Fronius WF 25i LaserHybrid 4 / 6 kW UC Operating Instruction [EN]

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WF 25i LaserHybrid 6 kW UC WF 25i LaserHybrid 4 kW UC SB 360i LaserHybrid

Operating instructions

EN-US

42,0426,0291,EA 006-17122021

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 8 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 11 Safety Measures in Normal Operation 12 Safety Inspection 12 Modifications 13 Spare and Wearing Parts 13 Calibrating Power Sources 13 The CE label 13 Copyright 13

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General information 15

General 17

General 17 Intended Use 17 Applications 17 Scope of Supply 18 Optional Components 18

Requirements 19

Mechanical Requirements 19 Robot Requirements 19 Ground Connection 19 Alignment 20

System Overview 21

System overview 21 Other LaserHybrid systems 22 Design Variants 24

Operating controls and connections 27

Product description 29

Product description 29 Product description SB 360i LaserHybrid 30

Connection Specifications 32

Connection specifications 32 Compressed air diagram 34 Pressure monitoring in the SplitBox SB 360i LaserHybrid 34

Commissioning 35

General 37

Safety 37 Setup Regulations 37 Grid Connection 37 Setting Up LaserHybrid Welding System 37

Installing the Laser Welding Head on the Robot 39

Mount Laser Welding Head on the Robot 39

Installing and Connecting SplitBox SB 360i LaserHybrid 40

Mounting the SplitBox SB 360i LaserHybrid on the robot 40 Connecting the SplitBox SB 360i LaserHybrid 42

Connecting the CrossJet and Additional Extraction 45

Connecting/Changing the Wirefeeding Hose on the Laser Welding Head 46

Installing/Changing Wirefeed Rollers 47

Preparation 47 Installing/Replacing the Wirefeed Rollers 47 Final Tasks 48

Connecting the Laser Optics 49

Preparing Welding Torch 52

Equip Welding Torch 52

Place LaserHybrid hosepack on the robot 54

Placing the hosepack on the robot 54

Threading the Wire Electrode 56

Setting up Laser Welding Head 58

Stick Out 58 Adjustable axes 58 Adjustment device on the laser welding head 58 Adjusting the x axis 59 Adjusting the y axis 60

Set the radial airflow 61

Requirements 61 Setting the radial airflow 61

Creating Reference Program 64

Safety 64 General 64 Create a Reference Program 64

Signal Sequence for LaserHybrid Welding 66

Safety 66 Signal Sequence for LaserHybrid Welding 66

Measures before Starting Welding 68

Operation Recommendations for LaserHybrid Welding System 69

Recommendations for the operation of a LaserHybrid welding system 69 Specifications for the compressed air supply 69

Maintenance 71

Replacing the Welding Torch and Welding Torch Wearing Parts 73

Safety 73 Welding Torch Spare Parts 73 Replacing the Welding Torch 73 Replacing welding torch wearing parts 74

Replace the spatter guard plate 76

Removing the Spatter Guard Plate 76 Mounting the Spatter Guard Plate 76

Replace the LaserHybrid UC hosepack 77

Removing the LaserHybrid UC Hosepack 77 Connect the LaserHybrid UC Hosepack 79

Replacing the Laser Optics 82

Safety 82 Disconnecting the fiber optic cable from the laser optics 82 Removing the Laser Optics 83 Assembly Positions for Installing the Laser Optics 86 Installing the laser optics 86

Checking Position of the Wire Electrode in relation to the Laser Focus 90

Safety 90

General 90 Checking Position of the Wire Electrode in relation to the Laser Focus 90 Example: Use of the Reference Program after Welding Torch Replacement 90

Measures to Reduce Contamination of the Optics 92

Appendix 95

Technical data 97

Laser welding head WF 25i LaserHybrid UC 97 LaserHybrid Hosepack MHP 360i LH-UC 97 SB 360i LH 98

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Safety Instructions

Explanation of Safety Instructions

DANGER!

Indicates an immediate danger.

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

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WARNING!

Indicates a possibly dangerous situation.

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

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CAUTION!

Indicates a situation where damage or injury could occur.

Minor injury or damage to property may result if appropriate precautions are not

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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 ac-

cording 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 LaserHybrid 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 Instructions

- 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.

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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 regulations and are trained in handling the LaserHybrid head

- have read and understood these Operating Instructions, especially the section "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

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. potential 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.

Danger from Toxic Gases and Vapors

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

Danger Posed by Shielding Gas Leak

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.

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 problems

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.

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: a) 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).

b) Welding power-leads

- Keep them as short as possible

- Route them close together (also to avoid EMC problems)

- Route them far from other lines

c) Equipotential bonding d) Workpiece grounding

- If necessary, establish grounding using suitable capacitors

e) 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 properly.

- 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).

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.

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Informal Safety Measures

Safety Measures at the Installation Location

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.

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.

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.

Safety Measures in Normal Operation

Safety Inspection The operator is required to have the LaserHybrid head tested by an electrician after

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.

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

BGV D1, Sections 33 /49Welding, Cutting and Related Work Methods

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

General Requirements

VDE 0702-1 Repeating Tests on Electrical Devices

Modifications Do not carry out any alterations, installations, or modifications to the LaserHybrid head

without first obtaining the manufacturer’s permission.

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

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Spare and Wearing Parts

Calibrating Power Sources

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

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.

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.

magnetic 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

EN-US

General

The laser welding head WF 25i LaserHybrid UC is ideal for components with limited accessibility and is available in two versions:

- WF 25i LaserHybrid 6 kW UC Focal length of the laser optics = 300 mm

- WF 25i LaserHybrid 4 kW UC Focal length of the laser optics = 200 mm

The WF 25i LaserHybrid UC is referred to as the laser welding head for the rest of these Operating Instructions.

Laser welding head WF 25i LaserHybrid 6 kW UC with optional camera

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 effort

- 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.

Intended Use The WF 25i LaserHybrid UC is intended exclusively for automatic MIG/MAG welding in

combination 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 from the Operating Instructions for the individual components

- carrying out all the specified inspection and servicing work.

Applications The laser welding head is primarily used for MIG laser and MAG laser applications:

- in axle and bodywork production in the automotive industry for plate thicknesses of 1–4 mm

- in pipeline construction for plate thicknesses of 6–16 mm for the root pass

- in tank and boiler manufacturing.

Scope of Supply - 1 laser welding head WF 25i LaserHybrid UC (complete)

- 1 LaserHybrid UC hosepack

- 1 metal gauge to set the focal spot

- 1 flat spanner, size 8/10 mm

- 1 slotted screwdriver, 2.5 mm

- 1 Allen key, 2.5 mm

- 1 ballpoint Allen wrench, size 3 mm

- 1 ballpoint Allen wrench, size 4 mm

- 1 drive wheel spanner

- 1 stick out gauge

- 1 PushIn coupling connection

- 1 hose, 4x750 mm

- 1 flow volume meter up to 25 l/min

- 1 Operating Instructions

- Wirefeed accessories, depending on configuration

Optional Components

The following components are optional for the laser welding head WF 25i LaserHybrid UC:

- Focus monitor

- Various laser beam sources

- Temperature sensor

- CrashBox

- Additional data line 3 x 0.5 mm²

Requirements

EN-US

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 approx. 7 kg. The optics weigh approx. an additional 2 kg. A mass of approx. 9 kg must be allowed for if the laser welding head is fully equipped with optics and hosepack. Therefore it must be possible for the robot axles to move a mass of 8 kg safely with the accelerations specified. The maximum resulting robot axle acceleration must not exceed 3 G (corresponds to approx. 30 m/s²).

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 work-

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piece surface when aligning the LaserHybrid head.

System Overview

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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 UC (12) LaserHybrid cleaning station

EN-US

* 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-

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brid systems

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

(3) Wirefeeding hose (4) Interconnecting hosepack (5) Robot (6) SplitBox SB 360i LaserHybrid (7) LaserHybrid hosepack (8) WF 25i LaserHybrid UC (9) LaserHybrid cleaning station (10) Welding wire drum (11) Unwinding wirefeeder:

WF 25i REEL 4R

+ OPT/i WF wire straightener (4,100,880,CK)

+ WF MOUNTING Wall (12) Control line for unwinding wirefeeder (13) Remote control (14) Power source TPS 500i

+ robot interface

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

+ upright bracket (screwed on)

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

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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 6 kW UC (11) LaserHybrid cleaning station

EN-US

Design Variants

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 300i LH W/7.5 m – 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 weld 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 300i LH W/7.5 m – LaserHybrid hosepack

- Wirespool

- WF 25i REEL 4R – unwinding wirefeeder

- WF reel carriage D300

- Wirefeeding hose L=10 m

- Laser welding head

Application: Only for test systems (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 300i LH W/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 seam 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 300i LH W/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

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

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

Power source is on a gantry and moves at the same time

- TPS 500i – power source

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

- SB 360i LaserHybrid – SplitBox, mounted on the gantry

- MHP 300i LH W/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 seam in rail vehicle manufacturing, etc.

Operating controls and connections

Product description

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Product description

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Item Name

(1) CrossJet exhaust air connection

(2) Protective cover/fiber optic cable connection

(3) Additional extraction tube

(3a)

Optional additional extraction tube

with matching spatter guard plate

Depending on the configuration, one of the two extraction tubes is fitted on deliv-

ery.

(4) Camera (option)

(5) Laser optics

(6) Radial air flow

(7) Gas nozzle

(8) LaserHybrid welding torch

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(8)

(14)

(13)

(12)

(11)

(9)

(8)

(10)

(9) Adjustment device

(10) Wirefeeder roller cover

(11) Motor cover

(12) Control box

(13) Robot connection bracket

The controls are located on the opposite robot connection bracket:

a) Wire-return button

b) Wire-threading button

c) Gas-test button

Product description SB 360i LaserHybrid

(14) Robot support

(15) CrashBox (option)

(16) Laser optics water cooling connection

(17) LaserHybrid UC hosepack

Back

Item Name

(1) (+) Current socket with fine thread

(2) Shielding gas connection socket

For connecting the power cable from the interconnecting hosepack

Front

(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 hosepack

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

EN-US

(14) Welding torch cooling connecting plug

For connecting the welding torch cooling to the LaserHybrid hosepack

Connection Specifications

(1)

(2)

(3)

(4)

(5)

(6)

(7)

Connection specifications

Item Name

(1) Fiber optic cable for laser

Bending radius > 200 mm

IMPORTANT! For the fiber optic cable, only use fibers </= 0.3 mm! Larger fibers

may impair the welding result and lead to damage to the laser welding head.

(2) Additional extraction connection

For connecting a hose as per the following data:

- Inner diameter Di = 41 mm

- max. length = 10 m

- Recommended extraction capacity = min. 60 m³/h

(3) CrossJet exhaust air connection

For connecting a hose as per the following data:

- Inner diameter Di = 50 mm

(4) CrossJet compressed air connection

(from the LaserHybrid interconnecting hosepack)

- Operate at 6 bar and a volumetric flow of 60 m³/h

- CrossJet exhaust air 170 m³/h

(5) Laser optics water cooling connections

(from the LaserHybrid interconnecting hosepack)

(6) External wirefeeding hose (Fronius)

(7) LaserHybrid interconnecting hosepack (Fronius)

Hosepack incl. compressed air for CrossJet and radial air flow, laser optics water

cooling, and media coupling

EN-US

Compressed air

WF 25i LaserHybrid 6 kW UCSB 360i LaserHybrid

MHP LH

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(4)

(5)

diagram

MHP LH = LaserHybrid hosepack

Item Name

(1) Compressed air supply line

(min. 4.5 bar)

Pressure monitoring in the SplitBox SB 360i LaserHybrid

(2) Solenoid valve

(3) Internal pressure measurement

(4) Radial air flow branch

(5) CrossJet air supply line connec-

tion

(6) CrossJet exhaust air

(7) Additional extraction

* Cover hidden

NOTE!

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

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 personnel.

▶

Observe the safety rules in the OI, in particular the "Safety Inspection" section.

▶

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 LaserHybrid Welding System

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. All preparation steps must only be performed if

▶ ▶

WARNING!

the power switch of the power source is set to “O”, the mains cable has been disconnected from the grid.

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

Set up welding system:

Mount upright brackets

Mount cooling unit on upright bracket

Connect power source to cooling unit

Set up welding wire drum

Mount WF MOUNTING drum on the welding wire drum

Set up and connect unwinding wirefeeder

Connect power source with robot control

Connect remote control

Set up laser welding head:

Mount laser welding head on the robot

Mount and connect SplitBox SB 360i LaserHybrid

Connect CrossJet

Connecting/changing the wirefeeding hose on the laser welding head

Installing/changing the wirefeed rollers

Connect laser optics and additional extraction

Equip welding torch

Place LaserHybrid hosepack on the robot

Thread the wire electrode

Other activities before start-up:

Adjust the laser welding head

Set the radial airflow

Create a reference program

Signal sequence for LaserHybrid welding

Measures before starting welding

Create ground earth connection between the workpiece and power source

Installing the Laser Welding Head on the Robot

EN-US

Mount Laser Welding Head on the Robot

NOTE!

The laser welding head does not have standard collision protection.

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

E.g.: 44,0350,5203 Fronius CrashBox QS 400 (for ABB robot 4600)

Mount the laser welding head on the robot according to the robot manufacturer's specifications.

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 support

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

Insert strain-relief device of the inter-

connecting hosepack into the opening and push forwards

Secure strain-relief device of the inter-

connecting 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 LaserHybrid

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 the

SplitBox SB 360i LaserHybrid

Connect the interconnecting hosepack

to the SplitBox: a) Power cable b) Welding torch cooling return (red) c) Welding torch cooling supply

(blue) d) Shielding gas e) SpeedNet (from the interconnect-

ing hosepack)

f) SpeedNet (remote control)

* gas purging connection

Connect the LaserHybrid hosepack to

the welding torch connection (Fronius System Connector)

Close clamping lever

Open the cover on the LaserHybrid

hosepack

Connect welding torch cooling con-

necting plug to the LaserHybrid hosepack

Connect the CrossJet air inlet

Only one CrossJet air outlet hose is avail-

able for applications with the laser welding head WF 25i LaserHybrid 4/6 kW UC.

IMPORTANT! When connecting the CrossJet air outlet hose, ensure that the cutting ring is present!

Connect CrossJet air outlet

Secure the hose to the connection

socket using hexagonal nut, size 24 mm tightening torque = 50 Nm

IMPORTANT! When securing the hexagonal nut to the connection socket, counter with a 21 mm wrench.

Unscrew the free connection socket size 21 mm

EN-US

Insert blanking plug size 17 mm

(1)

Connect interconnecting hosepack to the power source

Option:

(1) Data line 3 x 0.5 mm²

Connect hoses for optics cooling (push-in) blue marking = coolant supply

(e.g. for analyzing additional pressure monitoring)

Connecting the CrossJet and Additional Extraction

EN-US

Connecting the CrossJet and Additional Extraction

Connecting the CrossJet:

With a hose clamp, slide the hose with

an inner diameter of 50 mm over the CrossJet exhaust air connection

Tighten the hose clamp

Connect the additional extraction:

With hose clamp, slide the hose with

an inner diameter of 40 mm over the additional extraction connection

Tighten the hose clamp

Connecting/Changing the Wirefeeding Hose on the

Laser Welding Head

Connecting/ Changing the Wirefeeding Hose on the Laser Welding Head

Insert wirefeeding hose into the laser

welding head

Press and hold locking button

Insert the wirefeeding hose until the

locking button is released

Tighten the strain-relief device

24 mm

Replacing the Wirefeeding Hose

Unthread the wire electrode from the

wirefeeding hose by pushing the wire return button

Release the strain-relief device

24 mm

Push the locking button and simultan-

eously disconnect the wirefeeding hose

Pull out the wirefeeding hose

Installing/Changing Wirefeed Rollers

Preparation

Remove two Allen screws

size 3 mm

Remove wirefeeder roller cover

EN-US

Installing/Replacing the Wirefeed Rollers

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

roller.

Disconnect the wirefeeding hose

Swing open the clamping stirrup

Remove the screw-type shaft

Remove the wirefeed roller

Remove the hexagonal nut, size

10 mm – use the drive wheel spanner included in the scope of supply for the laser welding head to hold on the wirefeed roller

Remove the wirefeed roller

Final Tasks

Install by performing the steps in the reverse order

NOTE!

When mounting the covers, ensure that the cables are not trapped, crushed, or damaged in any other way.

Position the wirefeeder roller cover

Mount the wirefeeder roller cover with

two Allen screws size 3 mm

Connecting the Laser Optics

EN-US

Connecting the Laser Optics

CAUTION!

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

Observe the Operating Instructions, specifications, and safety instructions provided

▶

by the laser optics manufacturer Before connecting, position the laser welding head so that the longitudinal axis of

▶

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

Position the laser welding head so that

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

Clean the connection area and plug of

the fiber optic cable using compressed air

Remove the protective cover from the

fiber optic cable connection

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:

a) Press the button b) Withdraw the rubber sleeve in the

direction of the optics c) Connect the fiber optic cable con-

nector

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 Allen

screw, 2.5 mm tightening torque = 4 Nm

Position the laser welding head in the vertical line

Connect the optics cooling supply

(blue marking)

EN-US

Preparing Welding Torch

Equip Welding Torch

Insert the inner liner into the welding

torch from below

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 Allen

screw, 4 mm

Fold bracket downwards

EN-US

Place LaserHybrid hosepack on the 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)

10 /

(3a)

(3)

(4)

(6)

(7)

(8)

(7)

(10)

(5)

(9)

(6)

(11)

(13)

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

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

(3) Optional extension arm

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

Mounting plate depending on robot

(42,1000,0112)

(44,0350,0254)

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

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

(with adapter insert)

(9) Opening for LaserHybrid hosep-

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

M4 x 60 mm (12) Allen screw

(13) Adapter insert for extraction hose

(14) Allen screw

M8 x 20 mm

kit, diameter 41/51 mm

(42,0411,9036)

M6 x 25 mm

Installation

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

bot 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 LaserHybrid

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 LaserHy-

brid 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! 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

Remove three Allen screws, size

4 mm

Remove cover

Remove Allen screw, size 3 mm

Remove Allen screw, size 3 mm on

the opposite side

Remove wirefeeder roller cover

Close clamping stirrup

Press the wire threading button until

the wire electrode comes out of the welding torch

Set contact pressure

EN-US

Setting up Laser Welding Head

14 mm

(1)

(2)

(3)

x (± 2 mm)

y (± 3 mm)

Stick Out

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

two Cartesian coordinate axes:

An adjustment in the z axis can only take place via the collimation of the laser optics.

NOTE!

When setting the spatial position of the welding torch, pay attention to a general stick out of 14 mm.

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

Adjustment device on the laser welding head

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!

▶

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

(1)

(2)

(1)

(2)

The adjustment device essentially consists

0 5

+ 3 mm

2 0

- 3 mm

of:

Adjusting the x axis

(1) Adjustment screw with gauge

Allen screw, size 3 mm ¼-turn corresponds to an adjustment path of 0.25 mm

(2) Scale depicting adjustment range

NOTE!

When using a steel welding torch inner liner, the welding potential may be present at the laser welding head's adjustment unit!

NOTE!

The x adjustment range of ± 3 mm starts from the second graduation mark on the x scale.

The laser and wire electrode are in the same position in position 0.

EN-US

(1)

(2)

Loosen the threaded pin (1),

(1)

(2)

size 3 mm

Adjust the x axis using the adjustment

screw (2) and Allen key, size 3 mm: one turn corresponds to 1.0 mm

After adjusting the x axis, re-tighten

the threaded pin (1)

Adjusting the y axis

Loosen the threaded pin (1),

size 3 mm

Adjust the y axis using the adjustment

screw (2) and Allen key, size 3 mm: one turn corresponds to 1.0 mm

After adjusting the y axis, re-tighten

the threaded pin (1)

Set the radial airflow

(1)

(2) (3)

Requirements IMPORTANT! The radial airflow must be adjusted before starting-up the laser welding

head.

The flow volume meter from the laser welding head's scope of supply is required to adjust the radial airflow.

EN-US

Setting the radial airflow

IMPORTANT! When removing the protect-

ive glass tray, make sure that this is not contaminated, scratched, or otherwise damaged.

Remove the protective glass tray (1)

from the laser optics

Disconnect the air hose (2)

Swivel the air connection (3) to the

side

IMPORTANT! When inserting the protective glass tray, make sure that this is not contaminated, scratched, or otherwise damaged.

Re-insert the protective glass tray

(4)

(5)

Connect the hose (5) and adapter (4)

(6)

(4)

(5)

from the laser welding head's scope of supply

Connect the hose

Fit the flow volume meter (6) on the

hose and adapter

Open the air supply

Adjust the air volume to 25 l/min using

a slotted screwdriver

Remove the flow volume meter (6)

Disconnect the hose (5) and adapter

(4)

(2) (3)

IMPORTANT! When removing the protect-

(1)

ive glass tray, make sure that this is not contaminated, scratched, or otherwise damaged.

Remove the protective glass tray from

the laser optics

Swivel the air connection (3) back

Connect the air hose (2)

IMPORTANT! When inserting the protect-

ive glass tray, make sure that this is not contaminated, scratched, or otherwise damaged.

Insert the protective glass tray (1)

EN-US

Creating Reference Program

(1)

Safety

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

▶ ▶

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

A reference program must be created:

- after initial installation of the laser welding head

- when programing a new component, if the x and y values on the adjustment units

Create 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 in comparison with 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.

Create a reference program before welding the first series component

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.

have changed.

Requirement:

- The laser welding head must be set up and completely connected.

- The wire electrode must be threaded in.

- The respective stick out must be set for the wire electrode.

- Observe the focal width specification on the laser optics

Mount gauge (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 gauge

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 weld-

ing head until the wire electrode touches the gauge

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 gauge

Save the settings in the robot as the reference program

Conduct test welding

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-

ing, overwrite the reference program that was initially created

EN-US

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" section

▶

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

EN-US

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

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: 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

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

EN-US

CAUTION!

Replacing the Welding Torch

Remove Allen screws,

size 2.5 mm

Remove the media coupling cover

Remove Allen screws,

size 4 mm

Disconnect the media coupling

tightening torque for assembly: 4 Nm

Remove three Allen screws,

size 3 mm

tightening torque for assembly: 2,5 Nm

Remove the welding torch in a down-

wards direction

Replacing welding torch wearing parts

View from below

Install by performing the steps in the reverse order

IMPORTANT! When assembling the welding torch, pay attention to the condition and presence of the O-rings.

Replacing the gas nozzle (Allen key, size 4 mm)

Replacing the union nut (flat spanner, 12 mm) Replacing the contact tip

Replacing the welding torch inner liner

EN-US

Replace the spatter guard plate

(1)

(2)

(3)

(1)

(3)

(2)

(1)

Removing the Spatter Guard Plate

Mounting the Spatter Guard Plate

Remove Allen screws (1) and (2),

size 3 mm

Slide the spatter guard plate (3) to the

rear and remove

Engage the spatter guard plate (1)

and slide forwards

Mount the spatter guard plate (1) with

two Allen screw (2) and (3) size 3 mm

Replace the LaserHybrid UC hosepack

EN-US

Removing the LaserHybrid UC Hosepack

Remove three Allen screws

size 4 mm

Remove cover

Disconnect the coolant hose

Remove Allen screw, size 2.5 mm

Remove the media coupling cover

Loosen the three cable ties

Remove the Allen screw, size 4 mm

Disconnect the media coupling

Disconnect the hose

Unscrew the coupling

Disconnect the black cable

Unscrew the hexagonal nut

size 46 mm

Pull the LaserHybrid UC hosepack up

and out

Connect the

LaserHybrid UC Hosepack

Fasten the three cable ties

Insert the LaserHybrid UC hosepack

into the opening from above

EN-US

Slide the hexagonal nut over the

hosepack components

Tighten the hexagonal nut

size 46 mm

Screw in the coupling

Connect the black cable

Connect the hose

Position the media coupling

Mount the media coupling with the Al-

len screw size 4 mm

Fasten the hosepack components with

three cable ties; cut the cable ties to length

Position the media coupling cover

Mount the media coupling cover with

an Allen screw, size 2.5 mm

Connect the coolant hoses

The coolant supply hose with the blue color marking is on the bottom.

Position the cover

Secure the cover with three Allen

screws, size 4 mm

EN-US

Replacing the Laser Optics

Safety

Disconnecting the fiber optic cable from the laser optics

WARNING!

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

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

▶

Observe the safety rules in the OI, in particular the "Safety Inspection" section.

▶

CAUTION!

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

Observe the Operating Instructions, specifications, and safety instructions provided

▶

by the laser optics manufacturer. Before disconnecting the fiber optic cable from the laser optics, position the laser

▶

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

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

Disconnect the hoses for the optics

cooling supply (blue) and the optics cooling return (red)

Remove the Allen screw, size 2.5 mm,

disconnect the optics cooling

Disconnect the fiber optic cable:

a) Press the button b) Pull back the rubber sleeve in the

direction of the optics

c) Disconnect the connector for the

fiber optic cable

Attach the protective cover on the con-

nector of the fiber optic cable

Attach the protective cover on the con-

nection socket of the fiber optic cable

Connect the fiber optic cable to the laser optics as specified in the "Connecting the laser optics" section from page 49.

EN-US

Removing the Laser Optics

Remove three Allen screws

size 4 mm

Remove cover

Disconnect the hose for additional ex-

traction

Remove two Allen screws

size 3 mm

Slide the spatter guard plate to the

rear and remove

Remove the two Allen screws

Move the extraction tube

Unscrew the CrossJet extraction tube

Move the extraction tube so that the

protective glass can be removed

IMPORTANT! When removing and inserting the protective glass, make sure that this is not contaminated, scratched, or otherwise damaged.

Remove the protective glass from the

laser optics

Disconnect the air hose

Swivel the air connection to the side

Re-insert the protective glass

Remove two Allen screws

size 3 mm

Swivel the CrossJet to the side

View from below

Remove the four Allen screws on the

underside of the laser welding head size 2.5 mm

Remove two Allen screws

size 3 mm

Remove two Allen screws

size 3 mm

Remove the bracket

EN-US

Remove the laser optics

Assembly Posi-

(A)

(B)

(1)

tions for Installing the Laser Optics

E.g. laser optics with camera module (1) (without camera)

(A) Assembly position for laser optics with camera module

(B) Assembly position for laser optics without camera module

Installing the laser optics

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

torch match in terms of the focal length.

IMPORTANT! When inserting the laser optics, make sure that the register pins on the underside of the laser optics are located in the openings provided.

Insert the laser optics into the laser

welding head

View from below

Insert and tighten the four Allen

screws on the underside of the laser welding head size 2.5 mm

Mount the bracket

Loosely mount the bracket with two Al-

len screws (do not tighten) size 3 mm

Loosely fasten the two Allen screws

(do not tighten) size 3 mm

EN-US

Tighten the two Allen screws

size 3 mm tightening torque = 2.5 Nm

Tighten the two Allen screws

size 3 mm tightening torque = 2.5 Nm

Swivel the CrossJet into position

Mount CrossJet with two Allen screws

3 mm tightening torque = 2.5 Nm

Move the extraction tube so that the

protective glass tray can be removed

IMPORTANT! When removing and inserting the protective glass tray, make sure that this is not contaminated, scratched, or otherwise damaged.

Remove the protective glass tray from

the laser optics

Swivel the air connection back

Connect the air hose

Re-insert the protective glass tray

Screw in the CrossJet extraction tube

Position the extraction tube

Fasten the extraction tube with two Al-

len screws size 3 mm tightening torque = 2.5 Nm

Position the spatter guard plate

Mount the spatter guard plate with two

Allen screws size 3 mm

Position the cover

Mount the cover with three Allen

screws size 4 mm

Connect the hose for the additional

extraction

EN-US

Connect the fiber optic cable as spe-

cified in the "Connecting the laser optics" section from page 49.

Checking Position of the Wire Electrode in relation

(1)

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:

- Each time the laser welding head is replaced

- Each time the laser optics are replaced

- Each time the welding torch is changed

Checking 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.

Switch off MIG/MAG power source

Replace components

Switch on MIG/MAG power source

Using the robot, move to the reference

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

Thread the wire electrodes up to the

gauge

Check the position of the wire elec-

trode 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- and y-adjustment mechanisms

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 installed:

switch on power source

Adjust the stick out according to application

Upload the reference program and slowly approach the reference position on the ad-

justment 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 position on the mechanical setting options for the laser welding head – NOT on the robot

IMPORTANT! Under no circumstances should the robot reference program be overwritten!

Start of production

EN-US

Measures to Reduce Contamination of the Optics

Crossjet and Extraction

1. Please observe the values for the crossjet and extraction specified in these Operating Instructions.

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

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

4. To prevent dust from penetrating the focusing lens, the laser welding head must be vertical when the protective glass is being changed (welding torch pointing toward the floor).

5. 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.

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

7. If there are welding fumes on the protective glass, replace the protective 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 methanol

- Store the protective glass in a dust-free area

8. If there is welding spatter on the protective glass, the protective glass must be replaced with a new pane of glass immediately. Dispose of the protective glass that has welding spatter.

9. Check the protective glass from time to time at the start of production in order to determine a change interval specific to the application.

Automated Torch Cleaning Device

10. When using an automatic torch cleaning device: Switch on the crossjet and extraction during the cleaning process.

Changing the Fiber Optic Cable

11. The laser welding head must be in a horizontal position when you are changing the fiber optic cable so that no dust can fall into the optics from above.

IMPORTANT! Clean with compressed air before changing.

EN-US

Appendix

Technical data

EN-US

Laser welding head WF 25i LaserHybrid UC

WF 25i LaserHybrid 4 kW UC

Max. laser performance on the workpiece 4000 W

Weight (without laser optics) 7 kg

Laser optics Trumpf BEO D35/F200

Duty cycle of the laser optics 100% at 4 kW and per minute

Dimensions 360 x 150 x 514 mm

Max. current carrying capacity (100% D.C. at 40 °C) M21 (EN439) C1 (EN 439)

WF 25i LaserHybrid 6 kW UC

Max. laser performance on the workpiece 6000 W

Weight (without laser optics) 7 kg

Laser optics Trumpf BEO D35/F300

Duty cycle of the laser optics * 60% at 6 kW and per minute

250 A 250 A

LaserHybrid Hosepack MHP 360i LH-UC

Dimensions 360 x 150 x 610 mm

Max. current carrying capacity (100% D.C. at 40 °C) M21 (EN439) C1 (EN 439)

* Corresponds to 36 s of welding, 24 s break

Max. welding current (100% ED at 40°C) 360 A

Wire diameter 1.0–1.6 mm

Voltage rating (V-Peak) 141 V

Cooling system Liquid cooling

Coolant Original Fronius coolant

Hosepack length 4.2/7.5 m

Lowest cooling capacity as per IEC 60974-2, depending on the hosepack length

Coolant pressure min./max. 3.0/5.0 bar

Minimum flow of coolant 1.0 l/min

1400/1500 W

360 A 360 A

This product meets the requirements set out in standard IEC 60974-7.

SB 360i LH

Supply voltage 24 V DC / 60 V DC

Nominal current 0.5 A / 0.8 A

Welding current at 10 min / 40 °C (104 °F) 40% D.C.* 500 A

60% D.C.* 450 A

100% D.C.* 360 A

Maximum pressure of shielding gas 7 bar/101.53 psi

Coolant Original Fronius

Maximum pressure of coolant 5 bar/72.53 psi

Protection class IP 20

Mark of conformity CE

Dimensions l × w × h 560.4 x 334.93 x 113 mm

22.06 x 13.19 x 4.45 in.

Weight 9.6 kg/21.16 Ib

*) D.C. = duty cycle

EN-US

Fronius International GmbH

Froniusstraße 1

4643 Pettenbach

Austria

contact@fronius.com

www.fronius.com

Under www.fronius.com/contact you will find the adresses

of all Fronius Sales & Service Partners and locations.

spareparts.fronius.com

SPAREPARTS

ONLINE

Fronius WF 25i LaserHybrid 4 / 6 kW UC Operating Instruction [EN]

Specifications and Main Features

Frequently Asked Questions

User Manual