Fronius WF 25i / 60i CMT LaserHybrid FW Operating Instruction [EN]

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Operating instructions

WF 25i LaserHybrid FW WF 60i LaserHybrid FW CMT SB 360i LaserHybrid

EN-US

Operating instructions

42,0426,0306,EA 010-31032022

Table of contents

Safety Instructions 6

Explanation of Safety Instructions 6 General 6 Intended Use 7 Environmental Conditions 7 Obligations of the Operating Company 7 Obligations of Personnel 7 Personal Protective Equipment 8 Danger from Toxic Gases and Vapors 8 Danger Posed by Shielding Gas Leak 9 Danger from Flying Sparks 9 Danger from Welding Current 9 Stray Welding Currents 9 EMC Measures 9 Particular Hazard Areas 10 Informal Safety Measures 11 Safety Measures at the Installation Location 12 Safety Measures in Normal Operation 12 Safety Inspection 13 Modifications 13 Spare and Wearing Parts 13 Calibrating Power Sources 13 The CE label 13 Copyright 13

General information 15

EN-US

General 17

General 17 Intended use 17 Applications 17 Laser welding head versions 18 Applications 19 Scope of supply 21 Optional Components 21

Requirements 22

Mechanical Requirements 22 Robot Requirements 22 Ground Connection 22 Alignment 23

System Overview 24

System overview 24 Other LaserHybrid systems 26 Design versions 28

Operating controls and connections 31

Product description 33

Product description 33 Control Panel WF 25i Robacta Drive / WF 60i Robacta Drive CMT 34 Product description SB 360i LaserHybrid 36

Connection Specifications 37

Connection specifications 37 Compressed air diagram 38 Pressure monitoring in the SplitBox SB 360i LaserHybrid 39

Commissioning 41

General 43

Safety 43 Setup Regulations 43

Grid Connection 43 Setting up the LaserHybrid welding system 44 Setting up the CMT LaserHybrid welding system 45

Installing the Laser Welding Head on the Robot 46

Connection options on the robot 46 Mounting the drive unit on the laser welding head 47 Mounting the Laser Welding Head on the Robot 47

Installing and Connecting SplitBox SB 360i LaserHybrid 48

Mounting the SplitBox SB 360i LaserHybrid on the robot 48 Connecting SplitBox SB 360i LaserHybrid 50

Connecting Crossjet 52

Connecting the CrossJet 52

Connecting LaserHybrid Hosepack to Laser Welding Head 54

Mounting the Hosepack on the WF Robacta Drive (Conventional) 54 Connecting/Changing the Wirefeeding Hose on the Laser Welding Head 55

Installing/Changing Wirefeed Rollers 56

Inserting/replacing the WF 25i Robacta drive feed rollers 56 Inserting/replacing the WF 60i Robacta Drive CMT drive feed rollers 58

Connecting Laser Optics and Extra Extraction 60

Connecting the laser optics 60 Connecting the additional extraction system 63

Preparing Welding Torch 66

Fitting the inner liner in the torch body 66 Mounting the welding torch on the WF Robacta Drive (conventional) 67

Installing Hosepack on Robot 69

Placing the hosepack on the robot 69

Adapting the Additional Extraction System 72

Safety 72 Adapting the Additional Extraction System 72

Threading the Wire Electrode 73

Threading the wire electrode 73 Setting the Contact Pressure on the WF 25i Robacta Drive 73 Setting the contact pressure on the WF 60i Robacta Drive CMT 74

Setting up Laser Welding Head 75

Stick Out 75 Adjustable axes 75 Adjustment device on the laser welding head 76 Adjusting the x axis 76 Adjusting the y axis 77 Adjusting the z Axis 77

Creating Reference Program 78

Safety 78 General 78 Creating a Reference Program 78

Signal Sequence for LaserHybrid Welding 80

Safety 80 Signal Sequence for LaserHybrid Welding 80

Measures before Starting Welding 82

Operation Recommendations for LaserHybrid Welding System 83

Recommendations for the Operation of a LaserHybrid Welding System 83 Specifications for the compressed air supply 83

Maintenance 85

Replacing the Welding Torch and Welding Torch Wearing Parts 87

Safety 87 Mounting Wearing Parts on the Welding Torch 87

Replacing the Spatter Guard Plate and Extra Extraction 88

Replacing the spatter guard plate 88 Replacing the Additional Extraction System 88

Replacing the Laser Optics 89

Safety 89

Preparation 89 Removing the Laser Optics 91 Installing the laser optics 91 Final Tasks 94

Checking Position of the Wire Electrode in relation to the Laser Focus 95

Safety 95 General 95 Checking Position of the Wire Electrode in relation to the Laser Focus 95 Example: Use of the Reference Program after Welding Torch Replacement 96

Measures to Reduce Contamination of the Optics 97

Appendix 99

Technical data 101

WF 25i LaserHybrid 90° 10 kW FW (Laser Welding Head) 101 LaserHybrid hosepack MHP 360i LH 101 SB 360i LH 101 WF 25i Robacta Drive /W 102 WF 60i Robacta Drive /W CMT 102 MTB 700 LH /W 103 MTB 500i LH /W 103

EN-US

Safety Instructions

Explanation of Safety Instructions

DANGER!

Indicates an immediate danger.

Death or serious injury may result if appropriate precautions are not taken.

▶

WARNING!

Indicates a possibly dangerous situation.

Death or serious injury may result if appropriate precautions are not taken.

▶

CAUTION!

Indicates a situation where damage or injury could occur.

Minor injury or damage to property may result if appropriate precautions are

▶

not taken.

NOTE!

Indicates the possibility of ﬂawed results and damage to the equipment.

General The LaserHybrid head has been manufactured using state-of-the-art technology

and according to recognized safety standards. If used incorrectly or misused, however, it can cause

injury or death to the operator or a third party,

damage to the LaserHybrid head and other material assets belonging to the

operating company, inefficient operation of the LaserHybrid head.

All persons involved in the commissioning, operation, maintenance, and servicing of the LaserHybrid head must

be suitably qualified,

have knowledge of welding and

have read and implemented carefully these Operating Instructions and the

OI for the following system components: Laser Laser optics Power source and associated wirefeeder Robot and its controller

The Operating Instructions must always be at hand wherever the LaserHybrid head is being used. In addition to the Operating Instructions, all applicable local rules and regulations regarding accident prevention and environmental protection must also be followed.

All safety instructions and warning signs on the LaserHybrid head itself must:

be kept in a legible state

not be damaged/marked

not be removed

not be covered, pasted, or painted over.

For the location of the safety and danger notices on the LaserHybrid head, refer to the section headed "General" in the Operating Instructions for the LaserHy-

brid head. Before switching it on, resolve any faults that could compromise safety.

Your personal safety is at stake!

Intended Use The LaserHybrid head is to be used exclusively for its intended purpose.

The LaserHybrid head is intended exclusively for LaserHybrid welding of aluminum, CrNi and steel materials. Any other use does not constitute proper use. The manufacturer is not responsible for any damage resulting from improper use.

Proper use also means:

Completely reading and obeying all instructions in the Operating Instruc-

tions Completely reading and obeying all safety instructions and danger notices

Carrying out all the specified inspection and servicing work.

Never use the LaserHybrid head or the power source to thaw pipes.

The LaserHybrid head is designed for operation in industry and business. The manufacturer shall not be liable for any damage resulting from use in a living area. The manufacturer shall not be liable for faulty or incorrect work results either.

EN-US

Environmental Conditions

Obligations of the Operating Company

Operation or storage of the LaserHybrid head outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer is not responsible for any damage resulting from improper use.

Temperature range of the ambient air:

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

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

Relative humidity:

Up to 50% at 40°C (104°F)

Up to 90% at 20°C (68°F)

Ambient air: free of dust, acids, corrosive gases or substances, etc. Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)

The operating company must only allow persons to work with the LaserHybrid head if they

are familiar with the basic occupational safety and accident prevention regu-

lations and are trained in handling the LaserHybrid head have read and understood these Operating Instructions, especially the sec-

tion "Safety Rules," and have confirmed this with their signature are trained according to the requirements for the work results.

The safety-conscious work of the personnel must be checked regularly.

Obligations of Personnel

All persons who are assigned to work with the LaserHybrid head must do the following before beginning work:

Follow the basic regulations for occupational safety and accident prevention

Read these Operating Instructions, especially the section "Safety Rules," and

confirm that they have understood and will follow them by signing

Before leaving the workplace, ensure that no personal injury or property damage can occur in one's absence.

Personal Protective Equipment

Danger from Toxic Gases and Vapors

Please take the following precautions for your own personal safety:

Persons present in the sealed cell for the LaserHybrid process must

wear rigid, wet-insulating footwear

protect hands with appropriate gloves (featuring electrical insulation and

thermal protection) protect their eyes from laser beams by wearing regulation-compliant safety

glasses for lasers. To protect their face and eyes against UV beams, further protection in the form of a protective shield with regulation-compliant filter insert for laser protection class 4 must also be used in front of the safety glasses for lasers and the person's face. Do not look into the laser beam, even with a regulation-compliant filter insert for laser protection class 4. Only wear suitable (ﬂame-resistant) clothing

Wear hearing protection designed for crossjet noise (120 dbA)

If there are persons present in the sealed cell for the LaserHybrid process,

inform them of all the dangers that may be posed during operation (e.g. po-

tential accumulation of gases hazardous to health, risk of asphyxiation due to lack of oxygen in the breathable air, hazards posed by laser light, etc.) provide protective equipment

construct protective walls or install protective curtains.

The fumes produced during welding contain toxic gases and vapors.

Welding fumes contain substances that may cause birth defects and cancer in some circumstances.

Keep your head out of the welding fumes and gases.

Take the following precautionary measures for fumes and harmful gases:

Do not breathe them in.

Extract them from the work area using appropriate equipment.

Ensure that there is sufficient fresh air.

Use breathing apparatus with air supply if there is insufficient ventilation.

When no welding is taking place, close the valve of the shielding gas cylinder or the main gas supply.

If there is uncertainty as to whether the extraction capacity is sufficient, compare the measured toxic emission values against the permissible limit values.

The following components are factors that determine how toxic the welding fumes are:

The metals used for the workpiece

Electrodes

Coatings

Cleaning agents, degreasers, and the like

Consult the corresponding material safety data sheets and manufacturer's instructions for the components listed above.

Keep ﬂammable vapors (such as solvent vapors) out of the laser and arc radiation range.

Danger Posed by Shielding Gas Leak

Risk of asphyxiation due to uncontrolled shielding gas leak

Shielding gas is colorless and odorless and may suppress the oxygen in the ambient air in the event of leakage.

Ensure there is a sufficient supply of fresh air with a ventilation ﬂow rate of

at least 20 m³ per hour. Please observe the safety and maintenance information for the shielding gas

cylinder or the main gas supply. When no welding is taking place, close the valve of the shielding gas cylinder

or the main gas supply. Always check the shielding gas cylinder or main gas supply for uncontrolled

gas leakage before each start-up.

EN-US

Danger from Flying Sparks

Danger from Welding Current

Flying sparks can cause fires and explosions.

Never undertake welding near ﬂammable materials.

Flammable materials must be kept at least 11 meters (35 ft.) from the LaserHybrid welding process or protected with a certified cover.

Keep suitable, tested fire extinguishers on hand.

Sparks and pieces of hot metal may also get into surrounding areas through small cracks and openings. Take appropriate measures to ensure that there is no risk of injury or fire.

Do not undertake welding in areas at risk of fire and explosion, or on sealed tanks, drums, or pipes if these have not been prepared in accordance with corresponding national and international standards.

Do not undertake welding on containers in which gases, fuels, mineral oils, and the like are/were stored. Residues pose a risk of explosion.

An electric shock can be fatal. Every electric shock poses a risk of death.

All welding power-leads must be secured, undamaged, and insulated. Replace loose connections and scorched cables immediately.

Stray Welding Currents

EMC Measures WARNING! Electromagnetic field! Electromagnetic fields may cause health

If the following instructions are not observed, stray welding currents may occur, which can result in the destruction of ground conductors, the power source used, the LaserHybrid head, and other electrical equipment.

Ensure that the workpiece terminal is securely connected to the workpiece. If the ﬂoor is electrically conductive, set up the power source so that it is insulated wherever possible.

problems that are not yet known.

The operator is responsible for ensuring that there is no electromagnetic interference with electrical and electronic equipment.

If electromagnetic interference is discovered, the operator is obliged to take action to rectify the situation.

Check and evaluate possible problems and the interference immunity of equipment in the vicinity according to national and international regulations:

Safety devices

Grid power lines, signal lines, and data transfer lines

EMC and telecommunications equipment

Devices for measuring and calibrating

The health of persons close by, e.g., those with pacemakers and hearing aids

Persons with pacemakers must seek advice from their doctor before staying in the immediate vicinity of where the welding work is taking place.

Supporting measures to avoid EMC problems:

Grid power supply

If electromagnetic interference occurs despite a grid connection that

complies with regulations, take additional measures (e.g., use a suitable grid filter).

Welding power-leads

Keep them as short as possible

Route them close together (also to avoid EMC problems)

Route them far from other lines

Equipotential bonding

Workpiece grounding

If necessary, establish grounding using suitable capacitors

Shield, if necessary

Shield other devices in the vicinity

Shield the entire welding installation

Particular Hazard Areas

Laser beam poses a risk of injury to the eyes. In addition to using the protective shield with a regulation-compliant UV filter insert, eyes should be protected from laser beams using regulation-compliant safety glasses for lasers. It must still be ensured, however, that no one can accidentally look into the laser beam.

If the workpiece surface is especially bright or highly reﬂective, reﬂected laser- scattering radiation poses a further risk. Take suitable precautions so that persons present have adequate protection from laser-scattering radiation also.

Keep hands, hair, loose clothing, and tools away from moving parts, such as:

Ventilators

Gear wheels

Rollers

Shafts

Wirespools and welding wires

Do not insert body parts into rotating gear wheels on the wire drive or into rotating drive parts.

Covers and side parts must only be opened/removed during maintenance and repair work.

During operation:

Ensure that all covers are closed and all side parts have been mounted prop-

erly. Keep all covers and side parts closed.

Welding wire from the welding torch poses a high risk of injury (cuts to the hand, injuries to the face and eyes, etc.).

For this reason, always hold the welding torch away from your body (devices with wirefeeder) and wear suitable protective goggles.

Do not touch workpieces during or after welding – risk of burns.

Slag may ﬂy off from workpieces that are cooling down. For this reason, be sure to wear regulation-compliant protective equipment and ensure that other people are sufficiently protected even when reworking workpieces.

Leave the welding torch and other parts with a high operating temperature to cool before working on them.

Special regulations apply in areas where there is a risk of fire or explosion – observe relevant national and international regulations.

Power sources for work in spaces where electrical hazards pose a greater risk (e.g. the boiler room) must be marked with a (Safety) sign. The power source should not be located in these types of spaces, however.

Risk of scalding due to coolant leakage. Before disconnecting connections for the coolant supply hose or return connection, switch off the cooling unit.

When handling coolants, observe the specifications on the safety data sheet. The coolant safety data sheet is available from your service center or from the manufacturer's homepage.

Only use suitable load-carrying equipment from the manufacturer for transporting devices by crane.

Attach chains or ropes to all designated suspension points on suitable load-

carrying equipment. Chains or ropes must be as close to perpendicular as possible.

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

EN-US

Informal Safety Measures

Always use a suitable wirefeeder hoisting attachment with insulation on the crane for hoisting the wirefeeder (MIG/MAG and TIG devices).

If the device is fitted with a carrier belt or handle, this should be used exclusively for transportation by hand. The carrier belt is not suitable for transportation by crane, counterbalanced lift truck or other mechanical chain hoists.

All lifting equipment (belts, straps, chains, etc.) used in connection with the device or its components must be checked regularly (e.g., for mechanical damage, corrosion, or changes due to other environmental inﬂuences). The test interval and scope must, as a minimum, comply with the respective valid national standards and guidelines.

There is a risk of colorless, odorless shielding gas escaping without notice if an adapter is used for the shielding gas connection. Use suitable Teﬂon tape to seal the thread of the shielding gas connection adapter on the device side before installation.

The Operating Instructions must always be at hand wherever the LaserHybrid head is being used.

In addition to the Operating Instructions, all applicable local rules and regulations regarding accident prevention and environmental protection must also be made available and be followed.

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

Safety Measures at the Installation Location

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

be light-proof in relation to surrounding rooms

is shielded with at least 1 mm steel plate and/or approved laser protective

glass to protect against UV and laser beams The laser welding process and the arc welding process must be stopped

automatically and immediately as soon as the cell is opened.

A toppling device can be deadly! Set up the device securely on an even, solid surface

A tilt angle of no more than 10° is permitted

Special regulations apply in areas at risk of fire or explosion

Follow the appropriate national and international regulations.

Use instructions and checks within the company to ensure that the vicinity of the workplace is always clean and organized.

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

When setting up the device, ensure an all-round clearance of 0.5 m (1 ft. 7.69 in.) so that the cooling air can enter and leave unhindered.

Take care to ensure that the applicable national and regional guidelines and accident prevention regulations are observed when transporting the device, especially guidelines concerning hazards during transport and shipment.

Safety Measures in Normal Operation

Before transporting the device, always completely drain the coolant and dismantle the following components:

Wirefeeder

Wirespool

Shielding gas cylinder

It is essential to conduct a visual inspection of the device to check for damage after it has been transported but before it is commissioned. Have any damage repaired by trained service technicians before commissioning the device.

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

injury or death to the operator or a third party,

damage to the device and other material assets belonging to the operating

company, inefficient operation of the device.

Safety devices that are not fully functional must be repaired before the device is switched on.

Never bypass or disable safety devices.

Before conditioning the LaserHybrid head, ensure that no one can be put in danger.

The LaserHybrid head must be examined at least once a week for externally detectable damage and functionality of the safety devices.

Safety Inspection

The operator is required to have the LaserHybrid head tested by an electrician after every alteration, installation or modification, and all repairs and maintenance, and at least every 12 months, to ensure that it is in its correct state.

Regulation Title

IEC (EN) 60 974-1 Equipment for Arc Welding, Part 1: Welding Current

Sources

BGV A2, Section 5 Electrical Plants and Equipment

EN-US

BGV D1, Sections 33 / 49

VDE 0701-1 Repairing, Modifying and Testing Electrical Devices;

VDE 0702-1 Repeating Tests on Electrical Devices

Modifications Do not carry out any alterations, installations, or modifications to the LaserHy-

brid head without first obtaining the manufacturer’s permission.

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

Spare and Wearing Parts

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

When ordering, specify the exact name and part number according to the Spare Parts List as well as the serial number of your device.

Welding, Cutting and Related Work Methods

General Requirements

Calibrating Power Sources

The CE label The LaserHybrid head meets the basic requirements of the Low Voltage and

Regular calibration of power sources is required in accordance with international standards. The manufacturer recommends a calibration interval of 12 months. Please contact your service center if you require further details.

Electromagnetic Compatibility Directives and therefore has CE sign.

Text and illustrations were accurate at the time of printing. Fronius reserves 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 Operating Instructions, we will be most grateful for your comments.

General information

General

General The

WF 25i LaserHybrid 90° 10 kW FW and WF 60i LaserHybrid 90° 10 kW FW CMT laser welding heads are a further development of the 10 kW LaserHybrid head that are used specifically on components with fillet and butt welds

The WF 25i LaserHybrid 90° 10 kW FW and WF 60i LaserHybrid 90° 10 kW FW CMT will be referred to as the laser welding head throughout the rest of these Operating Instructions.

Additional benefits of laser welding heads:

High welding speed and great cost effectiveness

High process stability combined with a low level of rejects and reworking

High quality weld seam

Low heat input, reduced distortion

High availability of the welding system, long service life of wearing parts

Flexible use of the welding system

High gap tolerance

Adaptation for fiber, disk, and diode laser possible

EN-US

Intended use The laser welding heads are intended exclusively for automated MIG/MAG weld-

ing in combination with Fronius system components. Any other use does not constitute proper use. The manufacturer shall not be held liable for any loss resulting from improper use.

Intended use also means

Following all the instructions from the OIs for the individual components

Carrying out all the specified inspection and maintenance work

Applications The laser welding head is used for MAG laser applications:

For all components with fillet welds for plate thicknesses from 1.5 mm

For penetration welds from one side up to a plate thicknesses of 8 mm

For lap joints with plate thicknesses of 1.5 - 3 mm

steel, aluminum, CrNi, and special steel

Laser welding

(1)

(2)

(3)

head versions

The laser welding head is available in 4 versions, depending on application, accessibility and space constraints:

Version (1): Drive unit on the left with central robot support and 2 mounting brackets *

Version (2): Drive unit on the right with central robot support and 2 mounting brackets *

Version (3): Drive unit on the left with extension **, right-hand robot support and one mounting bracket *

(4)

Version (4): Drive unit on the right with extension **, left-hand robot support and one mounting brack-

(1) (2)

PB PB

et *

The laser welding head is supplied configured for the relevant application.

Applications Laser welding head version (1) + (2):

EN-US

Example 1: Two-sided, simultaneous fillet weld - PB welding position

Angle of contact of the laser: approx. 80° The position of the wire electrode to the laser is defined by the laser welding head.

for fillet welds, PB welding position

for ribs in shipbuilding

required for lap joints

in crane construction

Laser welding head version (3) + (4):

(3) (4)

PC PC

(3) - 90°

Example 2: Simultaneous butt weld on both sides - PC welding position

Angle of contact of laser: 90° The position of the wire electrode relative to the laser is defined by the laser welding head.

Example 3: Butt weld on top - PA welding position

for circumferential welds on boil-

ers in pipeline construction

for lap joints

for fillet welds, PA welding posi-

tion for butt welds

Scope of supply

1 laser welding head

1 LaserHybrid hosepack MHP 360i LH/W/FSC/FW/ with external wirefeeding

hose 1 drive unit

1 torch body

1 optical adjustment gauge

1 metal gauge to set the focal point

1 extractor tool for register pins

1 combination wrench 10 mm

1 open-end wrench 10 mm

1 wrench 8x10

1 bit 1/4" with handle and ﬂexible shaft

1 bit 1/4" 840/4 Z.

1 TX20 Torx screwdriver

1 Allen key, 5 mm

1 Allen key, 2.5 mm / laser

1 Allen key, 6 mm / laser

1 ballpoint Allen wrench, size 3 mm

1 ballpoint Allen wrench, size 4 mm

1 Operating Instructions

Miscellaneous screws

additionally for CMT applications:

Wire buffer kit

EN-US

Optional Components

The following components are optionally available for the laser welding head:

Seam tracking system, e.g. secured at the front on the welding head

Process monitoring to increase the weld seam quality, e.g. connected to the

laser optics Focus monitoring

Requirements

Mechanical Requirements

Robot Requirements

Ground Connection

The following mechanical requirements must be met in order to ensure a stable and repeatable LaserHybrid process:

Accurate welding torch guidance for robots or single-purpose machines (e.g.

longitudinal chassis) Precise weld seam preparation

Low component tolerances

Precise and very fast weld seam management systems with little deviation

The laser welding head weighs around 19 kg. The optics weigh a further 3 kg approximately. A total weight of around 30 kg should be expected for the complete laser welding head when fitted with optics and hosepack. It must therefore be possible for the robot axles to move a weight of 30 kg safely with the accelerations specified.

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

Grounding cable with bifilar winding

Grounding cable coiled

Alignment

CAUTION!

Danger of serious damage by laser radiation reﬂected directly into the laser optics!

This can cause serious damage to the fiber optic.

Always avoid 90° angles to the

▶

workpiece surface when aligning the LaserHybrid head.

EN-US

System Overview

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(11)

(10)

(8)

(9)

(12)

System overview LaserHybrid system with SplitBox SB 360i LaserHybrid installed on the robot

(1) Welding wire drum * (2) Unwinding wirefeeder:

WF 25i REEL 4R + OPT/i WF wire straightener (4,100,880,CK) + WF MOUNTING Drum

(3) Control line for unwinding

wirefeeder (4) Remote control (5) TPS 500i power source

+ robot interface **

+ CU 1400i Pro MC or CU

2000i MC Single cooling unit

+ upright console (screwed)

* As an alternative to the welding wire drum, a wirespool can also be used

for wirefeeding. The following components are required for this purpose: WF 25i REEL 4R unwinding wirefeeder + OPT/i WF reel carriage D300

(6) Wirefeeding hose (7) Interconnecting hosepack (8) Robot (9) SplitBox SB 360i LaserHybrid

+ Mounting SB 360i LH ***

(10) LaserHybrid

MHP 360i LH/W/FSC/FW hosepack

(11) WF 25i LaserHybrid 90° 10 kW

(12) LaserHybrid cleaning station

** e.g., RI FB Inside/i or RI FB Pro/i

*** Robot support for the SplitBox SB 360i LaserHybrid, depending on type

of robot

CMT LaserHybrid system with SplitBox SB 360i LaserHybrid and wire buffer in-

(1)

(2)

(3)

(6)

(7)

(11)

(10)

(8)

(9)

(12)

(4)

(5)

(13)

(14)

(6)

stalled on the robot

EN-US

(1) Welding wire drum * (2) Unwinding wirefeeder:

WF 25i REEL 4R

+ OPT/i WF wire straightener

(4,100,880,CK)

+ WF MOUNTING Drum (3) Control line for unwinding

wirefeeder (4) Remote control (5) TPS 500i power source

+ robot interface **

+ CU 1400i Pro MC or CU

2000i MC Single cooling unit

(6) Wirefeeding hose (7) Interconnecting hosepack (8) Wire buffer (9) Wire buffer control line (10) Robot (11) SplitBox SB 360i LaserHybrid

+ Mounting SB 360i LH ***

(12) LaserHybrid

MHP 360i LH/W/FSC/FW hosepack

(13) WF 60i LaserHybrid 90° 10 kW

FW CMT

(14) LaserHybrid cleaning station

+ upright console (screwed)

* As an alternative to the welding wire drum, a wirespool can also be used

for wirefeeding. The following components are required for this purpose: WF 25i REEL 4R unwinding wirefeeder + OPT/i WF reel carriage D300

** e.g., RI FB Inside/i or RI FB Pro/i

*** Robot support for the SplitBox SB 360i LaserHybrid, depending on type

of robot

Other LaserHy-

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(11)

(10)

(8)

(9)

(12)

brid systems

The following LaserHybrid systems can also be fitted with the WF 60i LaserHybrid 90° 10 kW FW CMT laser welding head. In this case, the wire buffer and control line are also included.

LaserHybrid system with SplitBox SB 360i LaserHybrid installed on the wall

(1) Welding wire drum (2) Unwinding wirefeeder:

WF 25i REEL 4R

+ OPT/i WF wire straightener

(4,100,880,CK)

+ WF MOUNTING Wall (3) Control line for unwinding

wirefeeder (4) Remote control (5) TPS 500i power source

+ robot interface

+ CU 1400i Pro MC or CU

2000i MC Single cooling unit

+ upright console (screwed)

(6) Wirefeeding hose (7) Interconnecting hosepack (8) Robot (9) SplitBox SB 360i LaserHybrid

+ wall bracket SB 360i LH

(10) LaserHybrid

MHP 360i LH/W/FSC/FW hosepack

(11) WF 25i LaserHybrid 90° 10 kW

(12) LaserHybrid cleaning station

LaserHybrid system with SplitBox SB 360i LaserHybrid installed on the power

(5)

(6)

(2)

(1)

(3)

(8)

(10)

(7)

(9)

(4)

(11)

source

EN-US

(1) Remote control (2) Control line for unwinding

wirefeeder (3) TPS 500i power source

+ robot interface

+ CU 1400i Pro MC or CU

2000i MC Single cooling unit

+ upright console (screwed)

+ interconnecting hosepack (4) SplitBox SB 360i LaserHybrid

+ OPT/i TPS Mount SB 360i

(6) Unwinding wirefeeder:

WF 25i REEL 4R + OPT/i WF Reel carriage D300

(7) LaserHybrid

MHP 360i LH/W/FSC/FW

hosepack (8) Wirefeeding hose (9) Robot (10) WF 25i LaserHybrid 90° 10 kW

FW (11) LaserHybrid cleaning station

LH*

(5) Wirespool D300

* Support for the SplitBox SB 360i LaserHybrid, mounted on the power

source

Design versions The following design versions can also be fitted with the WF 60i LaserHybrid 90°

10 kW FW CMT laser welding head. In this case, the wire buffer and control line are also included.

Power source is in the welding cell (I)

TPS 500i - power source

HP 95i CON W/1.2 m/95 mm² – interconnecting hosepack

SB 360i LaserHybrid - SplitBox, mounted on the power source

MHP 360i LH/W/FSC/FW 7.5m – LaserHybrid hosepack

Welding wire drum

WF 25i REEL 4R – unwinding wirefeeder

WF MOUNTING Drum

Wirefeeding hose L=10 m

Laser welding head

Application: The robot only makes slight compensatory movements. Robot axles seven and eight carry out the majority of the welding feed movement.

Example: Circumferential welds on boilers, axles, etc.

Power source is in the welding cell (II)

TPS 500i - power source

HP 95i CON W/1.2 m/95 mm² – interconnecting hosepack

SB 360i LaserHybrid - SplitBox, mounted on the power source

MHP 360i LH/W/FSC/FW 7.5m – LaserHybrid hosepack

Wirespool

WF 25i REEL 4R – unwinding wirefeeder

WF reel carriage D300

Wirefeeding hose L=10 m

Laser welding head

Application: For test systems only (wirespool is not used in series production)

Power source is not in the welding cell (I)

TPS 500i - power source

HP 95i CON W/10 m/95 mm² – interconnecting hosepack

SB 360i LaserHybrid – SplitBox, mounted on the robot or on the wall

MHP 360i LH/W/FSC/FW 4.2 m – LaserHybrid hosepack

Welding wire drum

WF 25i REEL 4R – unwinding wirefeeder

WF MOUNTING Drum

Wirefeeding hose L=20 m

Laser welding head

Application: Robot axles 1–6 carry out the welding feed movement.

Example: Longitudinal seams on boilers, battery trays, etc.

Power source is not in the welding cell (II)

TPS 500i - power source

HP 95i CON W/10 m/95 mm² – interconnecting hosepack

SB 360i LaserHybrid - SplitBox, wall mounting

MHP 360i LH/W/FSC/FW 7.5m – LaserHybrid hosepack

Welding wire drum

WF 25i REEL 4R – unwinding wirefeeder

WF MOUNTING Drum

Wirefeeding hose L=20 m

Laser welding head

Application: Robot axles 1–6 carry out the welding feed movement.

Example: Longitudinal seams on boilers, battery trays, etc.

Power source mounted and travels on a gantry

TPS 500i - power source

HP 95i CON W/10 m/95 mm² – interconnecting hosepack

SB 360i LaserHybrid – SplitBox, mounted on gantry

MHP 360i LH/W/FSC/FW 4.2 m or 7.5 m – LaserHybrid hosepack

Welding wire drum

WF 25i REEL 4R – unwinding wirefeeder

WF MOUNTING Drum

Wirefeeding hose L=20 m

Laser welding head

EN-US

Application: Robot axles 1–8 carry out the welding feed movement.

Example: Longitudinal seams in rail vehicle construction, large base frame (e.g. press brake), etc.

Operating controls and connec-

tions

Product description

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(10)

(12)

(11)

(8)

(9)

Product description

EN-US

Item Name

(1) Robot support

(central / left / right depending on configuration)

(2) Mounting brackets

(3) Laser optics

(4) Adjustment device

(5) Gas nozzle

(6) MTB torch body

(7) Additional extraction

(8) Drive unit WF 25i Robacta Drive / WF 60i Robacta Drive CMT

(9) Drive unit support

(10) MHP robot hose pack

(11) CrossJet connection

(1) (2)

(4)

(5)

(3)

(12) External wirefeeding hose

Control Panel WF 25i Robacta Drive / WF 60i Robacta Drive CMT

No. Function

(1) Gas-test button

To set the required quantity of gas on the gas pressure regulator

After pressing the gas-test button, gas is released for 30 s. Pressing the button again ends the process early

No. Function

(2) F1 button

No function at present

(3) Wire-return button

For retracting the wire electrode without gas or current

Whilst the button is being pressed, the wirefeeder operates at the preset wire-return speed

There are two options available for retracting the wire electrode:

Option 1

Retract the wire electrode at the preset wire-return speed: Press and hold the wire-return button

After pressing the wire-return button, the wire electrode is retracted

by 1 mm (0.039 in.) After a brief pause, the wirefeeder continues retracting the wire elec-

trode – if the wire-return button is kept pressed down, then the speed increases with each further second by 10 m/min (393.70 ipm) until the preset wire-return speed is reached

Option 2

Retract the wire electrode in 1 mm steps (0.039 in. steps) – always press the wire-return button for less than 1 second (tap)

IMPORTANT! Only retract the wire electrode a small amount at a time, to avoid the wire electrode becoming entangled on the wirespool during retraction.

IMPORTANT! If there is a ground earth connection with the contact tip, then before the wire-return button is pressed, the wire electrode is retracted by pressing the wire-return button until the wire electrode is short-circuit-free—however by a maximum of 10 mm (0.39 in.) each time the but-

ton is pressed. If the wire electrode is retracted further, press the wire-return button again.

(4) Wire-threading button

For threading the wire electrode into the torch hosepack without gas or current

Whilst the button is being pressed, the wirefeeder operates at the preset feeder inching speed

There are two options available for the wire threading:

Option 1

Thread the wire electrode at the preset feeder inching speed: Press and hold the wire-threading button

After pressing the wire-threading button, the wire electrode will be

threaded in by 1 mm (0.039 in.) After a brief pause, the wirefeeder continues threading in the wire

electrode – if the wire-threading button is kept pressed down, then the speed increases with each further second by 10 m/min (393.70 ipm) until the preset feeder inching speed is reached If the wire electrode meets a ground earth connection, then the

wirefeeding is stopped and the wire electrode is retracted again by 1 mm (0.039 in.)

EN-US

Option 2

Thread the wire electrode in 1 mm steps (0.039 in. steps) – always press the wire-threading button for less than 1 second (tap)

If the wire electrode meets a ground earth connection, then the wirefeeding is stopped and the wire electrode is retracted again by 1 mm (0.039 in.)

IMPORTANT! If there is a ground earth connection with the contact tip, then before the wire-threading button is pressed, the wire electrode is retracted by pressing the wire-threading button until the wire electrode is short-circuit-free—however, this must not exceed 10 mm (0.39 in.) each time the button is pressed. If after the 10 mm (0.39 in.) wire retraction there is still a ground earth connection with the contact tip, then when the wire-threading button is pressed again, the wire electrode is retracted again by a maximum of 10 mm (0.39 in.). The process is repeated until there is no longer any ground earth connection with the contact tip.

(5) Display

Status display

Product descrip-

(1)

(2)

(3) (4)

(5)

(6) (7)

(8)

(14)

(13)

(12)

(11)

(9)

(8)

(10)

tion SB 360i LaserHybrid

Back

Front

Item Name

(1) (+) Current socket with fine thread

For connecting the power cable from the interconnecting hosepack

(2) Shielding gas connection socket

(3) SpeedNet connection

For connecting the SpeedNet cable from the interconnecting hosepack

(4) SpeedNet connection

For connecting system add-ons, such as remote control

(5) Gas purging connection

(6) Welding torch cooling connection - coolant return (red)

For connecting the coolant return hose from the interconnecting hosepack

(7) Welding torch cooling connection - coolant supply (blue)

For connecting the coolant supply hose from the interconnecting hosepack

(8) SplitBox SB 360i LaserHybrid mount

(9) Welding torch connection (FSC)

For connecting the LaserHybrid hosepack

(10) Crossjet OUT connection

(11) Crossjet OUT connection

(12) Crossjet IN connection

(13) Interconnecting hosepack (to the power source)

Originally not included in the SB 300i LaserHybrid; the interconnecting

(14) Welding torch cooling connecting plug

hosepack is used during the installation into the SB 300i LaserHybrid.

For connecting the welding torch cooling to the LaserHybrid hosepack

Connection Specifications

(1)

(2)

(3)

(4)

(5)

(6)

(7)

Connection specifications

EN-US

Item Name

(1) Laser optics water cooling connection

(return opposite)

(2) Fiber optic cable for laser

Bending radius > 200 mm

(3) CrossJet extraction connection

For connecting a hose as per the following data:

inner diameter Di = 51 mm

outer diameter Do = 57 mm

max. length = 10 m

(4) CrossJet supply

For connecting a hose as per the following data:

inner diameter Di = 12 mm

WF 25i LaserHybrid 90° 10 kW FWSB 360i LaserHybrid

MHP LH

(1)

(2)

(3) (4)

(5)

(6)

(7)

(8)

outer diameter Do = 14 mm

p = 6 bar

Required filling capacity = 6 bar - 1500 l/min

Required extraction capacity = 280 m³/h

(5) Additional extraction connection

For connecting a hose as per the following data:

inner diameter Di = 41 mm

max. length = 10 m

recommended extraction unit:

min. fan power = 100 m³/h min. negative pressure = 20,000 Pa

(6) External wirefeeding hose (Fronius)

(7) Radial air supply

For connecting a hose as per the following data:

outer diameter Do = 6 mm

Compressed air diagram

MHP LH = LaserHybrid hosepack

(5)

(4)

(6)

(9)

(7)

(8)

(7)

(4)

Item Name

(1) Compressed air supply line

(2) Solenoid valve

(3) Internal pressure measure-

ment

(4) Pressure measurement option

(5) Radial air ﬂow branch

(6) CrossJet gas nozzles branch

(7) CrossJet supply

(8) CrossJet exhaust air

(9) Additional extraction

NOTE!

The "VALVE ON" signal for controlling the solenoid valve (2) is transmitted on bit 26 (away from 0).

EN-US

Pressure monitoring in the SplitBox SB 360i LaserHybrid

The pressure is measured after the solenoid valve. If the pressure falls below 4.5 bar for longer than 2 seconds, then the "Powersource Ready" bit is withdrawn and the warning code 16835 (laser Crossjet air pressure supply low) is output.

From power source software version 2.4.0:

If the pressure drops below 4.5 bar for longer than 2 seconds, the "Warning-Bit" is set and the error code 16835 (laser Crossjet air pressure supply low) is output.

The current Crossjet pressure is displayed in the SmartManager (power source website) under "Actual system data".

Commissioning

General

EN-US

Safety

Setup Regulations

WARNING!

Work performed incorrectly can cause serious injury and damage to property.

This setting work must only be carried out by trained and qualified person-

▶

nel. Observe the safety rules in the OI, in particular the "Safety Inspection" sec-

▶

tion.

The power sources have been tested according to protection class IP 23. This means:

Protection against solid foreign bodies larger than Ø 12 mm (0.47 in.)

Protection against spraywater up to an inclined angle of 60°

The welding system can be set up and operated outdoors in accordance with protection class IP 23. However, the effects of direct moisture (e.g. from rain) must be avoided.

WARNING!

Toppling or falling devices can be deadly.

Securely set up the devices on a level and stable surface.

▶

The ventilation channel of the power sources is an important safety device. When selecting the setup location, ensure that the cooling air can enter and exit unhindered through the vents on the front and back. Any electrically conductive dust (e.g. from grinding work) must not be allowed to be sucked directly into the system.

Grid Connection The device is designed for the grid voltage listed on the rating plate. The fuse

protection required for the grid lead can be found in the "Technical Data" section. If mains cables or mains plugs are not included with your version of the appliance, attach the appropriate mains cable or mains plug in accordance with your country's standards.

CAUTION!

An under-dimensioned electrical installation can lead to serious damage.

The grid lead and its fuse protection should be designed to suit the existing

▶

power supply. The technical data on the rating plate should be followed.

▶

Setting up the LaserHybrid welding system

WARNING!

If a power source is connected to the grid during installation, there is a danger of serious personal injury and property damage.

Please read the "Safety Rules" chapter for the power source in the Operating

▶

Instructions before using it for the first time. Carry out all the preparation steps only when

▶

the power switch on the power source is set to the - O - position, the mains cable cord is disconnected from the grid.

Initial situation: Robot and robot control are available and ready for operation

Set up welding system:

Mount upright consoles

Mount cooling unit on upright console

Connect power source to cooling unit

Set up welding wire drum

Mount WF MOUNTING drum onto the welding wire drum

Set up and connect unwinding wirefeeder

Connect power source with robot control

Connect the remote control

Set up laser welding head:

Mount WF 25i Robacta Drive on the laser welding head

Mounting the laser welding head on the robot

Mount and Connect SplitBox SB 360i LaserHybrid

Connect CrossJet

Connect the LaserHybrid hosepack to the laser welding head

Connect/replace the wirefeeding hose on the laser welding head

Install/replace wirefeed rollers

Connect laser optics and additional extraction system

Equip welding torch

Place LaserHybrid hosepack on the robot

Thread the wire electrode

Other activities before start-up:

Adjust the laser welding head

Create a reference program

Signal sequence for LaserHybrid welding

Measures before start of welding

Establish ground earth connection between workpiece and power source

Setting up the CMT LaserHybrid welding system

WARNING!

If a power source is connected to the grid during installation, there is a danger of serious personal injury and property damage.

Please read the "Safety Rules" chapter for the power source in the Operating

▶

Instructions before using it for the first time. Carry out all the preparation steps only when

▶

the power switch on the power source is set to the - O - position, the mains cable cord is disconnected from the grid.

Initial situation: Robot and robot control are available and ready for operation

Set up welding system:

Mount upright consoles

Mount cooling unit on upright console

Connect power source to cooling unit

Set up welding wire drum

Mount WF MOUNTING drum onto the welding wire drum

Set up and connect unwinding wirefeeder

Connect power source with robot control

Connect the remote control

Mount the wire buffer with mounting plate

(e.g. on the hosepack holder extension arm or using balancer)

EN-US

Set up laser welding head:

Mount WF 60i Robacta Drive CMT on the laser welding head

Mounting the laser welding head on the robot

Mount and Connect SplitBox SB 360i LaserHybrid

Connect unwinding wirefeeder and wire buffer by means of control line

Connect CrossJet

Connect the LaserHybrid hosepack to the laser welding head

Connect the wirefeeding hose to the wire buffer and the laser welding head

Install wirefeed rollers

Connect laser optics and additional extraction system

Equip welding torch

Place LaserHybrid hosepack on the robot

Thread the wire electrode

Other activities before start-up:

Adjust the laser welding head

Create a reference program

Signal sequence for LaserHybrid welding

Measures before start of welding

Establish ground earth connection between workpiece and power source

Installing the Laser Welding Head on the Robot

90 mm

238 mm

Connection options on the robot

The following connection options apply to all laser welding head versions.

Example: Laser welding head version 1 – Drive unit on the left with central robot support and 2 mounting brackets

Mounting the

drive unit on the laser welding head

If the drive unit is not mounted on the laser welding head when it is delivered, mount it following the instructions below.

Insert the drive unit in the holder

Mount the drive unit using two Al-

len screws, 5 mm Tightening torque = 10 Nm

EN-US

Mounting the Laser Welding Head on the Robot

NOTE!

The laser welding head does not have any collision protection fitted as standard.

Fronius therefore recommends the use of a commercially available collision protection solution for robotic applications in order to prevent damage to the laser welding head in the event of a crash.

Mount the laser welding head to

the robot according to the specifications of the robot manufacturer.

Installing and Connecting SplitBox SB 360i Lase-

rHybrid

Mounting the SplitBox SB 360i LaserHybrid on the robot

Disconnect SplitBox SB 360i LaserHybrid and SplitBox mount

Depending on the robot, mount an appropriate support for the SplitBox

mount on the robot

IMPORTANT! Observe robot manufacturer's mounting instructions.

Mount SplitBox mount on the sup-

port using 4 Allen screws size 6 mm Tightening torque = 24 Nm

Insert strain-relief device of the in-

terconnecting hosepack into the opening and push forwards

Secure strain-relief device of the

interconnecting hosepack using 2 Allen screws size 4 mm

Open clamps (x2)

Insert interconnecting hosepack

into the clamps

Close clamps

EN-US

Insert SplitBox SB 360i LaserHy-

brid into the SplitBox mount as per the diagram

Secure SplitBox into the SplitBox

mount using 3 TX25 screws from above and 3 TX25 from below Tightening torque = 3.5 Nm

Connecting

SplitBox SB 360i LaserHybrid

Connect interconnecting hosepack

to SplitBox:

Power cable

Welding torch cooling return

ﬂow (red) Welding torch cooling supply

line (blue) Protective gas shield

SpeedNet (from interconnect-

ing hosepack)

SpeedNet (remote control)

* Gas purging connection

Connect LaserHybrid hosepack to

welding torch connection (FSC)

Close clamping lever

Open cover on LaserHybrid hosep-

ack

Connect connecting plug for weld-

ing torch cooling to the LaserHybrid hosepack

Connect crossjet air inlet

IMPORTANT! When connecting cross-

(1)

jet air outlet hoses, make sure that cutting rings are present!

Connect crossjet air outlet (x 2)

Fix the hoses in place on the con-

nection using hexagon nuts size 24 mm Tightening torque = 50 Nm

IMPORTANT! Use ﬂat spanner size 22 mm to hold the items in place when fixing the hexagon nuts in place on the connection

Connect hoses for optics cooling

(push-in) Blue marking = coolant supply line

EN-US

Connecting Interconnecting Hosepack to Power Source

Option:

(1) Data line 3 x 0.5 mm²

(e.g. for analyzing additional pressure monitoring)

Connecting Crossjet

Connecting the CrossJet

Insert CrossJet exhaust air hose

into the opening

Position fixing plate so that it is in a

groove of the CrossJet exhaust hose (x2 - also on the opposite side)

Secure fixing plate with 2 Allen

screws, 3 mm (x2 - also on the opposite side)

Depending on the robot move-

ment, determine the required length of the air hoses and cut the air hoses accordingly to size

Withdraw protective hose

IMPORTANT! When connecting

the CrossJet air outlet hoses, ensure that the cutting rings are present!

Connect CrossJet air outlet

Secure hose to the connection us-

ing a hexagonal nut, 24 mm Tightening torque = 50 Nm

IMPORTANT! When securing the hexagon nut to the 22 mm connection socket, counter with a 22 mm wrench.

Repeat process on the other side

EN-US

Pull protective hoses over the con-

nections

Connecting LaserHybrid Hosepack to Laser Weld-

42,0411,1315

45,0200,1261

11 Nm / 8.11 lb-ft

ing Head

Mounting the Hosepack on the WF Robacta Drive (Conventional)

IMPORTANT! Only mount the drive unit when the power source is switched off.

CAUTION!

Risk of damage due to dirty or wet coupling points

When removing or attaching the hosepack, ensure that the coupling point is

▶

clean and dry. Remove any coolant that has escaped from the coupling point.

▶

1 2

EN-US

Connecting/ Changing the Wirefeeding Hose on the Laser Welding Head

Place the starting piece on the

wirefeeding hose

Screw the starting piece as far as it

will go onto the wirefeeding hose

Press the green locking button and

hold it

Push the wirefeeding hose into the

drive unit until the tension on the locking button is released

Let go of the locking button

Push the wirefeeding hose onwards

until the lock engages and the locking button pops out

Removal:

Press the locking button and hold

Pull the wirefeeding hose from the

drive unit

Installing/Changing Wirefeed Rollers

0 mm *

Inserting/replacing the WF 25i Robacta drive feed rollers

3 4

* If the roller mount is opened as far as it will go with slight resistance, the roller mount will stay in this position.

5 6

7 8

Torx 40 1 Nm

0.74 lb-ft

9 10

EN-US

11 12

Inserting/repla-

0 mm *

12 mm

42,0411,0160

cing the WF 60i Robacta Drive CMT drive feed rollers

3 4

* If the roller mount is opened as far as it will go with slight resistance, the roller mount will stay in this position.

7 8

12 mm 5 Nm

3.69 lb-ft

42,0411,0160

9 10

EN-US

11 12

Connecting Laser Optics and Extra Extraction

Connecting the laser optics

NOTE!

The following activities were described on the basis of version (1) - Drive unit on the left with central robot support and 2 mounting brackets *.

The procedure for the other three versions is the same.

CAUTION!

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

Observe the Operating Instructions, specifications, and safety instructions

▶

from the manufacturer of the laser optics. Before connecting, position the laser welding head so that the longitudinal

▶

axis of the laser welding head is outside of the horizontal (> 90°). This will ensure that no dirt can get into the laser optics from above.

Remove the 5 Allen screws size 6

For installation: the 3 shorter screws are one below the other; the 2 longer screws are opposite.

Remove the 2 register pins:

Fit and screw on extractor tool

for register pins Knock the striking weight of

the extractor tool back in order to remove the register pins

Remove mounting bracket

Position the laser welding head so

that the longitudinal axis of the laser welding head is outside the horizontal (> 90°)

Clean connection area using com-

pressed air

Remove the protective cover from

the fiber optic cable connection

EN-US

Clean connector of the fiber optic

cable using compressed air

Remove the protective cover from

the fiber optic cable connector

IMPORTANT! When connecting the

fiber optic cable, pay attention to the position of the register pin on the connector!

Connect fiber optic cable:

Press the button

Pull back the rubber sleeve in

the direction of the optics Connect the fiber optic cable

connector

Check whether the rubber sleeve is

cleanly sealed all around the fiber optic cable connector

IMPORTANT! The picture opposite shows an incorrectly positioned rubber sleeve! The rubber sleeve shown has a kink in the area indicated by the arrows, and therefore it is not fully sealed.

INCORRECTLY positioned rubber sleeve! The rubber sleeve does not seal fully.

Connect the optics cooling using

the Allen screws, size 2.5 mm Tightening torque = 4 Nm

Connect the optics cooling supply

(blue marking)

Connect the optics cooling return

EN-US

Connecting the additional extraction system

Position the laser welding head in the vertical line

Push hose over the connection

Secure hose with hose clamp

Attach the mounting bracket

Push slot nut upwards, so that the

top hole of the slot nut is positioned under the top hole of the mounting bracket.

Use a short Allen screw (6 mm) to

lightly fix the slot nut and mounting bracket

Insert register pins (x2)

Fit and screw on extractor tool for

Knock the striking weight of the

extractor tool forward in order to position the register pins

For installation: the 3 shorter screws are one below the other; the 2 longer screws are opposite.

Insert the remaining 4 Allen

screws, size 6 mm

Fix the mounting bracket in place

using 5 Allen screws size 6 mm Tightening torque = 24 Nm

EN-US

Preparing Welding Torch

Fitting the inner liner in the torch body

Plastic inner liner:

1 2

Steel inner liner:

1 2

42,0411,1315

45,0200,1261

EN-US

Mounting the welding torch on the WF Robacta Drive (conventional)

IMPORTANT! When removing or attaching the welding torch, ensure that the

coupling point is clean and dry. Remove any coolant that has escaped from the coupling point.

Installing Hosepack on Robot

(1)

(2)

(4)

44,0360,0099

10 x 5 Nm

2,9 Nm

8 Nm

27 Nm

(11)

42,1000,0112

44,0350,0254

(11)

(12)

(14)

M10 / 45 Nm

(3a)

(3)

(4)

(6)

(7)

(8)

(7)

(10)

(5)

(9)

(6)

(11)

(13)

EN-US

Placing the hosepack on the robot

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

scope of supply for the laser welding head.

(1) Mounting HP LH xx

Mounting plate depending on robot

(2) Item profile 10 50 x 50 mm, 2

m (42,1000,0112)

(3) Optional extension arm

(44,0350,0254)

(3a) Mounting plate for CMT wire buffer (45,1200,0247)

(4) Slot nut (5) Lower sheet metal part (6) Opening for wirefeeding hose

(7) Opening for fiber optic cable (8) Opening for extraction hose

(with adapter insert) (9) Opening for LaserHybrid

hosepack (10) Opening for extraction hose (11) Allen screw

M4 x 60 mm (12) Allen screw

M8 x 20 mm (13) Adapter insert for extraction

hose kit, diameter 41/51 mm

(42,0411,9036) (14) Allen screw

M6 x 25 mm

Installation

Mount the mounting plate (1) to the robot arm according to the instructions

of the robot manufacturer

Cut the profile 10 50 x 50 mm (2) to length according to the robot arm

Mount the profile 10 50 x 50 mm (2) using slot nuts and 4 hexagonal bolts,

size 17 mm, to the mounting plate (1) Tightening torque = 10 Nm

Remove Allen screw, size 3 mm (11), and disassemble the lower sheet metal

part (5) of the LaserHybrid hosepack holder

Loosen the 2 Allen screws, size 6 mm (12), between the lower sheet metal

part (5) and the slot nut (4) so that the slot nut (4) can be pushed into the top slot on the profile 10 50 x 50 mm (2)

Push the slot nut (4) with the lower sheet metal part (5) into the top slot on

the profile 10 50 x 50 mm (2)

Tighten the 2 Allen screws, size 6 mm (12), and secure the lower sheet metal

part (5) with the slot nut (4) to the profile 10 50 x 50 mm (2) Tightening torque = 27 Nm

Repeat steps 4 - 7 for all LaserHybrid hosepack holders

Using the Allen screw, size 3 mm (11), attach the components of the Lase-

rHybrid hosepack holder(s) back onto the lower sheet metal part (5) Tightening torque = 2.9 Nm

Only for CMT LaserHybrid welding systems:

Mount wire buffer with mounting plate (3a) on the extension arm (3)

EN-US

For all LaserHybrid hosepack holders, remove the top and lower plastic parts

10 Allen screws, size 5 mm (14)

Position hoses, cables, and LaserHybrid hosepack into the openings of the

LaserHybrid hosepack holders

For all LaserHybrid hosepack holders, fit the plastic parts and secure

10 Allen screws, size 5 mm (14), tightening torque = 4 Nm

Adapting the Additional Extraction System

Safety

Adapting the Additional Extraction System

WARNING!

Work performed incorrectly can cause serious injury and damage to property.

This setting work must only be carried out by trained and qualified person-

▶

nel. Observe the safety rules in the OI, in particular the "Safety Inspection" sec-

▶

tion.

To make components more accessible, the position of the additional extraction system can be adapted to the existing available space.

NOTE!

The additional extraction system is factory-set for the LaserHybrid welding process.

Every change in position of the additional extraction system can affect the extraction performance.

Loosen 4 Allen screws

size 2.5 mm

NOTE!

When adapting the position of the additional extraction system, ensure that the gas shield remains intact and that no shielding gas is extracted from the welding area.

Adapt the position of the addition-

al extraction system according to the application and accessibility

Tighten screws

Threading the Wire Electrode

EN-US

Threading the wire electrode

IMPORTANT! Before threading the wire electrode, carefully deburr the end of

the wire electrode!

Requirement:

Wirefeeding hose connected

Wire electrode is threaded into the unwinding wirefeeder

Correct wirefeed rollers and inlet nozzles available in the laser welding head

Setting the Contact Pressure on the WF 25i Robacta Drive

Press the wire threading button until the wire electrode comes out of the welding torch

NOTE!

Set the contact pressure so that the wire electrode is not deformed, but correct wire transport is guaranteed.

IMPORTANT! If the contact pressure is changed significantly, the system must

be calibrated. The process for calibrating the system is explained in the OI of the power source.

Contact pressure standard values for steel rollers:

Setting the contact pressure on the WF 60i Robacta Drive CMT

Al,

1 - 2 AlSi AlMg 2 - 4 FCW 3 - 5 CuSi 5 - 7 Steel 6 - 8 CrNi 6 - 8

NOTE!

Set the contact pressure in such a way that the wire electrode is not deformed but nevertheless ensures proper wirefeeding.

IMPORTANT! If the contact pressure is changed significantly, the system must

be calibrated. The process for calibrating the system is explained in the OI of the power source.

Contact pressure standard values for steel rollers:

Al,

1 - 2 AlSi AlMg 2 - 4 FCW 3 - 5 CuSi 5 - 7 Steel 6 - 8 CrNi 6 - 8

Setting up Laser Welding Head

(1)

(2)

(3)

15 - 20 mm

(± 5 mm)

z (± 5 mm)

90°

EN-US

Stick Out

Adjustable axes The spatial position of the arc process to the laser beam can be adjusted in all

three Cartesian coordinate axes.

NOTE!

When setting the spatial position of the welding torch, pay attention to a general stick out of 15-20 mm.

Standard stick out = 20 mm

Using an adjustment device, com-

▶

pensate for a stick out < 20 mm in the x, y, and z axis according to the focal length of the laser optics. Observe the specifications on the

▶

laser optics!

(1) Welding torch (2) Contact tip (3) Stick out

CAUTION!

Risk of damage to the optical fiber due to the laser beam being vertical to the workpiece surface.

If the laser beam is at 90° to the workpiece surface, then the laser beam is reﬂected directly into the laser optics. This may cause serious damage to the optical fiber.

Adjustment

(1)

(2) (3) (4) (5)

(6)

device on the laser welding head

The laser welding head is equipped with an adjustment device, which allows for precise positioning in the x, y, and z coordinate axes.

(1) Scale for the y axis

(2) Adjustment screw with gradu-

ation for the y axis

Adjustment range +/- 5 mm

Allen screw, 5 mm

¼-turn corresponds to an ad-

justment path of 0.25 mm

(3) Scale for the z axis

(4) Adjustment screw with graduation for the x axis

Adjustment range +/- 5 mm Allen screw, 5 mm

Adjusting the x axis

¼-turn corresponds to an adjustment path of 0.25 mm

(5) Scale for the x axis

(6) Adjustment screw with graduation for the z axis

Adjustment range +/- 5 mm Allen screw, 5 mm

¼-turn corresponds to an adjustment path of 0.25 mm

Loosen the 2 Allen screws by 1

turn respectively size 4 mm

Adjust x axis by turning the adjust-

ment screw: Allen key, size 5 mm ¼-turn corresponds to 0.25 mm

EN-US

Adjusting the y axis

Adjusting the z Axis

Loosen threaded pin on the adjust-

ment device size 2.5 mm

Adjust y axis by turning the adjust-

ment screw (3): Allen key, size 5 mm ¼-turn corresponds to 0.25 mm

After adjusting the y axis, re-tight-

en the threaded pin on the adjustment device

Loosen threaded pin on the adjust-

ment device size 2.5 mm

Adjust z axis by turning the adjust-

ment screw: Allen key, size 5 mm ¼-turn corresponds to 0.25 mm

After adjusting the z axis, re-tight-

en the threaded pin on the adjustment device

Creating Reference Program

Safety

Work performed incorrectly can cause serious injury and damage to property.

▶ ▶

General A pilot laser with low power is required for the described adjustment work.

A reference program will also need to be created:

Creating a Reference Program

The scope of supply for the laser welding head includes a metal gauge for the exact adjustment of the wire electrode position with respect to the laser focus. This gauge is mounted in the working area of the robot and is used to create a reference program for the series components.

WARNING!

This setting work must only be carried out by trained and qualified personnel. Observe the safety rules in the OI, in particular the "Safety Inspection" section.

After the laser welding head is installed for the first time When programming a new part, if the x-, y- and z-values have changed on the adjustment units.

Create a reference program before welding the first series component

Requirement:

The laser welding head must be set up and fully connected.

The wire electrode must be threaded in.

With the wire electrode, the stick out must be adjusted for the relevant ap-

plication Observe the focal width specification on the laser optics

Mount gauge (1) in the working area of the robot

Switch on pilot laser

Position laser welding head via robot so that the pilot laser beam hits the

gauge at an angle of 90°

(1)

Default setting for the parameter finding of the component to be welded:

Using the robot, approach the

gauge so that the laser focus is in the cross hairs of the gauge

Using the robot, lower the laser

welding head until the wire electrode touches the gauge

Using the x and y adjustment units

on the laser welding head, position the wire electrode with respect to the laser focus

Standard value: r = 4 mm (with a stick out of 20 mm and in accordance with the focal length indicated on the laser optics)

Document the distance of the wire electrode to the laser focus in the x and y

axis in accordance with the scaling on the gauge

Save the settings in the robot as the reference program

Carry out a test weld

The best welding result is used as the basis for the reference program.

EN-US

If changes are required to the mechanical x, y, and z settings on the basis of

the test weld, overwrite the reference program that was initially created

Signal Sequence for LaserHybrid Welding

Safety

WARNING!

Work performed incorrectly can cause serious injury and damage to property.

The welding process may only be programmed by trained personnel.

▶

Observe the safety rules in the OI, in particular the "Safety Inspection" sec-

▶

tion

CAUTION!

Risk of damage to the optical fiber due to the laser welding head being perpendicular to the workpiece surface during welding.

If the laser optics unit is at 90° to the workpiece surface, then the laser beam is reﬂected directly into the laser optics. This may cause serious damage to the optical fiber.

Always guide the laser welding head to be trailing or leading!

▶

NOTE!

When welding lots of short weld seams in direct succession, only switch off the CrossJet ﬂow and external extraction system at the end of the entire process.

This will avoid contamination of the protective glass due to welding fumes.

Signal Sequence for LaserHybrid Welding

Robot start position:

Set signal "Extraction on"

Set signal "Crossjet on"

NOTE!

The "VALVE ON" signal for controlling the solenoid valve in the SplitBox SB 360i LaserHybrid is transmitted to bit 26 (start counting with 0).

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

Preheating start position:

Requirement: The laser must be ready for beam release.

Set signal "Gas test"

Set signal "Laser on"

The following factors determine the preheating temperature: Travel speed Laser output Distance to the workpiece surface

Preheating end position:

Reset signal "Laser on"

Reset signal "Gas test"

LaserHybrid welding start position:

Requirement: The laser must be ready for beam release.

Set signal "Arc on"

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

Set signal "Laser on"

Set signal "Start robot"

LaserHybrid welding end position:

Stop robot movement

Reset signal "Laser on"

Reset signal "Welding on"

Wait until the current ﬂow signal = zero

Robot end position:

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

Reset signal "Crossjet on"

Reset signal "Extraction on"

EN-US

Measures before Starting Welding

Check the coolant ﬂow on the laser optics cooling system

Check the coolant ﬂow on the welding torch cooling system

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

Check whether a protective glass is present in the laser optics

Check whether all covers are correctly mounted on the laser welding head

Test CrossJet

Test extraction

Test shielding gas

Operation Recommendations for LaserHybrid Welding System

Recommendations for the Operation of a LaserHybrid Welding System

For smooth operation, the following items should always be available when using a LaserHybrid welding system:

LaserHybrid service station

Compressed-air gun supplied with 6 bar

Mobile tool trolley with the following tools and spare parts:

20 x contact tips, for each diameter

10 x gas distributors

4 x gas nozzles

One drive roller set incl. compression lever with axles

Allen key set

Side cutter

Release spray

Optics cleaning set from the respective optics manufacturer

1 x protective glass tray, packed to be dust-proof (as reserve)

Min. 10 x protective glasses, packed to be dust-proof

EN-US

Specifications for the compressed air supply

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

Delivery time for a new laser welding head:

Delivery time for laser optics:

Repair of laser optics:

IMPORTANT! Throughout all servicing on the laser welding head, the external extraction system must be switched on.

To ensure proper functioning, the following specifications for the compressed air supply must be met:

Compressed air supply constant at min. 5 bar

Compressed air free of oil

Compressed air free of water

Compressed air free of dust – no contaminants larger than 5 µm

min. 8 weeks! min. 8 weeks! min. 8 weeks!

Maintenance

Replacing the Welding Torch and Welding Torch

Wearing Parts

Safety

Risk of burns due to the intensely heated welding torch during operation.

The welding torch may only be cleaned, and its components checked, once it

▶

has cooled down.

Mounting Wearing Parts on the Welding Torch

EN-US

CAUTION!

Replacing the Spatter Guard Plate and Extra Ex-

traction

Replacing the spatter guard plate

Replacing the Additional Extraction System

Remove 4 Allen screws

size 2.5 mm

Replace the spatter guard plate

Assemble in reverse order

Loosen 4 Allen screws

size 2.5 mm

Replace the extraction system

Replacing the Laser Optics

EN-US

Safety

Preparation

WARNING!

Work performed incorrectly can cause serious injury and damage to property.

This assembly work must only be carried out by trained and qualified person-

▶

nel. Observe the safety rules in the OI, in particular the "Safety Inspection" sec-

▶

tion.

CAUTION!

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

Observe the Operating Instructions, specifications, and safety instructions

▶

from the manufacturer of the laser optics. Before removal, position the laser optics in front of the laser welding head so

▶

that the longitudinal axis of the laser welding head is outside of the horizontal (> 90°). This will ensure that no dirt can get into the laser optics from above.

NOTE!

For better accessibility, before the laser optics unit is removed, the mounting bracket can be removed.

The following steps are shown when the mounting bracket is removed.

NOTE!

The following activities were described on the basis of version (1) - Drive unit on the left with central robot support and 2 mounting brackets *.

Follow the same procedure for maintenance of the other three versions.

Remove the mounting bracket as described on page 60, work steps 1 and 2.

IMPORTANT! Only disconnect the

coolant hose at the laser optics end, never from the fiber optic cable.

Loosen Allen screw and disconnect

coolant hose from the laser optics size 2.5 mm

Disconnecting the fiber optic cable

from the laser optics

Disconnection of the fiber optic cable from the laser optics is carried out in the reverse order to connection, see page 60, from work step 4:

Clean fiber optic cable and

connection area with compressed air Withdraw the rubber sleeve in

the direction of the optics Press the button on the under-

side Remove the fiber optic cable

Apply the protective covers to

the connector of the fiber optic cable and to the fiber optic cable connection socket

Disconnect the hose for the radial

air ﬂow

Removing the

Laser Optics

Loosen the Allen screws

M5 x 20 mm, size 4 mm

Do not remove the screws. It must be possible to move the clamp.

Loosen the Allen screws

M5 x 25 mm, size 4 mm

Remove the screws

Remove the bracket

CAUTION!

If dropped, the laser optics unit can be damaged to such an extent that it is rendered unusable.

Remove and handle the laser optics carefully.

▶

EN-US

Installing the laser optics

Remove the Allen screws

M5 x 20 mm, size 4 mm

The screws are needed again when the new laser optics unit is installed.

Remove laser optics from the laser

welding head

CAUTION!

If dropped, the laser optics unit can be damaged to such an extent that it is rendered unusable.

Insert and handle laser optics carefully.

▶

(1)

(2)

(a)

(b)

(c)

(b)

(c)

(d)

(1) Optical adjustment gauge

with

(a) register pins (b) holes for screw fixing

(2) Positioning area on the laser optics

with

Place the optical adjustment gauge onto the laser optics so that the register

pins engage in the holes for the register pins on the laser optics

Secure the optical adjustment gauge with 2 Allen screws

M5 x 16 mm, size 4 mm

On both mounting brackets:

Loosen 3 Allen screws

size 6 mm

Remove the 2 register pins

If necessary, move the profile until

the laser optics unit with the mounted optical adjustment gauge has space

0 mm

Place the laser optics with the op-

tical adjustment gauge onto the laser welding head

Push the laser optics with the op-

tical adjustment gauge forward as far as it will go onto the mounting bracket

Push the slot nuts under the holes

of the optical adjustment gauge

Secure the optical adjustment

gauge with 2 Allen screws to the slot nuts M8 x 16 mm, size 6 mm

IMPORTANT! Secure the laser optics only with the existing 2 Allen screws M5 x 20 mm, size 4 mm. Do not use the screws M5 x 16 mm out of the scope of supply of the laser optics!

EN-US

Position the 2 Allen screws M5 x 20

mm and tighten them size 4 mm Tightening torque = 5.7 Nm

CAUTION!

Risk of damage to the laser optics due to stresses!

Incorrect assembly can cause that stresses that result in the failure of the laser optics

The sequence of the following steps must be observed!

▶

Fit the bracket

Secure the bracket with 2 Allen

screws M5 x 25 mm size 5 mm Tightening torque = 5.7 Nm

Tighten 2 Allen screws M5 x 20 mm

size 4 mm Tightening torque = 5.7 Nm

Remove 2 Allen screws M5 x 16

mm, size 4 mm

Remove 2 Allen screws M8 x 16

mm, size 6 mm

Remove the optical adjustment

gauge

Insert register pins on both mounting brackets

Tighten the screws on both mounting brackets

Tightening torque = 24 Nm

Check the position of the laser focus using the reference program

Final Tasks

Connect up all connection sockets on the laser optics according to the OI of

the laser optics manufacturer:

Fiber optic cable

Cooling hoses

Air hose for radial air ﬂow

Checking Position of the Wire Electrode in rela-

(1)

tion to the Laser Focus

Safety

Work performed incorrectly can cause serious injury and damage to property.

▶ ▶

General A pilot laser with low power is required for the described adjustment work.

Check the position of the wire electrode in relation to the laser focus:

WARNING!

This setting work must only be carried out by trained and qualified personnel. Observe the safety rules in the OI, in particular the "Safety Inspection" section.

Each time the laser welding head is replaced Each time the laser optics are replaced Each time the welding torch is changed

EN-US

Checking Position of the Wire Electrode in relation to the Laser Focus

Switch off MIG/MAG power source

Replace components

Switch on MIG/MAG power source

Using the robot, move to the refer-

ence point on the gauge (1): the laser focus is in the cross hair on the gauge

Thread in wire electrode up to the

gauge

Check the position of the wire

electrode in relation to the laser focus: the position of the wire electrode must match the values documented on the gauge using scaling.

If necessary, correct the position

of the wire electrode in relation to the laser focus using the x, y, and z adjustment devices

Example: Use of the Reference Program after Welding Torch Replacement

Switch off power source

Change welding torch

Welding torch replacement is complete, wearing parts have been fitted:

switch on power source

Adjust stick out to 15 - 20 mm according to application

Upload the reference program and slowly approach the reference position on

the adjustment gauge

Thread in wire electrode until this touches the adjustment gauge

Check the position of the wire electrode to the laser focus

Only if the position is incorrect:

correct the x/y/z axis position on the mechanical setting devices of the laser welding head – NOT on the robot

IMPORTANT! Do not under any circumstances overwrite the reference program of the robot!

Start production

Measures to Reduce Contamination of the Optics

EN-US

Measures to Reduce Contamination of the Optics

Crossjet and Extraction

Please observe the values for the crossjet and extraction specified in these

1. Operating Instructions.

Switch on the crossjet and extraction at least five seconds before the start of

2. welding.

Do not switch off the crossjet and extraction until the laser welding head is

3. safely in the smoke-free zone.

Protective Glass (including Replacement)

IMPORTANT! Before changing the protective glass drawer, clean the area around

it with a cleaning cloth.

The environment must be clean when the protective glass drawer is being replaced.

To prevent dust from penetrating the focusing lens, the laser welding head

4. must be vertical when the protective glass is being changed (welding torch pointing toward the ﬂoor).

Before changing the protective glass:

Switch on the extraction and crossjet

Clean the welding head with compressed air as best as you can

IMPORTANT Do not blast the protective glass with the air current directly.

Switch off crossjet

Replace protective glass

IMPORTANT When replacing the protective glass, the extraction must be switched on and crossjet switched off.

Keep the amount of time the protective glass drawer is open to the minimum

6. necessary.

If there are welding fumes on the protective glass, replace the protective

7. glass with a new pane of glass.

The contaminated protective glass can be used again:

Pre-clean the protective glass with a cloth

Finish cleaning the protective glass with a cotton swab soaked in meth-

anol Store the protective glass in a dust-free area

If there is welding spatter on the protective glass, the protective glass must

8. be replaced with a new pane of glass immediately. Dispose of the protective glass that has welding spatter.

Check the protective glass from time to time at the start of production in or-

9. der to determine a change interval specific to the application.

Automated Torch Cleaning Device

When using an automatic torch cleaning device:

10. Switch on the crossjet and extraction during the cleaning process.

Changing the Fiber Optic Cable

The laser welding head must be in a horizontal position when you are chan-

11. ging the fiber optic cable so that no dust can fall into the optics from above.

IMPORTANT! Clean with compressed air before changing.

Appendix

100

Fronius WF 25i / 60i CMT LaserHybrid FW Operating Instruction [EN]

Specifications and Main Features

Frequently Asked Questions

User Manual