Fronius WF 25i LaserHybrid 10 kW, SB 360i LaserHybrid Operating Instruction [EN]

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Operating instructions

WF 25i LaserHybrid 10 kW SB 360i LaserHybrid

EN-US

Operating instructions

42,0426,0279,EA 017-31032022

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 Scope of supply 18 Optional components 19 Gas nozzle cross jet 19

Requirements 20

Mechanical Requirements 20 Robot Requirements 20 Ground Connection 20 Alignment 21

System Overview 22

System overview 22 Other LaserHybrid systems 23 Setup Variants 25

Operating controls and connections 27

Product description 29

Product description WF 25i LaserHybrid 10 kW 29 Crossjet versions 31 Product description SB 360i LaserHybrid 31

Collision Protection 33

General 33 Safety 33 Checking the Reference Point after a Collision 33 Signal Analysis 33

Connection Specifications 34

Connection specifications 34 Compressed air diagram 36 Pressure monitoring in the SplitBox SB 360i LaserHybrid 37

Commissioning 39

General 41

Safety 41 Setup Regulations 41 Grid Connection 41 Set Up LaserHybrid Welding System 42

Installing the Laser Welding Head on the Robot 43

Connection options on the robot 43 Mounting the laser welding head on the robot 44

Installing and Connecting SplitBox SB 360i LaserHybrid 45

Mounting the SplitBox SB 360i LaserHybrid on the robot 45 Connecting SplitBox SB 360i LaserHybrid 47

Connecting Crossjet 49

Connecting the CrossJet 49

Connecting LaserHybrid Hosepack to Laser Welding Head 51

Connecting the LaserHybrid hosepack to the laser welding head 51 Connecting/changing Wirefeeding Hose to/on Laser Welding Head 52

Installing/Changing Wirefeed Rollers 53

Connecting the IPG laser optics and additional extraction 54

Connecting the IPG laser optics 54 Connecting the IPG additional extraction 57

Connecting other laser optics and additional extraction 59

Connecting other laser optics 59 Connecting Extra Extraction 62

Preparing Welding Torch 65

Available welding torches 65 Equipping the MTB 500 LH welding torch 65 Equipping the LH 360 welding torch 67

Installing Hosepack on Robot 69

Placing the hosepack on the robot 69

Threading the Wire Electrode 72

Setting up Laser Welding Head 73

Stick out 73 Adjustable axes 74 Adjustment devices on the laser welding head 75 Adjusting the x axis 76 Adjusting the y axis 77 Adjusting the z axis 78

Creating Reference Program 79

Safety 79 General 79 Creating a reference program 79

Signal Sequence for LaserHybrid Welding 81

Safety 81 Signal Sequence for LaserHybrid Welding 81

Measures before Starting Welding 83

Operation Recommendations for LaserHybrid Welding System 84

Recommendations for the operation of a LaserHybrid welding system 84 Specifications for the compressed air supply 84

Maintenance 85

Overview of the laser optics 87

IPG laser optics 87 Trumpf, Precitec, and Highyag laser optics 88

Replacing the Welding Torch and Welding Torch Wearing Parts 89

Safety 89 Welding torch spare parts 89

Replacing the MTB 500 LH welding torch 90 Replacing the LH 360 welding torch 91 Replacing welding torch wearing parts 92

Replacing the Spatter Guard Plate and Extra Extraction 94

Replacing the IPG spatter guard plate 94 Replacing the IPG additional extraction 94 Replacing the spatter guard plate for other laser optics 95 Replacing the additional extraction for other laser optics 95

Replacing the IPG laser optics 96

Safety 96 Preparation 96 Removing the IPG laser optics 98 Installing the IPG laser optics 100 Checking/setting the focus of the IPG laser optics 103 Securing the laser optics 105 Final tasks 105

Replacing other laser optics 107

Safety 107 Replacing the Trumpf laser optics 107 Preparation 107 Removing the laser optics 110 Inserting the Laser Optics 112 Checking/setting the focus of the laser optics 115 Fixing the Laser Optics 117 Final tasks 118

Checking Position of the Wire Electrode in relation to the Laser Focus 121

Safety 121 General 121 Checking Position of the Wire Electrode in relation to the Laser Focus 121 Example: Reference Program Application after Welding Torch Change 122

Measures to Reduce Contamination of the Optics 123

EN-US

Appendix 125

Technical data 127

WF 25i LaserHybrid 10 kW (laser welding head) 127 LaserHybrid hosepack MHP 360i LH 127 SB 360i LH 128 MTB 500i LH /W 128

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 laser welding head combines the

benefits of a laser beam with the benefits of the MIG/MAG welding process. For the LaserHybrid process this results in a high penetration depth, a narrow heat-affected zone, filler metal and good gap bridging.

Additional benefits of the laser welding head:

high welding speed and great cost-effectiveness

high process stability combined with a low level of rejects and reworking ef-

fort high quality weld seam

low heat input, reduced distortion

high availability of the welding system, high service life of the wearing parts

ﬂexible use

high gap tolerance

adaptation for fiber, disk, and diode laser possible.

EN-US

Intended Use The WF 25i LaserHybrid 10 kW is designed exclusively for automated MIG/MAG

welding in connection with Fronius system components. Any other use does not constitute proper use. The manufacturer is not responsible for any damage resulting from improper use.

Proper use also means:

Following all the instructions in these operating instructions for the individu-

al components Carrying out all the specified inspection and servicing work

The WF 25i LaserHybrid 10 kW will be referred to as the "laser welding head" in the rest of these Operating Instructions.

Applications The WF 25i LaserHybrid 10 kW welding head is used for the following applica-

tions:

In the manufacturing of axles and bodies in the automotive industry, to make

sheets of 1–4 mm in thickness In rail vehicle manufacturing, for longitudinal seams and lap joints

In shipbuilding, for butt welds

In vehicle manufacturing, for lap joints and to weld wheel rims

In container construction, for lap joints, circumferential welds and butt

welds For corner joints on hoists

Scope of supply The scope of supply for the laser welding head includes the following compon-

ents:

1 laser welding head WF 25i LaserHybrid 10 kW (complete)

1 LaserHybrid hosepack

1 stick out gauge

1 ﬂow volume meter up to 25 l/min

1 Operating Instructions

Tool and wirefeed accessories, depending on configuration

Tool and wirefeed accessories:

Quant ity

1 Extractor tool for register pins

1 Gauge for setting the position of the focal spot

1 Stick out gauge

1 Allen key size 6 mm (for adjusting the position on the support unit)

1 Allen key size 5 mm (for adjusting the position on the support unit)

1 Allen key size 4 mm (for adjusting the position on the support unit)

1 Allen key size 3 mm (for fixing the suction hose)

1 Allen key size 2.5 mm (for adjusting laser optics)

Name

44,0450,1223

42,0201,1216

42,0201,1742

42,0435,0001

42,0410,0014

42,0410,0013

42,0410,0012

42,0435,0002

1 Trimming aide for inner liners

42,0001,4936

1 Wrench for welding torch coupling and hosepack coupling

45,0200,1404

1 Flat wrench size 12 mm

42,0410,0007

1 Flat wrench size 8/10 mm

42,0410,0004

1 Drive wheel spanner

42,0200,9344

Optional components

Possible laser optics:

IPG FLW-D50-S-V

Trumpf BEO D70

Precitec YW52

Highyag BIMO

The following components are optionally available for the laser welding head WF 25i LaserHybrid 10 kW:

Focus monitor

Temperature sensor

Crossjet pressure sensor

Suction hose set

Mounting plate 17.5 mm

Crossjet gas nozzles

Welding torch MTB 500 LH/W/0°/L228

Welding torch MTB 500 LH/W/0°/L284

EN-US

Gas nozzle cross jet

During welding, depending on the energy density and material, the laser triggers a plasma ﬂare of a varying height which absorbs the laser light. At constant laser output a penetration of different depths is created.

To ensure constant penetration despite the plasma ﬂare, it is possible to use the gas nozzle cross jet. The gas nozzle cross jet uses compressed air to generate a fine current of air that cuts off the plasma ﬂare at a defined height.

IMPORTANT!

Because the gas nozzle cross jet is situated very closely to the opening of the

gas outlet this can result in swirling gas and subsequently: pores. Furthermore, if the air current experiences resistance this can lead to acute

pore formation. The plasma ﬂare contains welding spatter and welding fume. If the plasma

ﬂare is blown out, the surrounding area will be severely polluted.

Scope of Application:

For freely accessible components

For a laser output of at least 4 kW

Mainly for butt welds with a full penetration root pass or where precise weld-

ing penetration depth is required

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

5°

Example: Work angle 5° leading

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) Power source TPS 500i

+ robot interface **

+ cooling unit CU 1400i Pro MC or CU 2000i MC Single

+ upright bracket (screwed on) (6) Wirefeeding hose (7) Interconnecting hosepack (8) Robot (9) SplitBox SB 360i LaserHybrid (10) LaserHybrid hosepack (11) WF 25i LaserHybrid 10 kW (12) LaserHybrid cleaning station

* As an alternative to the welding wire drum, the wirefeeding can also be

carried out via wirespools.

The following components are required for this purpose:

Unwinding wirefeeder WF 25i REEL 4R

+ OPT/i WF reel carriage D300

** For example: RI FB Inside/i or RI FB Pro/i

Other LaserHy-

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(11)

(10)

(8)

(9)

(12)

brid systems

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

EN-US

(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) Power source TPS 500i

+ robot interface

+ cooling unit CU 1400i Pro MC or CU 2000i MC Single

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

(5)

(6)

(2)

(1)

(3)

(8)

(10)

(7)

(9)

(4)

(11)

source

(1) Remote control (2) Control line for unwinding wirefeeder (3) Power source TPS 500i

+ robot interface

+ cooling unit CU 1400i Pro MC or CU 2000i MC Single

+ upright bracket (screwed on)

+ interconnecting hosepack (4) SplitBox SB 360i LaserHybrid (5) Wirespool D300 (6) Unwinding wirefeeder:

WF 25i REEL 4R

+ OPT/i WF reel carriage D300 (7) LaserHybrid hosepack (8) Wirefeeding hose (9) Robot (10) WF 25i LaserHybrid 10 kW (11) LaserHybrid cleaning station

Setup Variants

Power Source Located in Welding Cell (I)

TPS 500i – power source

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

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

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

Welding wire drum

WF 25i REEL 4R – wirefeeder reel

WF MOUNTING Drum

Wirefeeding hose L = 10 m

Laser welding head

Area of application: The robot only makes minor compensatory movements. Robot axles 7 and 8 carry out the majority of the welding feed movements.

Example: Circumferential welds on boilers, axles, etc.

Power Source Located in Welding Cell (II)

TPS 500i – power source

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

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

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

Wirespool

WF 25i REEL 4R – wirefeeder reel

WF reel carriage D300

Wirefeeding hose L = 10 m

Laser welding head

EN-US

Area of application: For test systems only (no wirespool in series production)

Power Source Not Located in Welding Cell (I)

TPS 500i – power source

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

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

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

Welding wire drum

WF 25i REEL 4R – wirefeeder reel

WF MOUNTING Drum

Wirefeeding hose L = 20 m

Laser welding head

Area of application: Robot axles 1–6 carry out the welding feed movements.

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

Power Source Not Located in Welding Cell (II)

TPS 500i – power source

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

SB 360i LaserHybrid – SplitBox, wall mounting

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

Welding wire drum

WF 25i REEL 4R – wirefeeder reel

WF MOUNTING Drum

Wirefeeding hose L = 20 m

Laser welding head

Area of application: Robot axles 1–6 carry out the welding feed movements.

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

Power Source Is on a Gantry and Moves Too

TPS 500i – power source

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

SB 360i LaserHybrid – SplitBox, mounted on gantry

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

Welding wire drum

WF 25i REEL 4R – wirefeeder reel

WF MOUNTING Drum

Wirefeeding hose L = 20 m

Laser welding head

Area of application: Robot axles 1–8 carry out the welding feed movements.

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

Operating controls and connec-

tions

Product description

(1)

(2)

(13)

(4)

(7)

(10)

(8)

(9)

(12)

(11)

(2)

(3)

(6)

(5)

(21)

(20)

(19)

(18)

(17)

(16)

(15)

(14)

Product description WF 25i LaserHybrid 10 kW

EN-US

Item Name

(1) Crossjet exhaust air

(must be connected to an extraction system)

(2) Crossjet supply

(3) Connection for optional pressure monitoring

For optional pressure monitoring, a LaserHybrid hosepack with additional

data line is required.

The pressure monitoring for laser welding head and LaserHybrid hosepack

is carried out in the SplitBox SB 360i LaserHybrid (see page 37).

(4) Radial air ﬂow supply

(5) Crossjet gas nozzles supply

(6) Fiber optic cable

(7) LaserHybrid hosepack connection

(8) Control box

(9) Drive unit cover

(10) Gas-test button

Wire-return button *

Wire-threading button *

The wire-return and wire-threading buttons are located on the opposite

side of the laser welding head.

(11) Mounting plate

Thickness 21 mm or 17.5 mm depending on application

(12) LaserHybrid welding torch

(13) Crossjet gas nozzles (optional)

(14) Gas nozzle

(15) Robot support

(16) Robot connection bracket

(17) Laser optics

(18) Additional extraction system

(19) Laser optics water cooling connections

(20) Radial air ﬂow connection

(21) Crossjet

Crossjet ver-

(1)

(2)

(3) (4)

(5)

(6) (7)

(8)

(14)

(13)

(12)

(11)

(9)

(8)

(10)

sions

Product description SB 360i LaserHybrid

The Crossjet is available in 2 versions:

EN-US

Square design Round design

Function and assembly is the same for both versions.

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 hosep-

ack

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

For connecting the coolant supply hose from the interconnecting hosep-

ack

(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

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

(14) Welding torch cooling connecting plug

For connecting the welding torch cooling to the LaserHybrid hosepack

Collision Protection

General The laser welding head is fitted with collision protection to protect the LaserHy-

brid welding torch and the entire laser welding head.

The collision protection works on the ﬂoating contact principle. Displacing the welding torch a certain amount will open the circuit (ring line) between the two inputs for the robot control.

The ring line runs from the laser welding head, via the LaserHybrid hosepack, on to the SplitBox SB 360i LaserHybrid, and from there on to the connection for the robot interface used on the power source.

EN-US

Safety

The collision protection and its digital analysis are not a substitute for an electromechanical emergency stop protection device.

▶

Checking the Reference Point after a Collision

Signal Analysis The signal from the collision protection is sent to the robot control via a robot in-

IMPORTANT! After a collision, check the reference point as follows:

Further information can be found on page 121.

terface. In the event of a collision, the ring line will open and the signal level will drop. The robot control must carry out the following program sequence:

WARNING!

Just like with collision protection, the emergency stop protection device also has to shut off the arc process and the laser process.

Set a 14 / 20 mm stick out on the LaserHybrid welding torch depending on

the application and design

Move to reference point

Using the gauge, check the position of the wire electrode in relation to the fo-

cal point in the x/y/z direction

Stop the laser and arc welding process immediately Stop the robot movement immediately

Connection Specifications

(1)

(2)

(7)

(3)

(6)

(2)

(5)

(4)

(10)

(9)

(8)

Connection specifications

Item Name

(1) 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

(2) Crossjet supply

For connecting a hose as per the following data:

inner diameter Di = 12 mm

outer diameter Do = 14 mm

p = 6 bar

required filling capacity = 6 bar - 1500 l/min

required extraction capacity = 280 m³/h

(3) Radial air supply

For connecting a hose as per the following data:

outer diameter Do = 6 mm

The hose connects the supply of radial air (3) with the radial air connec-

tion (10).

(4) Crossjet gas nozzles supply

For connecting a hose as per the following data:

outer diameter Do = 4 mm

The hose connects the Crossjet gas nozzles supply (4) with the Crossjet

gas nozzles (7).

(5) Fiber optic cable for laser

Bending radius > 200 mm

(6) LaserHybrid hosepack connection

MHP 360i LH/W/FSC/4.2 m

MHP 360i LH/W/FSC/7.5 m

(7) Crossjet gas nozzles

(8) 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

(9) Laser optics water cooling connection

EN-US

(10) Radial air ﬂow connection

NOTE!

Welding torch and gas nozzle are also cooled by the power source cooling unit.

The optics cooling is carried out by the laser cooling unit.

Under no circumstances should the laser optics be cooled with the power

▶

source cooling unit.

Compressed air

WF 25i LaserHybrid 10 kWSB 360i LaserHybrid

MHP LH

(1)

(2)

(3) (4)

(5)

(6)

(7)

(8)

(5)

(4)

(6)

(9)

(7)

(8)

(7)

(4)

diagram

MHP LH = LaserHybrid hosepack

Item Name

(1) Compressed air supply line

(min. 6 bar)

(2) Solenoid valve

(3) Internal pressure measure-

ment

(4) Pressure measurement option

(5) Radial air ﬂow branch

(6) Crossjet gas nozzles branch

(7) Crossjet air supply lines con-

nections

(8) Crossjet exhaust air

(9) Extraction

NOTE!

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

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".

EN-US

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.

▶

Set Up LaserHybrid Welding System

WARNING!

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

Please read the information in the "Safety Rules" chapter in the Operating Instructions for the power source before starting for the first time. Only perform all of the preparation steps if

the power switch for the power source is set to – O – ,

▶

the mains cable is disconnected from the grid.

▶

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

Set up welding system:

Install upright brackets

Install cooling unit on upright bracket

Connect power source to cooling unit

Set up welding wire drum

Assemble WF Mounting Drum on welding wire drum

Set up and connect wirefeeder reel

Connect power source to robot control

Connect remote control

Set up laser welding head:

Installing the Laser Welding Head on the Robot

Installing and Connecting SplitBox SB 360i LaserHybrid

Connect crossjet

Connecting LaserHybrid Hosepack to Laser Welding Head

Connecting/changing Wirefeeding Hose to/on Laser Welding Head

Installing/Changing Wirefeed Rollers

Connect laser optics and extra extraction

Preparing Welding Torch

Install LaserHybrid hosepack on robot

Threading the Wire Electrode

Other activities prior to start-up:

Setting up Laser Welding Head

Creating Reference Program

Signal sequence for LaserHybrid welding

Measures before starting welding

Set up ground earth connection between workpiece and power source

Installing the Laser Welding Head on the Robot

90 mm

406,5 mm

Connection options on the robot

EN-US

Example: Laser welding head with Trumpf laser optics

NOTE!

The IPG laser optics can only be mounted in the lower position and cannot be adjusted.

Mounting the

laser welding head on the robot

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

EN-US

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

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

EN-US

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

Connecting Interconnecting Hosepack to Power Source

Option:

(1) Data line 3 x 0.5 mm²

(e.g. for analyzing additional pressure monitoring)

Connecting Crossjet

EN-US

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

Pull protective hoses over the con-

nections

Connecting LaserHybrid Hosepack to Laser Weld-

45,0200,1404

ing Head

Connecting the LaserHybrid hosepack to the laser welding head

IMPORTANT! When connecting the LaserHybrid hosepack, ensure that pins and

connections on the interface are not bent or damaged. Position the LaserHybrid hosepack to be as straight as possible.

Connect LaserHybrid hosepack

EN-US

Secure LaserHybrid hosepack:

Tighten union nut using torch wrench and torque wrench Tightening torque = 11 Nm

Remove 2 Allen screws size 2.5 mm

on the opposite side

Remove drive unit cover

Connect CrashBox cable

Place cable in groove

Connecting/ changing Wirefeeding Hose to/on Laser Welding Head

Insert wirefeeding hose into laser

welding head

Press and hold locking button

Insert the wirefeeding hose into

the locking device as far as is needed to release the locking button

Release the locking button

Keep pushing the wirefeeding hose

until the locking device locks in place and the locking button pops out

Removal:

Press and hold locking button

Pull wirefeeding hose out of lock-

ing device

Installing/Changing Wirefeed Rollers

EN-US

Installing/Changing Wirefeed Rollers

IMPORTANT! The wire electrode has to be pulled out in order to change the

wirefeed roller.

Disconnect external wirefeeding

hose

Swing the clamping stirrup open

Remove the screwable shaft

Remove the wirefeeder roller

Remove the hexagon nut size

10 mm – use the driving wheel key supplied with the laser welding head to hold this on the wirefeeder roller

Remove the wirefeeder roller

The sequence is reversed for installation

NOTE!

Do not replace the supplied wirefeeder components with other models.

Failure to use the specified V groove rollers in particular may cause problems during the wirefeed.

Connecting the IPG laser optics and additional

extraction

Connecting the IPG laser optics

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 robot connection

bracket

Position the laser welding head so

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

IMPORTANT! Do not clean connection areas using compressed air!

Clean connection areas with a

cloth.

Remove the protective cover from

the fiber optic cable connector

Remove the protective cover from

the fiber optic cable connection

EN-US

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

Connect the fiber optic cable

connector

IMPORTANT! To seal the fiber optic

cable, use only an adhesive tape that can be removed without leaving any residue, such as Tesa type 4172.

Wrap the area around the connect-

or of the fiber optic cable and the fiber optic cable connection several times with adhesive tape and seal it cleanly

Connect the optics cooling system,

tighten union nut

Connect the optics cooling supply

(blue marking)

Position the laser welding head in the vertical line

Connect the optics cooling return

EN-US

Connecting the IPG additional extraction

Attach robot connection bracket

Push slot nut upwards, so that the

top hole of the slot nut is positioned under the top hole of the robot connection bracket.

Use a short Allen screw, size 6 mm,

to lightly fix the slot nut and robot connection 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 robot connection bracket in

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

Attach one half of the clamp to

the robot connection bracket

Secure the half-clamp with two Al-

len screws, size 2.5 mm

Position additional extraction in

the half-clamp

Attach the second half of the

clamp

Secure the additional extraction in

place with the clamp and with four Allen screws, size 2.5 mm

Attach suction hose and fix with

hose clamp

Connecting other laser optics and additional ex-

traction

Connecting other laser optics

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.

EN-US

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 robot connection

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

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.

EN-US

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

Connecting Extra Extraction

Position the laser welding head in the vertical line

Push the hose across the connec-

tion

Fix the hose in place with the hose

clamp

Position bracket for robot connec-

tion

Push the slot nut up so that the

top hole on the slot nut is positioned below the top hole on the bracket for the robot connection.

Fasten, but do not completely

tighten, the slot nut and bracket for the robot connection using a short Allen screw size 6 mm

EN-US

Insert 2 x register pins

Position and connect extractor tool

for register pins

Hit the vibrating mass on the ex-

tractor tool forward and then position the register pins

For assembly: the 3 x shorter screws are located one below the other; the 2 x longer screws opposite each other.

Insert the remaining 4 x Allen

screws size 6 mm

Fix the bracket for the robot con-

nection in place using 5 x Allen screws size 6 mm Tightening torque = 24 Nm

Preparing Welding Torch

(1) (2) (3)

EN-US

Available welding torches

Equipping the MTB 500 LH welding torch

The following welding torches are available for the laser welding head:

(1) MTB 500 LH/W/0°/L284

Standard welding torch for IPG laser optics, focal length F400

(2) MTB 500 LH/W/0°/L228

Standard welding torch for Trumpf, Precitec and Highyag laser optics, focal length F300

(3) LH 360A 0°

Optional welding torch for Trumpf, Precitec and Highyag laser optics, focal length F300

Open knurled nut

Remove the gas nozzle

Remove the contact tip

Insert the inner liner into the weld-

ing torch from below

Insert inner liner fully into the

welding torch using the contact tip

Apply the gas nozzle

Tighten knurled nut

Equipping the

LH 360 welding torch

Open knurled nut

Insert the inner liner into the weld-

ing torch from below

EN-US

Insert inner liner fully into the

welding torch using the contact tip

Position union nut via the contact

tip

Tighten the union nut

Size 12 mm Tightening torque = 3 Nm

Apply the gas nozzle

Secure the gas nozzle with an Al-

len screw, size 4 mm

Fold bracket downwards

Tighten knurled nut

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

Threading the Wire Electrode

IMPORTANT! Carefully deburr the end of the wire electrode before threading

the wire on it.

Requirement:

Wirefeeding hose connected

Wire electrode threaded in wirefeeder reel

Correct wirefeeder rollers and inlet nozzles present in laser welding head

Close clamping stirrup

Press the wire-threading button

until the wire electrode comes out of the welding torch

Set contact pressure

Setting up Laser Welding Head

Stick out There are two different mounting plates for the laser welding head with Trumpf

laser optics, depending on the application:

The TCP must not be positioned at

the laser focus. For high performance

With the same adjustment path,

guarantees a greater distance between laser focus and wire electrode tip

Mounting plate 21 mm

EN-US

Mounting plate 17.5 mm

The TCP may be positioned at the

laser focus depending on the application.

(1)

(2) (3)

NOTE!

When adjusting the spatial position of the welding torch, pay attention to the corresponding stick out depending on the mounting plate that is used.

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

Mounting plate 17.5 mm:

Stick out = 14 mm

Mounting plate 21 mm:

Stick out = 20 mm

For all other laser optics, stick out = 20 mm.

Adjustable axes The spatial position of the arc process in relation to the laser beam can be adjus-

ted in three Cartesian coordinate axes:

CAUTION!

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

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!

▶

Adjustment

(1)

(2)

(3)

(4)

(5)

(6)

devices on the laser welding head

The laser welding head is equipped with adjustment devices, which allow for precise positioning in the x, y, and z coordinate axes:

(1) Scale for the z axis

(2) Adjustment screw with gradu-

ation for the y axis

Adjustment range +/- 4.5 mm Allen screw size 5 mm

¼-turn corresponds to an adjustment path of 0.25 mm

(3) Adjustment screw with graduation for the x axis

Adjustment range +7/-2 mm Allen screw size 5 mm

EN-US

¼-turn corresponds to an adjustment path of 0.25 mm Reading accuracy using vernier scale 0.1 mm

(4) Scale for the x axis

(5) Scale for additional adjustment option in the z axis

Adjustment range 0/+10 mm

Basic position for the Trumpf optics support = 0

For the additional adjustment in the z axis, loosen the two Allen screws size 5 mm and move the optics support. Tightening torque for Allen screws = 10 Nm

(6) Adjustment screw with graduation for the z axis

Adjustment range +12/-7 mm Allen screw size 5 mm

¼-turn corresponds to an adjustment path of 0.25 mm Reading accuracy using vernier scale 0.1 mm

Adjusting the x

(1)(1)

axis

NOTE!

The x and y axes are adjusted with the drive unit cover removed.

After adjusting them, refit the drive unit cover.

▶

Loosen 2 Allen screws size 5 mm

(1)

Adjust x axis using adjustment

screw and Allen key size 5 mm: 1 turn corresponds to 1.0 mm

After adjusting the x axis, re-tighten the 2 Allen screws size 5 mm (1)

Adjusting the y

(1)

axis

NOTE!

The x and y axes are adjusted with the drive unit cover removed.

After adjusting them, refit the drive unit cover.

▶

Loosen 2 Allen screws size 5 mm

(1)

Adjust y axis using adjustment

screw and Allen key size 5 mm: 1 turn corresponds to 1.0 mm

EN-US

After adjusting the y axis, re-tighten the 2 Allen screws size 5 mm (1)

Adjusting the z

(1)

(2)

axis

NOTE!

The z axis is adjusted with the drive unit cover and the control box removed.

After adjusting it, refit the control box and drive unit cover.

▶

Loosen 2 Allen screws size 5 mm

(1)

Loosen 2 Allen screws size 5 mm

(2)

Adjust z axis using adjustment

screw and Allen key size 5 mm: 1 turn corresponds to 1.0 mm

After adjusting the z axis, re-tighten the 4 Allen screws size 5 mm (1) and (2):

Tightening torque for screw (1) = 6.5 Nm Tightening torque for screw (2) = 10 Nm

Creating Reference Program

EN-US

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 gage for the exact adjustment of the wire electrode position with respect to the laser focus. This gage 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.

The corresponding stick out of the wire electrode in mm must be set de-

pending on the laser optics:

Trumpf laser optics: Mounting plate 21 mm ... Stick out = 20 mm Mounting plate 17.5 mm ... Stick out = 14 mm

All other laser optics: Stick out = 20 mm

Observe the focal width specification on the laser optics

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

Switch on the pilot laser

Use the robot to position the laser welding head so that the laser optics are

at an angle of 90° to the gage

(1)

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

Using the robot, approach the gage

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

Using the robot, lower the laser

welding head until the wire electrode touches the gage

Use the x and y adjustment units

on the laser welding head to position the wire electrode in relation to the laser focus

Standard value: r = 3 mm

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

axis in accordance with the scaling on the gage

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.

If changes are required to the mechanical x/y settings on the basis of the test

weld, overwrite the reference program that was initially created

Signal Sequence for LaserHybrid Welding

EN-US

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"

Measures before Starting Welding

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

4 x welding torch inner liners (already cut to length)

One drive roller set incl. compression lever with axles

Allen key set

Diagonal cutting pliers

Release spray

Optics cleaning set from the respective optics manufacturer

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

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

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

Specifications for the compressed air supply

Delivery time for a new laser

welding head:

Delivery time for laser optics: min. 8 weeks!

Repair of laser optics: min. 8 weeks!

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!

Maintenance

Overview of the laser optics

2x M5 x 20 mm 8 mm

2x M5 x 20 mm 4 mm

4x M6 x 12 mm 4 mm

IPG + 4,101,310 *

IPG Wobble + 4,101,349 *

IPG laser optics

EN-US

* Optics support, optics holder, robot connection bracket, and mounting

material

NOTE!

The IPG Wobble optics can only be purchased from IPG.

Optics support, optics holder, robot connection bracket, and mounting material for the IPG Wobble optics are available from Fronius under item number 4,101,349.

Trumpf, Pre-

PRECITEC HIGHYAGTRUMPF

4x M5 x 16 mm 2x M5 x 25 mm

4x M5 x 12 mm

2x M5 x 16 mm 2x M4 x 12 mm

4x M5 x 12 mm

4x M5 x 16 mm

+ 4,101,078 * + 4,100,714 * + 4,101,068 *

citec, and Highyag laser optics

* Optics support ** Second robot connection bracket not shown

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.

Welding torch spare parts

MTB 500 LH/W/0°/L228 and MTB 500 LH/W/0°/L284

EN-US

CAUTION!

LH 360A 0°

Replacing the

45,0200,1404

MTB 500 LH welding torch

Note: The numbering of the arrows in the diagrams may differ from the work steps.

Remove the 2 Allen screws, size 2.5

Remove the 2 Allen screws, size

2.5 mm, on the opposite side

Remove drive unit cover

Open knurled nut

Loosen union nut using torch

wrench

Remove the welding torch in a

downwards direction

NOTE!

Assembly of the welding torch only with torch connector and torque wrench, tightening torque = 18 +/- 2 Nm

EN-US

Replacing the LH 360 welding torch

Note: The numbering of the arrows in the diagrams may differ from the work steps.

Remove the 2 Allen screws, size 2.5

Remove the 2 Allen screws, size

2.5 mm, on the opposite side

Remove drive unit cover

Open knurled nut

45,0200,1404

Loosen union nut using torch

wrench

Remove the welding torch in a

downwards direction

NOTE!

Assembly of the welding torch only with torch connector and torque wrench, tightening torque = 18 +/- 2 Nm

Replacing welding torch wearing parts

MTB 500 LH/W/0°/L228 and MTB 500 LH/W/0°/L284:

LH 360A 0°:

EN-US

IMPORTANT! Before assembly, clean gas distributor, thread of the union nut,

and torch body.

Replacing the Spatter Guard Plate and Extra Ex-

traction

Replacing the IPG spatter guard plate

Replacing the IPG additional extraction

Remove 4 Allen screws

Size 2.5 mm

Remove spatter guard plate

Install by performing the steps in the reverse order.

Remove the 4 Allen screws, size

2.5 mm

Remove the second half of the

clamp

Remove additional extraction from

the half-clamp

Install by performing the steps in the reverse order

Replacing the

spatter guard plate for other laser optics

Note: The numbering of the arrows in the diagrams may differ from the work steps.

Remove 2 Allen screws

Size 2.5 mm

Remove spatter guard plate

Install by performing the steps in the reverse order

EN-US

Replacing the additional extraction for other laser optics

Note: The numbering of the arrows in the diagrams may differ from the work steps.

Dismantle spatter guard plate as

described in previous section

Remove 2 Allen screws

Size 2.5 mm

Remove additional extraction

Install by performing the steps in the reverse order

Replacing the IPG laser optics

Safety

Preparation

WARNING!

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

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

Remove the 5 Allen screws, size 6

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 robot connection

bracket

Position the laser welding head so that the longitudinal axis of the laser weld-

ing head is outside the horizontal (> 90°)

Disconnect the hose for additional extraction

IMPORTANT! Only disconnect the

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

Loosen the union nut, disconnect

the cooling hose from the laser optics.

The disconnection of the fiber optic cable from the laser optics is carried out in the reverse order to connection, see page 54, from work step 8:

EN-US

Pull off the insulating tape for dust protection

Press button and disconnect fiber optic cable

Apply the protective covers to the connector of the fiber optic cable and to

the fiber optic cable connection socket

Disconnect radial air ﬂow

If present, dismantle additional ex-

traction (see page 94)

Remove 4 Allen screws

Size 2.5 mm

Remove spatter guard plate

IMPORTANT! Ensure that the O-rings do not get lost when removing the Cross-

jet.

Removing the IPG laser optics

O-rings on the Crossjet

Remove 4 Allen screws

Size 3 mm

Remove Crossjet

Loosen 6 hexagon socket grub

screws - do not remove Size 2.5 mm

Remove 4 Allen screws

Size 4 mm

Loosen 2 hexagonal bolts

Size 8 mm

Remove 2 Allen screws

Size 4 mm

Push the mounting bracket "B"

with the hexagonal bolts and the slot nuts in the profile away from the mounting "A"

EN-US

CAUTION!

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

Remove and handle the laser op-

▶

tics carefully.

Push laser optics out of the guide

and the bracket

Remove laser optics

Dismantle mount "A" from the laser optics

Remove 4 screws

Dismantle radial air ﬂow from laser optics

Ensure that the springs inserted on the underside are not lost.

The springs will be required again for installation.

Installing the IPG laser optics

IMPORTANT! When replacing the laser optics, ensure that the laser optics and

welding torch match in terms of the focal length.

Place radial air ﬂow on the laser optics

Fit the radial air ﬂow with 4 screws

Mount holder "A" on the laser optics

Make sure that the inserted springs are present on the underside

100

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.

▶

Fronius WF 25i LaserHybrid 10 kW, SB 360i LaserHybrid Operating Instruction [EN]

Specifications and Main Features

Frequently Asked Questions

User Manual