/ 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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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.
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.
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.
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.
General information
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)
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
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)
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
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
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)
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.
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.
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
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
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