Fronius TPSi Robotics Push/Pull Operating Instruction [EN]

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Operating Instructions

TPS/i Robotics welding system Pull PushPull CMT

Operating Instructions

42,0426,0219,EN 024-07032023

Contents

Safety rules 8

Explanation of safety notices 8 General 8 Intended use 9 Environmental conditions 9 Obligations of the operator 9 Obligations of personnel 9 Mains connection 9 Protecting yourself and others 10 Danger from toxic gases and vapours 10 Danger from ﬂying sparks 11 Risks from mains current and welding current 11 Meandering welding currents 13 EMC Device Classifications 13 EMC measures 13 EMF measures 14 Specific hazards 14 Requirement for the shielding gas 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 17 Commissioning, maintenance and repair 17 Safety inspection 18 Disposal 18 Safety symbols 18 Data protection 18 Copyright 18 Description of the warning notices on the device 19

System configurations 21

System configurations - conventional robot 23

PowerDrive with wire drum 23 PowerDrive with wire drum and external wirefeeding hose 24 PushPull with 4-roller unreeling wirefeeder and wire drum 25 PushPull with 4-roller unreeling wirefeeder and wirespool 26 PushPull with SB 60i, 4-roller unreeling wirefeeder and wirespool 27 PushPull with 2-roller unreeling wirefeeder, wire drum and external wirefeeding hose 28 CMT with SB 60i, 4-roller unreeling wirefeeder and wire drum 29 CMT with SB 500i, 4-roller unreeling wirefeeder, wire drum and external wirefeeding hose 30 CMT with SB 60i, 4-roller unreeling wirefeeder and wirespool 31

System configurations - PAP 32

PowerDrive with wire drum 32 PushPull with 4-roller unreeling wirefeeder and wire drum 33 PushPull with 4-roller unreeling wirefeeder and wirespool 34 PushPull with 2-roller unreeling wirefeeder and wire drum 35 PushPull with wire buffer, 4-roller unreeling wirefeeder and wire drum 36 PushPull with wire buffer, 4-roller unreeling wirefeeder and wirespool 37 CMT with SB 60i, 4-roller unreeling wirefeeder and wire drum 38 CMT with SB 500i, 4-roller unreeling wirefeeder and wire drum 39 CMT with SB 500i, 4-roller unreeling wirefeeder and wirespool 40

System components 41

SplitBox SB 500i R 43

Device concept 43 Proper use 43 Safety 43 Warning notices on the device 44

SplitBox SB 60i R 46

Device concept 46 Proper use 46 Safety 46 Warning notices on the device 47

TPSi wire buffer 49

General 49

CrashBox /i 50

General 50 Note on the correct operation of CrashBoxes 51 Also required for installation 51 Device concept 52 Areas of utilisation 52 Information on repairing CrashBoxes 52 Scope of supply 52

WF Robacta Drive 53

General 53 Warning notices on the device 53

PushPull hosepack 54

General 54 Scope of supply 54

Robot welding torch 55

Safety 55 General 55

WF 25i REEL R /4R, WF 30i REEL R /2R 57

Safety 57 Device concept 57 Application area 57 Proper use 57 Warning notices on the device 58

Interconnecting hosepack 60

General 60 General 60

PowerLiner 61

General 61

WireSense 62

General 62 Requirements 62 How it works 62 WireSense - edge detection 63 WireSense - contour detection 64 Technical details 65

OPT/i camera mount 66

General 66 Drilling template 66

Controls, connections and mechanical components 67

General 69

Safety 69 General 69

SplitBox SB 500i R / SB 500i R PAP 70

Controls, connections, and mechanical components of the SB 500i R 70 Controls, connections, and mechanical components of the SB 500i R PAP 71

SplitBox SB 60i R 73

SB 60i R:Controls, connections, and mechanical components 73 SB 60i R /L:Controls, connections, and mechanical components 74

WF 25i Robacta Drive / WF 60i Robacta Drive CMT 75

Control panel WF 25i Robacta Drive / WF 60i Robacta Drive CMT 75 Status indicators 75

WF 25i REEL R /4R, WF 30i REEL R /2R 77

Control elements, connections and mechanical components 77

Function of the gas-test, wire retract and wire threading buttons 79

Assembling system components - conventional robot 81

General 83

Safety 83 Assembly sequence, conventional robot 83

Fitting the SplitBox SB 500i R 84

Fitting the wirefeeder holder 84 Fitting the SB 500i R 84

Fitting the CrashBox /i to the robot 85

Fitting the CrashBox /i to the robot 85 Installing the CrashBox/i Dummy on the robot 86

Fitting the WF Robacta Drive to a conventional robot 88

Fitting the hosepack to the WF Robacta Drive (conventional) 88 Fitting the WF Robacta Drive to the robot (conventional) 89 Fitting the WF Robacta Drive to the robot 90 Optimum hosepack arrangement 91

Fitting the interconnecting hosepack 92

Fitting the Standard interconnecting hosepack to the robot 92

Connecting the MHP W hosepack 93

Connecting the SplitBox SB 500i R to the system components 96

Safety 96 General 96 Connecting the SplitBox SB 500i R to the system components 96

Assembling system components - PAP robot 99

General 101

Safety 101 Assembly sequence, PAP robot 101 Maximum axis rotation 102

Fitting the SplitBox SB 500i R PAP 103

Fitting the SB 500i R PAP 103

Installing the CrashBox Drive /i PAP on the robot 104

Installing the CrashBox Drive /i PAP on the robot 104 Installing the CrashBox Drive /i PAP Dummy on the robot 105

Fitting the WF Robacta Drive to a PAP robot 107

Fitting the hosepack to the WF Robacta Drive (PAP) 107 Fitting the WF Robacta Drive to the robot (PAP) 108

Fitting the interconnecting hosepack 111

Fitting the PAP interconnecting hosepack to the robot 111

Connecting the SplitBox SB 500i R PAP to the system components 112

Safety 112 General 112 Connecting the SplitBox SB 500i R PAP to the system components 112

Assembling further system components 115

Fitting the SplitBox SB 60i R 117

Fitting the SB 60i R to the robot 117 Fitting the SB 60i R to the balancer 117 Mounting the SB 60i R on the wall 118 Connecting the torch hosepack to the SplitBox SB 60i R 119

Fitting the TPSi wire buffer 120

Fitting the TPSi wire buffer 120 Connecting the control line to the wire buffer 121

Fitting the unreeling wirefeeder 122

Connecting the extension hosepack 123

Fitting the torch body to the WF Robacta Drive 125

Fitting the gas-saver nozzle 125

Fitting the inner liner inside the torch body 126 Fitting the torch body to the WF Robacta Drive 128

Fitting the OPT/i camera mount 129

Load-bearing capacity of the OPT/i camera mount 129 Safety 129 Fitting the OPT/i camera mount 130

Fitting the inner liner 131

Fitting the inner liner (unreeling wirefeeder - SplitBox SB 500i R) 131 Fitting the inner liner (unreeling wirefeeder- WF Robacta Drive with external wirefeeding hose) Fitting the PowerLiner (unreeling wirefeeder - WF Robacta Drive with external wirefeeding hose) Fitting the inner liner (unreeling wirefeeder - wire buffer) 133 Fitting the inner liner (SplitBox - WF 25i with internal inner liner) 134 Fitting the inner liner (wire buffer - WF Robacta Drive with internal wirefeeding hose) 135 Fitting the inner liner (wire buffer - WF Robacta Drive with external wirefeeding hose) 136 Fitting the inner liner inside the torch hosepack 137

Start-up 139

Inserting/replacing feed rollers 141

General 141 WF 25i Reel 4R: inserting/replacing feed rollers for the 4-roller drive 141 WF 30i Reel 2R: inserting/replacing feed rollers for the 2-roller drive 142 Inserting/replacing the WF 25i Robacta Drive feed rollers 143 Inserting/replacing the WF 60i Robacta Drive CMT feed rollers 145

Feeding in the wire electrode 148

Insulated routing of wire electrode to wirefeeder 148 Feeding in the wire electrode 148 Setting the contact pressure for the WF 25i Robacta Drive 149 Setting the contact pressure for the WF 60i Robacta Drive CMT 150

Start-up 151

Requirements 151 General 151

131

132

Troubleshooting, maintenance and disposal 153

Troubleshooting 155

Safety 155 Fault diagnosis 155

Care, maintenance and disposal 159

General 159 Safety 159 Every start-up 159 Special care of O-rings 159 Whenever the welding torch or torch hosepack is changed 160 Changing the torch hosepack, changing the interconnecting hosepack 160 Every 6 months 160 Recognising faulty wearing parts 161 Replacing the WF 25i Robacta Drive clamping lever 161 Replacing the WF 60i Robacta Drive CMT clamping lever 162 Replacing the WF Robacta Drive gas-saver nozzle 162 Replacing the SB 60i R inner liner 163 Replacing the TPSi wire buffer wire guide 165 Changing the direction of operation of the TPSi wire buffer 166 Replacing the TPSi wire buffer lever 167 Fitting wearing parts to the torch body 168 Fitting wearing parts to the torch body - MTW 700 i 168 Removing the CrashBox PAP from the robot 169 Entsorgung 170

Technical data 171

SB 500i R, R left variant, PAP 173

SB 500i R, R left-hand version, PAP 173

SB 60i R 174

CrashBox /i 175

PushPull hosepack 178

Gas-cooled PushPull hosepacks 178 Water-cooled PushPull hosepacks 179

WF 25i Robacta Drive 181

WF 25i Robacta Drive /G 181 WF 25i Robacta Drive /W 181

WF 60i Robacta Drive CMT 182

WF 60i Robacta Drive CMT /G 182

WF 60i Robacta Drive /W CMT 182 WF 25i REEL R /4R/G/W 184 WF 30i REEL R /2R/G/W 185 Robot welding torch 186

Gas-cooled robot welding torches 186

Water-cooled robot welding torches 187 Interconnecting hosepacks 189

HP 70i 189

HP 95i 189

HP 120i 189

HP 70i, HP PC Cable HD 70 189

Safety rules

Explanation of safety notices

DANGER!

Indicates immediate danger.

If not avoided, death or serious injury will result.

▶

WARNING!

Indicates a potentially hazardous situation.

If not avoided, death or serious injury may result.

▶

CAUTION!

Indicates a situation where damage or injury could occur.

If not avoided, minor injury and/or damage to property may result.

▶

NOTE!

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

General 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 operat-

ing 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!

Intended use The devices and components described in these Operating Instructions are in-

tended exclusively for automated MIG/MAG applications in conjunction with Fronius 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.

Proper use also includes:

Carefully reading and following all the instructions given in the Operating In-

structions Studying and obeying all safety instructions and danger notices carefully

Performing all stipulated inspection and servicing work

The manufacturer likewise accepts no liability for inadequate or incorrect results.

Environmental conditions

Obligations of the operator

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.)

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 sec-

tion "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

Mains connection

Before using the device, all persons instructed to do so undertake:

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

vention 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.

Devices with a higher rating may affect the energy quality of the mains due to their current consumption.

This may affect a number device types 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.

IMPORTANT! Ensure that the mains connection is earthed properly

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 us-

ing 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 protect-

ive 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 in-

jury

Danger from toxic gases and vapours

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.

The fumes produced during welding contain harmful gases and vapours.

Welding fumes contain substances that cause cancer, as stated in Monograph 118 of the International Agency for Research on Cancer.

Use at-source extraction and a room extraction system. If necessary, use a welding torch with an integrated extraction device.

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. Ensure that there is a ventilation rate of at least 20 m³ per hour at all times.

Otherwise, a welding helmet with an air supply must be worn.

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

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

Metals used for the workpiece

Electrodes

Coatings

Cleaners, degreasers, etc.

Welding process used

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

Recommendations for trade fair scenarios, risk management measures and for identifying working conditions can be found on the European Welding Association website under Health & Safety (https://european-welding.org).

Danger from ﬂy- ing sparks

Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation area.

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

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 base or cover for the earth or ground potential. This base 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 pretension.

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.

Protection class I devices require a mains supply with ground conductor and a connector system with ground conductor contact for proper operation.

Operation of the device on a mains supply without ground conductor and on a socket without ground conductor contact is only permitted if all national regulations for protective separation are observed. Otherwise, this is considered gross negligence. The manufacturer shall not be held liable for any damage arising from such usage.

If necessary, provide adequate earthing 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.

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

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.

Position the device with sufficient insulation against electrically conductive environments, such as insulation against conductive ﬂoor or insulation to conductive racks.

If power 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 wirefeeder.

EMC Device Classifications

EMC measures In certain cases, even though a device complies with the standard limit values for

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 lowvoltage mains.

EMC device classification as per the rating plate or technical data.

emissions, 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

Network, signal and data transfer lines

IT and telecommunications devices

Measuring and calibrating devices

Supporting measures for avoidance of EMC problems:

Mains supply

1. If electromagnetic interference arises despite the correct mains connec-

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

Welding power-leads

2. must be kept as short as possible

must be laid close together (to avoid EMF problems)

must be kept well apart from other leads

Equipotential bonding

Earthing of the workpiece

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

Shield, if necessary

5. Shield other devices nearby

Shield the entire welding installation

EMF measures Electromagnetic fields may pose as yet unknown risks to health:

Effects on the health of persons in the vicinity, e.g. those with pacemakers

and hearing aids Individuals with pacemakers must seek advice from their doctor before ap-

proaching the device or any welding that is in progress For safety reasons, maintain as large a distance as possible between the

welding power-leads and the head/torso of the welder Do not carry welding power-leads 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 wirefeeder) and wear suitable protective goggles.

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

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

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

Special provisions apply in areas at risk of fire or explosion

- observe relevant national and international regulations.

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

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

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

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

Hook chains or ropes onto all suspension points provided on the load-carry-

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

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

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

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

All lifting tackle (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.

Requirement for the shielding gas

Danger from shielding gas cylinders

Especially with ring lines, contaminated shielding gas can cause damage to equipment and reduce welding quality. Meet the following requirements regarding shielding gas quality:

Solid particle size < 40 µm

Pressure condensation point < -20 °C

Max. oil content < 25 mg/m³

Use filters if necessary.

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.

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

Safety measures at the installation location and during transport

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 tak-

ing place. Check the shielding gas cylinder or main gas supply for uncontrolled gas

leakage before every start-up.

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.

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.

Commissioning, maintenance and repair

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.

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

Disposal Waste electrical and electronic equipment must be collected separately and re-

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 12-month 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.

cycled in an environmentally responsible manner in accordance with the EU Directive and national law. Used equipment must be returned to the distributor or through a local, authorised collection and disposal system. Proper disposal of the old device promotes sustainable recycling of material resources. Ignoring this may lead to potential health/environmental impacts.

Packaging materials

Collected separately. Check your municipality’s regulations. Reduce the volume of the box.

Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage

and electromagnetic 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.

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.

Description of

A B

the warning notices on the device

For certain device versions, warning notices are affixed to the device.

The arrangement of the symbols may vary.

! Warning! Attention!

The symbols represent possible dangers.

A Drive rollers can injure fingers.

B The welding wire and drive parts are live during operation.

Keep hands and metal objects away!

1. An electric shock can be fatal.

1.1 Wear dry, insulating gloves. Do not touch the wire electrode with bare

hands. Do not wear wet or damaged gloves.

1.2 Use a base that is insulated from the ﬂoor and work area to protect

against electric shock.

1.3 Before working on the device, switch off the device and pull out the mains

plug or disconnect it from the power supply.

2. Inhalation of welding fumes can be harmful to health.

2.1 Keep your face away from any welding fumes.

2.2 Use forced-air ventilation or a local extraction system to remove welding

xx,xxxx,xxxx *

fumes.

2.3 Remove welding fumes with a fan.

3 Welding sparks can cause an explosion or fire.

3.1 Keep ﬂammable materials away from the welding process. Never weld

close to ﬂammable materials.

3.2 Welding sparks can cause a fire. Have fire extinguishers to hand. If neces-

sary, have a supervisor ready who can operate the fire extinguisher.

3.3 Do not weld on drums or closed containers.

4. Arc rays can burn the eyes and injure the skin.

4.1 Wear headgear and protective goggles. Use ear protection and a shirt col-

lar with button. Use a welding helmet with the correct tinting. Wear suitable protective clothing over the entire body.

5. Before working on the system or welding:

undertake training on the device and read the instructions!

6. Do not remove or paint over the warning sticker.

* Manufacturer order number of the sticker

System configurations

System configurations - conventional robot

(6)

(2)

(3)

(9)**

(8)

(4)

(5)

(1)*

(7)*

PowerDrive with wire drum

(1) Wirefeeding hose with inner liner

(2) TPSi power source

(3) CU cooling unit

(4) Upright console

(5) HP interconnecting hosepack

(6) SplitBox SB 500i R

(7) MHP /i R torch hosepack

(8) WF 25i Robacta Drive

(9) MTB /i R robot welding torch

Maximum wirefeed length: max. 6 m between wire drum and drive unit (max. 8 m with PowerLiner)

Possible wire diameters:

0.8 - 1.2 mm

Welding process: Standard, Pulse, LSC, PMC, PMC-MIX-DRIVE

IMPORTANT! Do not use a wire straightening section or guide roller in this configuration.

* Use the largest inner liner (incl. basic kit) ** Use the inner liner corresponding to the wire diameter (incl. basic kit)

PowerDrive with

(6)

(9)**

(8)

(5)

(1)*

(7)*

(2)

(3) (4)

wire drum and external wirefeeding hose

(1) Wirefeeding hose with inner liner

(2) TPSi power source

(3) CU cooling unit

(4) Upright console

(5) HP interconnecting hosepack

(6) SplitBox SB 500i R

(7) MHP /i R welding torch hosepack with external wirefeeding hose

(8) WF 25i Robacta Drive

(9) MTB /i R robot welding torch

Maximum wirefeed length: max. 6 m between wire drum and drive unit (max. 8 m with PowerLiner)

Possible wire diameters:

0.8 - 1.2 mm

Welding process: Standard, Pulse, LSC, PMC, PMC-MIX-DRIVE

IMPORTANT! Do not use a wire straightening section or guide roller in this configuration.

* Use the largest inner liner (incl. basic kit) ** Use the inner liner corresponding to the wire diameter (incl. basic kit)

PushPull with 4-

(8)

(11)**

(10)

(1)*

(9)*

(2)

(3)

(1)*

(4)

(5) (6)

(7)

roller unreeling wirefeeder and wire drum

(1) Wirefeeding hose with inner liner

(2) SpeedNet cable COM

(3) Unreeling wirefeeder WF 25i REEL 4R

(4) TPSi power source

(5) CU cooling unit

(6) Upright console

(7) HP interconnecting hosepack

(8) SplitBox SB 500i R

(9) MHP /i R torch hosepack

(10) WF 25i Robacta Drive

(11) MTB /i R robot welding torch

Maximum wirefeed length:

max. 15 m between drive unit and unreeling wirefeeder

(max. 20 m with PowerLiner) max. 8 m between unreeling wirefeeder and wire drum

(max. 10 m with PowerLiner)

Minimum length between unreeling wirefeeder and drive unit: 4 m

Possible wire diameters:

0.8 - 2.0 mm

Welding process: Standard, Pulse, LSC, PMC

* Use the largest inner liner (incl. basic kit) ** Use the inner liner corresponding to the wire diameter (incl. basic kit)

PushPull with 4-

(8)

(3)

(4)

(11)**

(10)

(5)

(6)

(1)

(9)*

(2)

(7)*

roller unreeling wirefeeder and wirespool

(1) SpeedNet cable COM

(2) Unreeling wirefeeder WF 25i REEL 4R

+ OPT/i WF Reel carriage D300

(3) TPSi power source

(4) CU cooling unit

(5) Upright console

(6) HP interconnecting hosepack

(7) Wirefeeding hose with inner liner

(8) SplitBox SB 500i R

(9) MHP /i R welding torch hosepack with external wirefeeding hose

(10) WF 25i Robacta Drive

(11) MTB /i R robot welding torch

Maximum wirefeed length: max. 15 m between drive unit and unreeling wirefeeder (max. 20 m with PowerLiner)

Possible wire diameters:

0.8 - 2.0 mm

Welding process: Standard, Pulse, LSC, PMC

* Use the largest inner liner (incl. basic kit) ** Use the inner liner corresponding to the wire diameter (incl. basic kit)

PushPull with

(10)

(11)**

(9)

(1)

(7)**

(2)

(8)

(3)

(4) (5)

(6)

SB 60i, 4-roller unreeling wirefeeder and wirespool

(1) SpeedNet cable COM

(2) Unreeling wirefeeder WF 25i REEL 4R

+ OPT/i WF Reel carriage D300

(3) TPSi power source

(4) CU cooling unit

(5) Upright console

(6) HP interconnecting hosepack SB 60i

(7) Wirefeeding hose with inner liner

(8) SplitBox SB 60i R

(9) MHP /i R torch hosepack

(10) WF 25i Robacta Drive

(11) MTB /i R robot welding torch

Maximum wirefeed length:

max. 4 m between drive unit and SB 60i R

max. 6 m between SB 60i R and unreeling wirefeeder

Minimum length between SB 60i R and drive unit: 1 m

Possible wire diameters:

0.8 - 1.6 mm

Welding processes: Standard, Pulse, LSC, PMC, PMC-MIX-DRIVE

* Use the largest inner liner (incl. basic kit) ** Use the inner liner corresponding to the wire diameter (incl. basic kit)

PushPull with 2-

(9)

(11)**

(8)

(1)

(7)*

(2)

(10)

(3)

(4) (5)

(6)

roller unreeling wirefeeder, wire drum and external wirefeeding hose

(1) Unreeling wirefeeder WF 30i REEL 2R

+ WF Mounting Drum

(2) SpeedNet cable COM

(3) TPSi power source

(4) CU cooling unit

(5) Upright console

(6) HP interconnecting hosepack

(7) Wirefeeding hose with inner liner

(8) SplitBox SB 500i R

(9) MHP /i R welding torch hosepack with external wirefeeding hose

(10) WF 25i Robacta Drive

(11) MHP /i R robot welding torch

Maximum wirefeed length: max. 8 m between drive unit and unreeling wirefeeder (max. 10 m with PowerLiner)

Possible wire diameters:

0.8 - 1.6 mm

Welding process: Standard, Pulse, LSC, PMC, PMC-MIX-DRIVE

IMPORTANT!

This configuration is only possible with wire drum. A wirespool cannot be

used. Do not use a wire straightening section or guide roller in this configuration.

* Use the largest inner liner (incl. basic kit) ** Use the inner liner corresponding to the wire diameter (incl. basic kit)

CMT with SB 60i,

(9)*

(4)

(5)

(11)**

(8)

(6)

(7)

(1)*

(1)**

(2)

(10)

(3)

(1(1

4-roller unreeling wirefeeder and wire drum

(1) Wirefeeding hose with inner liner

(2) SpeedNet cable COM

(3) Unreeling wirefeeder WF 25i REEL 4R

(4) TPSi power source

(5) CU cooling unit

(6) Upright console

(7) HP interconnecting hosepack SB 60i

(8) SplitBox SB 60i R

(9) MHP /i R torch hosepack

(10) WF 60i Robacta Drive CMT

(11) MTB /i R robot welding torch

Maximum wirefeed length:

max. 4 m between drive unit and SB 60i R

max. 6 m between SB 60i R and unreeling wirefeeder

max. 8 m between unreeling wirefeeder and wire drum

(max. 10 m with PowerLiner)

Minimum length between wirefeeder and drive unit: 1 m

Possible wire diameters:

0.8 - 1.6 mm aluminium, 0.8 - 1.4 mm steel

Welding process: Standard, Pulse, LSC, PMC, PMC-MIX-DRIVE, PMC-RIPPLE-DRIVE, CMT

* Use the largest inner liner (incl. basic kit) ** Use the inner liner corresponding to the wire diameter (incl. basic kit)

CMT with SB

(9)

(4)

(5)

(12)**

(8)

(6)

(7)

(1)*

(1)**

(2)

(10)*

(3)

(11)

500i, 4-roller unreeling wirefeeder, wire drum and external wirefeeding hose

(1) Wirefeeding hose with inner liner

(2) SpeedNet cable COM

(3) Unreeling wirefeeder WF 25i REEL 4R

(4) TPSi power source

(5) CU cooling unit

(6) Upright console

(7) HP interconnecting hosepack

(8) Wire buffer

(9) SplitBox SB 500i R

(10) MHP /i R welding torch hosepack with external wirefeeding hose

(11) WF 60i Robacta Drive CMT

(12) MTB /i R robot welding torch

Maximum wirefeed length:

max. 4 m between drive unit and wire buffer

max. 6 m between wire buffer and unreeling wirefeeder

max. 8 m between unreeling wirefeeder and wire drum

(max. 10 m with PowerLiner)

Minimum length between wirefeeder and drive unit: 1 m

Possible wire diameters:

0.8 - 1.6 mm aluminium, 0.8 - 1.4 mm steel

Welding process: Standard, Pulse, LSC, PMC, CMT

* Use the largest inner liner (incl. basic kit) ** Use the inner liner corresponding to the wire diameter (incl. basic kit)

+ 162 hidden pages

Fronius TPSi Robotics Push/Pull Operating Instruction [EN]

Specifications and Main Features

Frequently Asked Questions

User Manual