Fronius iWave 300i - User Manual

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Op erating

Instructions

iWave Robotics /i welding system

Push - CONV

Push - PAP

PushPull - CONV

42,0426,0434,EA 003-17032025

EN-US

Operating instructions

Main Page

Table of Contents3
Safety Instructions7
Explanation of Safety Instructions7
General7
Intended Use8
Environmental Conditions8
Obligations of the Operating Company8
Obligations of Personnel8
Grid Connection8
Personal Protection and Protection of Others9
Danger from Toxic Gases and Vapors9
Danger from Flying Sparks10
Risks from Mains Current and Welding Current10
Stray Welding Currents11
EMC Device Classifications12
EMC Measures12
EMF Measures13
Particular Hazard Areas13
Requirement for the Shielding Gas14
Danger from Shielding Gas Cylinders14
Danger Posed by Shielding Gas Leak15
Safety Measures at the Setup Location and During Transport15
Safety Measures in Normal Operation16
Maintenance and Repair16
Safety Inspection17
Disposal17
Safety Symbols17
Data Backup17
Copyright17
System Configurations19
System Configurations - Conventional Robot21
Conventional Robot - Push21
Conventional Robot - Pushpull23
Conventional Robot - Plasma25
Conventional Robot - Arctig27
Powersharing Mode28
Conventional Robot - Hot Wire29
System Configurations - PAP31
PAP Robot - Push31
PAP - Plasma33
PAP - Hot Wire35
System Components37
CWF 25I R Wirefeeder39
Device Concept39
Intended Use39
Notes on the Device40
Description of the Warnings on the Device42
Splitbox Hosepack SB TP 95I con R44
Device Concept44
Intended Use44
Notes on the Device44
Crashbox/I TIG/PAP46
Device Concept46
Note on the Repair of Crashboxes46
Crashbox /I47
Device Concept47
Note on the Repair of Crashboxes47
TTB 450I / 500I W R Robot Welding Torch48
Device Concept48
PTB 200I / 350I Robot Plasma Torches49
Device Concept49
TTB 360I / 720I W R Arctig Robot Welding Torches50
Device Concept50
Notes on the Device51
TPHP 500I R Torch Hosepack52
Device Concept52
Notes on the Device52
Hosepack Holder for Conventional Robots (Clamp/I TIG con Index Disc+)54
Pushpull Hosepack CWF 25I Drive R/G/W/FSC55
Device Concept55
KD Drive56
Wire Buffer57
Notes on the Device57
THP 720I R/W/Con/Arctig Torch Hosepack59
Device Concept59
Notes on the Device59
CW Standard Cold-Wire Feed61
Device Concept61
Notes on the Device62
CW Highend Cold-Wire Feed63
Device Concept63
Notes on the Device64
Options65
Powerliner65
Thpi Mounting Adapter66
Mounting Bracket67
TIG Crashbox Signal Cable(Crashbox Signal Cable/I TIG)68
Trailing Gas Nozzle68
Water-Cooled Gas Nozzle for PTW 350I Plasma Welding Torch69
Operating Controls, Connections and Mechanical Components71
Safety73
CWF 25I R Wirefeeder74
Front, Back74
Cold Wire Drive Unit KD Drive76
Controls, Connections, and Mechanical Components76
Splitbox Hosepack SB TP 95I con R77
Splitbox, Hosepack77
TPHP 500I R Torch Hosepack79
Operating Controls, Connections, and Mechanical Components79
THP 720I R/W/Con/Arctig Torch Hosepack81
Controls, Connections, and Mechanical Components81
Function of the Gas-Test, Wire-Return and Wire Threading Buttons83
Installing System Components - Conventional Robot85
General87
Safety87
Installation Sequence for Conventional Push Robots88
Installation Sequence of Conventional Robots - Pushpull88
Install the CWF 25I R Wirefeeder89
Fitting the CWF 25I R Wirefeeder89
Fitting the Tpsi Robot Flange and Tpsi Crashbox91
Mounting the Crashbox /I on a Conventional Robot91
Install the TPHP 500I R Welding Torch Hosepack94
Fitting the TPHP 500I R Torch Hosepack94
Connect the Wirefeeding Hose97
Connecting the Wirefeeding Hose97
Installing System Components - PAP Robot101
General103
Safety103
Installation Sequence PAP Robot104
Mounting Splitbox Hosepack SB TP 95I con R105
Install the CWF 25I R Wirefeeder107
Fitting the Robot Flange /I TIG/PAP and Crashbox/I TIG/PAP109
Fitting the Robot Flange and Crashbox109
Fitting the Crashbox Dummy111
Install the TPHP 500I R Welding Torch Hosepack112
Fitting the TPHP 500I R Torch Hosepack112
Connect the Wirefeeding Hose117
Connecting the Wirefeeding Hose117
Installing Additional System Components125
Connecting the Extension Hosepack127
Install the Cold-Wire Feed128
Mounting the CW Standard Cold-Wire Feed with Mounting Clamp128
Mounting the CW Standard Cold-Wire Feed with Mounting Rail129
Fitting the CW Highend Cold-Wire Feed141
Mounting the Pushpull Hosepack CWF 25I Drive R/G/W/FSC143
Mounting the KD Drive Cold-Wire Drive Unit on the Torch Hosepack143
Installing the Wire Buffer146
Connecting the Control Line to the Wire Buffer146
Routing the Pushpull Hosepack147
Connecting the KD Drive Cold-Wire Drive Unit148
Fitting the Welding Torch152
TTB 450I / 500I W R: Fitting the Welding Torch Wear Parts152
Fitting the Welding Torch158
Removing the Welding Torch158
Fitting the Plasma Welding Torch159
General159
Setting Gage159
PTB 200I / 350I W R: Fitting the Welding Torch Wear Parts160
PTB 200I / 350I W R: Setting the Tungsten Electrode161
Fitting the Water-Cooled Gas Nozzle to the PTB 350I Plasma Torch (Option)165
Install the Trailing Gas Nozzle166
Fitting the Trailing Gas Nozzle166
Fitting the Thpi Mounting Adapter170
Fitting the Wirefeeding Hose / Inner Liner171
Overview171
Cwf25I R for CW Highend Cold-Wire Feed - Conventional Robot171
Head of the Torch Hosepack for CW Highend Cold-Wire Feed - PAP172
Commissioning181
Inserting/Changing Feed Rollers183
General183
Insert / Change Feed Rollers in CWF 25I R183
Inserting/Changing Feed Rollers in KD Drive185
Threading in the Welding Wire190
Setting the Contact Pressure192
Setting the Contact Pressure on the KD Drive193
Setting up the CW Standard Cold-Wire Feed194
Setting Options194
Changing the Welding Torch Wear Parts196
Setting up the CW Highend Cold-Wire Feed198
Setting Options198
Setting the Wire Feed Angle198
Commissioning200
Requirements200
General200
Troubleshooting, Maintenance, and Disposal201
Troubleshooting203
Safety203
Fault Diagnosis, Troubleshooting - Plasma Welding Torches206
Care and Maintenance208
Safety208
During each Start-Up208
Special Care of O-Rings208
Each Time the Welding Torch or Torch Hosepack Is Changed209
Every 6 Months209
Replacing the Wire-Guide Insert in the Wire Buffer209
Changing the Working Direction of the Wire Buffer210
Replacing the Wire Buffer Lever212
Plasma Welding Torch Maintenance213
Maintenance Activities with each Start-Up of the Plasma Welding Torch213
Monthly Maintenance Activities213
Technical Data215
Technical Data217
CWF 25I R217
TTB 450I W R, TTB 500I W R217
TPHP 500I W R218
TTB 360I Arctig, TTB 720I Arctig, THB 720I R/W/Conv/Arctig219
TPHP 95I EXT /WSB TP 95I con R/W221
Crashbox Iwave222
Crashbox /I222
CWF 25I Drive R/G/W/FSC225
PTB 200I, PTB 350I225
Loading Limits, Dimension "X227

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Fronius iWave 300i Specifications

General

Brand	Fronius
Model	iWave 300i
Category	Robotics
Language	English

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