- this document
- all the operating instructions for the system components, especially the safety rules
Page 34
34
Warning notices
on the device
The device is fitted with safety symbols and a rating plate. The safety symbols and rating
plate must not be removed or painted over. The safety symbols warn against operating the
equipment incorrectly, as this may result in serious injury and damage.
Welding is dangerous. The following
basic requirements must be met to ensure the equipment is used properly:
- Welders must be sufficiently qualified
- Suitable protective equipment
must be used
- All persons not involved must be
kept at a safe distance from the
wirefeeder and the welding process
Do not use the functions described here
until you have fully read and understood the following documents:
- these Operating Instructions
- all the Operating Instructions for
the system components, especially the safety rules
Do not dispose of used devices with domestic waste. Dispose of them according to the safety rules.
Page 35
35
EN
PushPull hosepack
General The Robacta MHPi RD hosepack is designed for gas-cooled and water-cooled robot appli-
cations. It connects the SplitBox to the wirefeeder.
The length of the hosepack depends on the robot.
The following combinations are available:
- Robacta MHPi RD conventional
- SB500i -> WF 25i Robacta Drive
- SB60i -> WF 60i Robacta Drive CMT
- Robacta MHPi RD PAP
- SB500i -> WF 25i Robacta Drive
- SB500i -> WF 60i Robacta Drive CMT
- SB60i -> WF 60i Robacta Drive CMT
- Robacta MHPi RD conventional with external wirefeeding hose
- SB500i -> WF 25i Robacta Drive
- SB500i -> WF 60i Robacta Drive CMT
Scope of supply
Robacta MHPi RD conventional hosepack Robacta MHPi RD PAP hosepack
Robacta MHPi RD hosepack with external wirefeeding
hose
Not supplied:
- Inner liners
- Inlet nozzles
Page 36
36
WF Robacta Drive
General
The WF 25i Robacta Drive and WF 60i Robacta Drive CMT are designed for gas or
water-cooled systems. The built-in motor
ensures precise wirefeeding (pull system).
The torch body is fitted to the Robacta Drive.
Warning notices
on the device
The device is fitted with safety symbols and a rating plate. The safety symbols and rating
plate must not be removed or painted over. The safety symbols warn against operating the
equipment incorrectly, as this may result in serious injury and damage.
WF 25i Robacta Drive rating plate WF 60i Robacta Drive CMT rating plate
Welding is dangerous. The following basic requirements must be met to ensure
the equipment is used properly:
- Anyone performing automated welding must be sufficiently qualified
- Suitable protective equipment must be used
- All persons not involved must be kept at a safe distance from the wirefeeder and the welding process
Do not use the functions described here until you have fully read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the
safety rules
Page 37
37
EN
CrashBox /i
General
A CrashBox Drive /i PAP mounted onto the robot arm
with Robacta Drive and MTB
A CrashBox Drive /i mounted onto the robot arm with
clamp system, Robacta Drive und MTB
The CrashBox Drive /i is a protection device for the torch body, the drive unit and the torch
interchangeable-coupling. In the event of a collision, the CrashBox sends a signal to the
robot control, which stops the robot immediately.
The clamp system is used to hold the drive unit on conventional robots.
A robot-specific, isolated robot flange is necessary for fitting the CrashBox Drive /i.
Also required for
fitting to robot
arm
Depending on the particular robot:
- 1 x robot flange with screws
Robot flange as per price list
Observe torques:
Device concept The CrashBox Drive /i is designed specifically for fitting to the robot arm and for holding
gas-cooled and water-cooled robot hosepacks with robot drive units. For PAP systems, the
torch hosepack runs through the CrashBox and then through the robot arm. In conventional robot systems the torch hosepack runs along the robot arm and is attached to the clamp.
In the event of a crash, the magnetic coupling smoothly deflects the forces along a large
deflection path.
Thread dimension
Max. tightening torque
for screws of strength
class 8.8
M4 3.3 Nm
M5 6.5 Nm
M6 11.3 Nm
M8 27.3 Nm
M10 54 Nm
M12 93 Nm
Page 38
38
Areas of utilisation
The clamp system can be used for the following PushPull robot hosepacks:
- MHP /i G/W RD hosepacks
Scope of supply
CrashBox Drive /i PAP scope of supply Conventional CrashBox /i scope of supply
(1) CrashBox Drive /i holder
(2) Locking ring fitted to (3) on delivery
(3) Bellows
(4) Magnetic ring with three M4x16 cheesehead screws
Do not fit the CrashBox Drive /i holder (1) and magnetic ring (4) together before fitting to
the robot. The design of the two components means that they are very difficult to part.
(1) (2) (3) (2) (4)
(1) (2) (3) (2) (4)
Page 39
39
EN
Robot welding torch
Safety
General The following torch bodies are recommended for the CMT process:
- MTB 250i / 320i / 400i / 500i / 700i: 22 - 36°
- MTB 330i: 22°
The following maximum angles are permitted during the CMT process:
- MTB 250i / 320i / 400i / 500i / 700i: 45°
- MTB 330i: 36°
The robot welding torch transmits the arc power to the workpiece. The gas or water-cooled
TPS/i welding torch is designed for use with the CrashBox /i.
The torch body has an integrated lead for gas nozzle touch sensing.
CAUTION! Risk of burns from hot torch neck, hot torch neck coupling and other
hot welding torch components. Before starting work on the torch neck, the torch
neck coupling and all other welding torch components:
- allow the torch neck, torch neck coupling and all other welding torch components to cool down to room temperature (+25 °C, +77 °F)
- wear electrically insulated and heat protective gloves
- use a suitable tool
Standard: with wearing parts, without contact tip
OVT/WWP: without wearing parts
TXi: automatic torch body changeover
TXM: manual torch body changeover
Page 40
40
TPSi wire buffer
General As its name implies, the wire buffer acts as a buffer for the rapid reversing movements of
the wire electrode needed during the CMT welding process.
The wire buffer can also be used to help coordinate two drive systems that work in different
ways. The rear drive system steadily feeds the wire electrode into the wire buffer, while the
front highly-dynamic drive motor moves it to and fro up to 70 times per second.
The wire electrode is therefore fed to the front drive unit with hardly any force being applied,
thus guaranteeing a high-quality welding process.
The wire buffer is suitable for mounting on the side arm or on the balancer.
Page 41
Controls, connections and mechani-
cal components
Page 42
Page 43
43
EN
SplitBox
Safety
General remarks
Gas test/wire
threading control
panel (optional)
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. All the functions described may only be used by trained and qualified
personnel. Do not use the functions described until you have thoroughly read and
understood the following documents:
- this document
- all the operating instructions for the system components, especially the safety rules
NOTE! Depending on the system configuration, either the unreeling wirefeeder or
the robot hosepack drive unit is controlled by the gas-test, wire retract and wire
threading buttons.
(1)
(2)
(3)
(4)
No Function
(1) Operating status LED
shows steady green when the device is ready for use
No Function
(2) Gas-test button
for setting the required gas flow rate on the pressure regulator
- Gas will flow out for 30 seconds after the gas-test button is pressed. Press
the button again to stop the gas test flow before the end of this period.
(3) Wire retract button
for retracting the wire electrode with no accompanying flow of gas or current
- While the button is being pressed, the wirefeeder runs at the preset wire retract speed
The wire electrode can be retracted using one of two methods:
Variant 1
Retracting the wire electrode using the preset wire retract speed:
- Press and hold the wire retract button
- The wire electrode will be retracted 1 mm (0.039 in.) after the wire re-
tract button is pressed
- After a short pause, the wirefeeder continues to retract the wire elec-
trode. If the wire retract button remains pressed, the speed will increase
every second at a rate of 10 m/min (393.70 ipm) until the preset wire retract speed is reached
Variant 2
Retracting the wire electrode in 1 mm increments (0.039 in. increments) – always
press the wire retract button for less than one second (tap)
NOTE! Do not allow long lengths of wire electrode to be retracted, as the wire
electrode is not wound onto the wirespool when retracted.
Page 44
44
NOTE! If there was a ground earth connection with the contact tip before the wire
retract button was pressed, the wire electrode will be retracted when the button is
pressed until it is short-circuit-free – it retracts by no more than 10 mm (0.39 in.)
with each press of the button.
If the wire electrode is to be retracted further, the wire retract button must be
pressed again.
(4) Wire threading button
For threading the wire electrode into the torch hosepack with no accompanying
flow of gas or current
- While the button is being pressed, the wirefeeder runs at the preset wire retract speed
There are two wire threading variants available:
Variant 1
Threading the wire electrode using the preset feeder inching speed:
- Press and hold the wire threading button
- The wire electrode will be threaded 1 mm (0.039 in.) after the wire
threading button is pressed
- After a short pause, the wirefeeder continues to thread the wire elec-
trode. If the wire threading button remains pressed, the speed will increase every second at a rate of 10 m/min (393.70 ipm) until the preset
feeder inching speed is reached
- If the wire electrode comes into contact with a ground earth connection,
the wirefeeding will be stopped and the wire electrode will be retracted
again by 1 mm (0.039 in.)
Variant 2
Threading the wire electrode in 1 mm increments (0.039 in. increments) – always
press the wire threading button for less than one second (tap)
- If the wire electrode comes into contact with a ground earth connection, the
wirefeeding will be stopped and the wire electrode will be retracted again by
1 mm (0.039 in.)
NOTE! If there is a ground earth connection with the contact tip before the wire
threading button is pressed, when the button is pressed the wire electrode will be
retracted until it is short-circuit-free –- it retracts by no more than 10 mm (0.39 in.)
with each press of the button.
If there is still a ground earth connection with the contact tip after 10 mm (0.39 in.)
of wire retraction, pressing the wire threading button again will cause the wire
electrode to be retracted again by a maximum of 10 mm (0.39 in.). The process
will be repeated until there is no longer a ground earth connection with the contact
tip.
No Function
Page 45
45
EN
Control elements, connections and mechanical
components of the SplitBox
Safety
Control elements,
connections and
mechanical components
Front of SB 500i R (right variant) Rear of SB 500i R (right variant)
Front of SB 500i R (left variant) Rear of SB 500i R (left variant)
No. Function
(1) Blanking cover for option 3
(2) Blanking cover for option 4
(3) Blanking cover for option 1
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. All the functions described may only be used by trained and qualified
personnel. Do not use the functions described until you have thoroughly read and
understood the following documents:
- this document
- all the operating instructions for the system components, especially the safety rules
(1)(3) (6)
(9) (4)
(7)(8) (5)
(2)(10)
Page 46
46
(4) Welding torch connection
(5) SpeedNet connection socket
for connecting the SpeedNet cable from the interconnecting hosepack
(6) Blanking cover for option 5
(7) Shielding gas connection
(8) (+) current socket
for connecting the power cable from the interconnecting hosepack
(9) Blanking cover for option 2
(10) Wire infeed
Side view (right variant)
No. Function
(11) Cover
(12) Implementation
(13) Gas test / wire threading control
panel (option)
SB 60i R:
control elements,
connections and
mechanical components
Front
No. Function
(1) Hole for fitting to robot
(2) Cover
(3) Hole for fitting to robot
(4) Blanking cover / gas test / wire
threading control panel option
A
B
Page 47
47
EN
SB 60i R /L:
control elements,
connections and
mechanical components
A - Welding torch end
No. Function
(5) Welding torch connection
(6) Coolant hoses to welding torch
(7) Blanking cover (SpeedNet or exter-
nal sensor option)
B - Power source end
No. Function
(8) Wire infeed
(via QuickConnect and inner liner)
(9) 16 bar gas purging (option)
(10) Hosepack (fixed)
preconfigured for gas / watercooled applications
3 / 4 / 8 m
Front
No. Function
(1) Hole for fitting to robot
(2) Cover
(3) Hole for fitting to robot
(4) Blanking cover / gas test / wire
threading control panel option
A
B
Page 48
48
A - Welding torch end
No. Function
(5) Welding torch connection
(6) Coolant hoses to welding torch
(7) Blanking cover (SpeedNet or exter-
nal sensor option)
B - Power source end
No. Function
(8) Wire infeed
(via QuickConnect and inner liner)
(9) 16 bar gas purging (option)
(10) Hosepack (fixed)
preconfigured for gas / watercooled applications
3 / 4 / 8 m
Page 49
49
EN
SB 500i R PAP control elements, connections and
mechanical components
Safety
Control elements,
connections and
mechanical components
Front Rear
No. Function
(1) (+) current socket
for connecting the power cable from the interconnecting hosepack
(2) Shielding gas connection
(3) SpeedNet connection socket
for connecting the SpeedNet cable from the interconnecting hosepack
(4) Blanking cover for option 1
(5) Welding torch connection
(6) Blanking cover for option 3
(7) Blanking cover for option 4
(8) Blanking cover for option 5
(9) Blanking cover for option 2
(10) Wire infeed
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. All the functions described may only be used by trained and qualified
personnel. Do not use the functions described until you have thoroughly read and
understood the following documents:
- this document
- all the operating instructions for the system components, especially the safety rules
Page 50
50
Side view
No. Function
(11) Cover
(12) Implementation
(13) Gas test / wire threading control
panel (option)
Page 51
51
EN
WF 25i Robacta Drive control panel / WF 60i Robacta
Drive CMT
WF 25i Robacta
Drive control panel / WF 60i Robacta Drive CMT
(1) (2)
(4)
(5)
(3)
No. Function
(1) Gas-test button
for setting the required gas flow
rate on the pressure regulator
- Gas will flow out for 30 seconds after the gas-test button is pressed. Press the
button again to stop the gas
test flow before the end of
this period
No. Function
(2) F1 button
currently without function
(3) Wire retract button
for retracting the wire electrode with no accompanying flow of gas or current
- While the button is being pressed, the wirefeeder runs at the preset wire retract speed
The wire electrode can be retracted using one of two methods:
Method 1
Retracting the wire electrode using the preset wire retract speed:
- Press and hold the wire retract button
- The wire electrode will be retracted 1 mm (0.039 in.) after the wire re-
tract button is pressed
- After a short pause, the wirefeeder continues to retract the wire elec-
trode. If the wire retract button remains pressed, the speed will increase
every second at a rate of 10 m/min (393.70 ipm) until the preset wire retract speed is reached
Method 2
Retracting the wire electrode in 1 mm increments (0.039 in. increments) – always
press the wire retract button for less than one second (tap)
NOTE! Do not allow long lengths of wire electrode to be retracted, as the wire
electrode is not wound onto the wirespool when retracted.
NOTE! If there was a ground earth connection with the contact tip before the wire
retract button was pressed, the wire electrode will be retracted when the button is
pressed until it is short-circuit-free – it retracts by no more than 10 mm (0.39 in.)
with each press of the button.
If the wire electrode is to be retracted further, the wire retract button must be
pressed again.
NOTE! If there is a ground earth connection with the contact tip before the wire
threading button is pressed, when the button is pressed the wire electrode will be
retracted until it is short-circuit-free –- it retracts by no more than 10 mm (0.39 in.)
with each press of the button.
If there is still a ground earth connection with the contact tip after 10 mm (0.39 in.)
of wire retraction, pressing the wire threading button again will cause the wire
electrode to be retracted again by a maximum of 10 mm (0.39 in.). The process
will be repeated until there is no longer a ground earth connection with the contact
tip.
Page 52
52
(4) Wire threading button
For threading the wire electrode into the torch hosepack with no accompanying
flow of gas or current
- While the button is being pressed, the wirefeeder runs at the preset wire retract speed
Wire threading can be performed using one of two methods:
Method 1
Threading the wire electrode using the preset feeder inching speed:
- Press and hold the wire threading button
- The wire electrode will be threaded 1 mm (0.039 in.) after the wire
threading button is pressed
- After a short pause, the wirefeeder continues to thread the wire elec-
trode. If the wire threading button remains pressed, the speed will increase every second at a rate of 10 m/min (393.70 ipm) until the preset
feeder inching speed is reached
- If the wire electrode comes into contact with a ground earth connection,
the wirefeeding will be stopped and the wire electrode will be retracted
again by 1 mm (0.039 in.)
Method 2
Threading the wire electrode in 1 mm increments (0.039 in. increments) – always
press the wire threading button for less than one second (tap)
- If the wire electrode comes into contact with a ground earth connection, the
wirefeeding will be stopped and the wire electrode will be retracted again by
1 mm (0.039 in.)
(5) Display
status indicator
NOTE! If there is a ground earth connection with the contact tip before the wire
threading button is pressed, when the button is pressed the wire electrode will be
retracted until it is short-circuit-free –- it retracts by no more than 10 mm (0.39 in.)
with each press of the button.
If there is still a ground earth connection with the contact tip after 10 mm (0.39 in.)
of wire retraction, pressing the wire threading button again will cause the wire
electrode to be retracted again by a maximum of 10 mm (0.39 in.). The process
will be repeated until there is no longer a ground earth connection with the contact
tip.
No. Function
Page 53
53
EN
WF 25i REEL R /4R, WF 30i REEL R /2R
Safety
Controls, connections and mechanical
components
Front of WF 25i REEL R /4R/G/W Front of WF 30i REEL R /2R/G/W
Left side Rear
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. All the functions described may only be used by trained and qualified
personnel. Do not use the functions described until you have thoroughly read and
understood the following documents:
- this document
- all the operating instructions for the system components, especially the safety rules
(1)(3) (2) (1)(5) (4)
(6)(7)
(11) (8)(9)(10)
Page 54
54
Top/underside
No. Function
(1) Cover
(2) Protective cover for the 4-roller drive
(3) 4-roller drive
(4) Protective cover for the 2-roller drive
(5) 2-roller drive
(6) Opening for optional sash lock
(7) Control panel
(8) SpeedNet connection
(9) Blanking cover for optional component
(10) Blanking cover for optional component
(11) Blanking cover for optional component
(12) M20 thread
for connecting QuickConnect option
(13) Wire infeed/outfeed tube
Wire infeed (underside)
Wire outfeed (top)
(12)(13)
100 mm
50 mm
4 x M5
3.9 in.
2.0 in.
Page 55
55
EN
Control panel
Gas test/wire threading control panel
(1) (2) (3) (4)
No. Function
(1) Operating status LED
lights green when the device is
ready for use
(2) Gas-test button
for setting the required gas flow
rate on the pressure regulator
- Gas will flow out for 30 s after
pressing the gas-test button.
Press the button again to stop
the gas test flow before the
end of this period
No. Function
(3) Wire retract button
retraction of wire electrode without accompanying flow of gas or current
The wire electrode can be retracted using one of two methods:
Variant 1
retracting the wire electrode using the preset wire retract speed:
- Press and hold the wire retract button
- The wire electrode will be retracted 1 mm (0.039 in.) after the wire retract button is pressed
- After a short pause, the wire-feed unit continues to retract the wire electrode.
If the wire retract button remains pressed, the speed will increase every second at a rate of 10 m/min (393.70 ipm) until the preset wire retract speed is
reached.
Variant 2
retracting the wire electrode in 1 mm stages (0.039 in. stages) - always press the
wire retract button for less than one second (tap):
NOTE! Do not allow long lengths of wire electrode to be retracted, as the wire
electrode is not wound onto the wirespool or the welding wire drum when retracted.
NOTE! If there was a ground earth connection with the contact tip before the wire
retract button was pressed, the wire electrode will be retracted when the button is
pressed until it is short-circuit-free - it retracts by no more than 10 mm (0.39 in.)
with each press of the button.
If the wire electrode still needs to be retracted further, press the wire retract button
again.
Page 56
56
No. Function
(4) Wire threading button
to thread the wire electrode into the torch hosepack with no accompanying flow
of gas or current
There are two wire threading variants available:
Variant 1
threading the wire electrode using the preset feeder inching speed:
- Press and hold the wire threading button
- The wire electrode will be threaded 1 mm (0.039 in.) after the wire threading
button is pressed
- After a short pause, the wire-feed unit continues to thread the wire electrode.
If the wire threading button remains pressed, the speed will increase every
second at a rate of 10 m/min (393.70 ipm) until the preset feeder inching
speed is reached.
- If the wire electrode comes into contact with a ground earth connection, the
wire feeding will be stopped and the wire electrode will be retracted again by
1 mm (0.039 in.).
Variant 2
threading the wire electrode in 1 mm stages (0.039 in. stages) - always press the
wire threading button for less than one second (tap):
- If the wire electrode comes into contact with a ground earth connection, the
wire feeding will be stopped and the wire electrode will be retracted again by
1 mm (0.039 in.).
NOTE! If there is a ground earth connection with the contact tip before the wire
threading button is pressed, when the button is pressed the wire electrode will be
retracted until it is short-circuit-free - it retracts by no more than 10 mm (0.39 in.)
with each press of the button.
If there is still a ground earth connection with the contact tip after 10 mm (0.39 in.)
of wire retraction, pressing the wire threading button again will cause the wire
electrode to be retracted again by a maximum of 10 mm (0.39 in.). The process
will be repeated until there is no longer a ground earth connection with the contact
tip.
Page 57
Installation - conventional robot
Page 58
Page 59
59
EN
Fitting the welding system to a conventional robot
Safety
Fitting the TPS/i
welding system
to a conventional
robot
Individual components must be fitted to the robot in the following order:
1. Robot holder(s) must have already be fitted first
2. SplitBox
3. For CMT applications only: Wire buffer
4. CrashBox Drive /i
5. WF Robacta Drive
6. Torch hosepack
7. Interconnecting hosepack
8. Unreeling wirefeeder
Optimum hosepack arrangement
WARNING! Work that is carried out incorrectly can cause serious injury or dam-
age. The following activities may only be carried out by trained and qualified personnel. The operating instructions for system components, particularly the
chapter entitled "Safety rules", must be observed.
WARNING! An electric shock can be fatal. Before starting the work described below:
- turn the power source mains switch to the "O" position
- disconnect the power source from the mains
- ensure that the power source remains disconnected from the mains until all
work has been completed
WARNING! Risk of serious injury and damage from articles being dropped. All
the screw connections described below:
- must be checked after fitting to ensure they are tight
- must be checked following an unusual operating situation (e.g. crash) to ensure they are tight
- must be checked regularly to ensure they are tight
R
R
R < 200 mm R ≥ 200 mm
Page 60
60
Page 61
61
EN
Fitting the SplitBox
Fitting the wirefeeder holder
Fitting the SB
500i R
1 2
* = 2x M8 x 20 mm
Fitting the SB
500i R (left variant)
1 2
* = 2x M8 x 20 mm
NOTE! Depending on the robot, please also note the instructions and information
on installing the wirefeeder in the leaflets listed below:
7x
M6x16
6x
6FSt
6FSt
1x
1x
M6x16
1
2
7x
M6x16
6x
6FSt
6FSt
1x
1x
M6x16
1
2
Page 62
62
Fitting the SB 60i
R to the robot
The installation of the SplitBox SB 60i R is illustrated using the right version of the appliance. The left version of the appliance should be installed the other way around.
1 2
Fitting the SB 60i
R to the balancer
1 2
NOTE! Depending on the robot, please also note the instructions and information
in the leaflets on installing the holding plate for the SplitBox.
1
2
NOTE!
- Use a balancer with a load capacity of at least 18 kg
- Use a second balancer for hosepacks longer than 1.75 m. Position the balancer halfway along the length of the hosepack.
1
2
Page 63
63
EN
3
Mounting the SB
60i R on the wall
1 2
* = Depending on the surface, different fixings are required for fitting the wall bracket.
The installer is responsible for selecting the correct fixings.
1
3
1
2
3
NOTE! Use a balancer for hosepacks longer than 1.75 m. Position the balancer
halfway along the length of the hosepack.
Page 64
64
Fitting the TPSi wire buffer
Fitting the TPSi
wire buffer
1
Fitting to the robot
1
Fitting to a balancer
1 1
Page 65
65
EN
Installing the CrashBox Drive /i on the robot
Installing the
CrashBox on the
robot (conventional)
1 2
3 4
5 6
1
2
3 4
5 6
Page 66
66
Installing the
CrashBox/i Dummy on the robot
1 2
1
Observe the torques when fitting the robot
flange:
Thread dimension
Max. tightening torque
for screws of strength
class 8.8
M4 3.3 Nm
M5 6.5 Nm
M6 11.3 Nm
M8 27.3 Nm
M10 54 Nm
M12 93 Nm
1
2 3
Page 67
67
EN
Preparing the WF Robacta Drive and fitting to a conventional robot
Fitting the gassaver nozzle
1 2
3 4
1
2
3 4
Page 68
68
Fitting the hosepack to the WF
Robacta Drive
(conventional)
IMPORTANT! Whenever the hosepack is fitted or removed, ensure that the coupling point
is clean and dry. Remove any coolant that has escaped from the coupling point.
1 2
3 4
IMPORTANT! Only fit the drive unit when the power source is switched off.
1
2
3 4
Page 69
69
EN
Fitting the WF Robacta Drive to the
CrashBox (conventional)
1 2
3
Fitting the inner
liner inside the
torch body Plastic inner liner:
1 2
1
2
42 Nm
3
IMPORTANT! For the MTB 330i welding torch, the plastic inner liner is fitted from the front.
1
2
Page 70
70
3
3
Steel inner liner:
1 1
1
1
2
3
Page 71
71
EN
Fitting the welding torch to the
WF Robacta Drive
(conventional)
IMPORTANT! Whenever the welding torch is fitted or removed, ensure that the coupling
point is clean and dry. Remove any coolant that has escaped from the coupling point.
1 2
3
4
1
2
3
4
Page 72
72
Fitting the interconnecting hosepack
Fitting the standard interconnecting hosepack to
the robot
1 2
Connecting the
extension hosepack
1
* Only on water-cooled hosepack
CON = interconnecting hosepack
EXT = extension hosepack
1
SB 500i
2
CAUTION! Risk of injury and damage from loose connections. All cables, leads
and hosepacks must be properly secured, undamaged, insulated and adequately
dimensioned.
1
Page 73
73
EN
1
2
Page 74
74
Connecting the SplitBox to the system components
Safety
General
Connecting the
SplitBox to the
system components
IMPORTANT! Whenever the torch hosepack is fitted or removed, ensure that the coupling
point is clean and dry. Remove any coolant that has escaped from the coupling point.
1
SB 500i R (right variant)
1
SB 500i R (left variant)
WARNING! An electric shock can be fatal. Before starting the work described below:
- turn the power source mains switch to the "O" position
- disconnect the power source from the mains
- ensure that the power source remains disconnected from the mains until all
work has been completed
CAUTION! Risk of injury and damage from loose connections. All cables, leads
and hosepacks must be properly secured, undamaged, insulated and adequately
dimensioned.
NOTE! Also follow the instructions and information in the documents
42,0410,1946 and 42,0410,2010 when connecting the wire-feed unit to the system components.
1 1
Page 75
75
EN
2
Fitting the inner
liner (unreeling
wirefeeder - SplitBox SB 500i R)
1 2
3 4
2
1
2
3 4
Page 76
76
Fitting the inner
liner (SplitBox WF 25i with internal inner liner)
1
2 3
4
1
2 3
4
Page 77
77
EN
Fitting the inner
liner (unreeling
wirefeeder- WF
Robacta Drive
with external
wirefeeding hose)
1 2
3
Fitting the inner
liner (wire buffer WF Robacta Drive
with external
wirefeeding hose)
1 2
1
2
3
1
2
Page 78
78
3
Fitting the inner
liner (unreeling
wirefeeder - wire
buffer)
1 2
3 4
3
1
2
3 4
Page 79
79
EN
5
Fitting the inner
liner (unreeling
wirefeeder - SplitBox SB60i)
1 2
3 4
5
1
2
3 4
Page 80
80
Fitting the inner
liner inside the
torch hosepack
1 2
3 4
5
* Steel inner liner
** Plastic inner liner
NOTE! Ensure that the hosepack is straight when fitting the inner liner, otherwise
the liner might not be inserted correctly.
1
1
2
3
*
**
4
5
Page 81
81
EN
1 2
*** Screw the cap onto the inner liner as far as it will go. The inner liner must be visible
through the hole in the cap.
Connecting the
torch hosepack to
the SplitBox SB
60i R
IMPORTANT! Whenever the torch hosepack is fitted or removed, ensure that the coupling
point is clean and dry. Remove any coolant that has escaped from the coupling point.
The connection of the torch hosepack to the SplitBox SB 60i R is illustrated using the right
version of the appliance.
The left version of the appliance should be connected to the torch hosepack the other way
around.
1 2
***
6 7
1
2
Page 82
82
Connecting the
control line to the
wire buffer
1 2
3
NOTE! Carefully place the control line in the strain-relief device provided (Figure
2).
1
2
3
Page 83
83
EN
Fitting the unreeling wirefeeder
Fitting the unreeling wirefeeder
Ensure that the unreeling wirefeeder is fitted in the correct direction. The threading
direction of the wire electrode is marked
with an arrow.
The unreeling wirefeeder is designed exclusively for vertical installation on the following
mounts:
- WF Mounting WALL 4,100,846
- WF Mounting Drum 4,100,845
Operating a 2-roller WF30i REEL R /2R unreeling wirefeeder with a basket-type spool is
not permitted.
In accordance with the fitting instructions, mount the unreeling wirefeeder onto the wall
bracket or the wire drum mount
Use the QuickConnect option to connect the wirefeeding hose to the unreeling wirefeeder
Use Fronius SpeedNet to connect the unreeling wirefeeder to the power source in the
welding system
WARNING! An electric shock can be fatal. If the power source is connected to the
mains supply while the work described below is being carried out, there is a risk
of serious injury and damage. Only carry out the work described below when:
- the power source mains switch is in the "O" position
- the power source is disconnected from the mains
1
2
3
Page 84
84
Page 85
Installation - PAP
Page 86
Page 87
87
EN
Fitting the welding system to a PAP robot
Safety
Fitting the TPS/i
welding system
to a PAP robot
Individual components must be fitted to the robot in the following order:
1. Robot holder(s) must have already be fitted first
2. SplitBox
3. For CMT applications only: Wire buffer
4. CrashBox Drive /i
5. WF Robacta Drive
6. Torch hosepack
7. Interconnecting hosepack
8. Unreeling wirefeeder
Maximum axis rotation
WARNING! Work that is carried out incorrectly can cause serious injury or dam-
age. The following activities may only be carried out by trained and qualified personnel. The operating instructions for system components, particularly the
chapter entitled "Safety rules", must be observed.
WARNING! An electric shock can be fatal. Before starting the work described below:
- turn the power source mains switch to the "O" position
- disconnect the power source from the mains
- ensure that the power source remains disconnected from the mains until all
work has been completed
WARNING! Risk of serious injury and damage from articles being dropped. All
the screw connections described below:
- must be checked after fitting to ensure they are tight
- must be checked following an unusual operating situation (e.g. crash) to ensure they are tight
- must be checked regularly to ensure they are tight
Page 88
88
Fitting the SplitBox
Fitting the SB
500i R PAP
1 2
1
2
Page 89
89
EN
Fitting the TPSi wire buffer
Fitting the TPSi
wire buffer
1
Fitting to the robot
1
Fitting to a balancer
1 1
Page 90
90
Installing the CrashBox Drive /i PAP on the robot
Installing the
CrashBox on the
robot
1 2
3 4
1
Observe the torques when fitting the robot
flange:
Thread dimension
Max. tightening torque
for screws of strength
class 8.8
M4 3.3 Nm
M5 6.5 Nm
M6 11.3 Nm
M8 27.3 Nm
M10 54 Nm
M12 93 Nm
1
2 3
4 5
Page 91
91
EN
5 6
Installing the
CrashBox/i Dummy on the robot
1 2
3
6 7
1
2
3
Page 92
92
WF Robacta Drive
Fitting the gassaver nozzle
1 2
3 4
Fitting the hosepack to the WF 25i
Robacta Drive
1 2
1
2
3 4
1
2
Page 93
93
EN
3 4
5
Fitting the WF Robacta Drive to the
robot
1 2
IMPORTANT! Whenever the torch hosepack is fitted or removed, ensure that the coupling
point is clean and dry. Remove any coolant that has escaped from the coupling point.
3 4
5
1
2
Page 94
94
3 4
5
Fitting the inner
liner inside the
torch body Plastic inner liner:
1 2
3 4
5
IMPORTANT! For the MTB 330i welding torch, the plastic inner liner is fitted from the front.
1
2
Page 95
95
EN
3
3
Steel inner liner:
1 1
1
1
2
3
Page 96
96
Fitting the welding torch to the
WF Robacta Drive
IMPORTANT! Whenever the welding torch is fitted or removed, ensure that the coupling
point is clean and dry. Remove any coolant that has escaped from the coupling point.
1 2
3
1
2
3
Page 97
97
EN
Fitting the interconnecting hosepack
Fitting the PAP interconnecting
hosepack to the
robot
1 2
3
IMPORTANT! Values for the "a" and "b" distances can be found in the leaflets for the
different robot manufacturers.
Connecting the
extension hosepack
1
* Only on water-cooled hosepack
CON = interconnecting hosepack
EXT = extension hosepack
1
2
3
CAUTION! Risk of injury and damage from loose connections. All cables, leads
and hosepacks must be properly secured, undamaged, insulated and adequately
dimensioned.
1
Page 98
98
1
2
Page 99
99
EN
Connecting the SplitBox to the system components
Safety
General
Connecting the
SplitBox to the
system components
IMPORTANT! Whenever the torch hosepack is fitted or removed, ensure that the coupling
point is clean and dry. Remove any coolant that has escaped from the coupling point.
1 2
3 4
WARNING! An electric shock can be fatal. Before starting the work described below:
- turn the power source mains switch to the "O" position
- disconnect the power source from the mains
- ensure that the power source remains disconnected from the mains until all
work has been completed
CAUTION! Risk of injury and damage from loose connections. All cables, leads
and hosepacks must be properly secured, undamaged, insulated and adequately
dimensioned.
NOTE! Also follow the instructions and information in the documents
42,0410,1946 and 42,0410,2010 when connecting the wire-feed unit to the system components.
1
2
3 4
Page 100
100
Fitting the inner
liner (unreeling
wirefeeder - SplitBox SB 500i R)
1 2
3 4
Fitting the inner
liner (SplitBox WF 25i with internal inner liner)
1
1
2
3 4
1
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