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Fronius
Welding System
MIG/MAG
Fronius MIG/MAG User Manual
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42,0426,0219,EN
014-06082020
TPS/i Robotics
Pull
welding
system
TPS/i Robotics PushPull CMT
welding system
Operating Instructions
MIG/MAG robot welding system
EN
2
Table of Contents
Default Chapter
3
Table of Contents
3
Safety Rules
9
Explanation of Safety Notices
9
General
9
Intended Use
10
Environmental Conditions
10
Obligations of the Operator
10
Obligations of Personnel
10
Mains Connection
10
Protecting Yourself and Others
11
Danger from Toxic Gases and Vapours
11
Danger from Flying Sparks
12
Risks from Mains Current and Welding Current
12
Meandering Welding Currents
13
EMC Device Classifications
14
EMC Measures
14
EMF Measures
14
Specific Hazards
15
Requirement for the Shielding Gas
16
Danger from Shielding Gas Cylinders
16
Danger from Escaping Shielding Gas
16
Safety Measures at the Installation Location and During Transport
17
Safety Measures in Normal Operation
17
Commissioning, Maintenance and Repair
18
Safety Inspection
18
Disposal
18
Safety Symbols
18
Data Protection
19
Copyright
19
Description of Warning Notices on the Device
20
General Information
23
System Configurations - Conventional Robot
25
Powerdrive with Wire Drum
25
Powerdrive with Wire Drum and External Wirefeeding Hose
26
Pushpull with 4-Roller Unreeling Wirefeeder and Wire Drum
27
Pushpull with 4-Roller Unreeling Wirefeeder and Wirespool
28
Pushpull with SB 60I, 4-Roller Unreeling Wirefeeder and Wirespool
29
Pushpull with 2-Roller Unreeling Wirefeeder, Wire Drum and External Wirefeeding Hose
30
CMT with SB 60I, 4-Roller Unreeling Wirefeeder and Wire Drum
31
CMT with SB 500I, 4-Roller Unreeling Wirefeeder, Wire Drum and External Wirefeeding Hose
32
CMT with SB 60I, 4-Roller Unreeling Wirefeeder and Wirespool
33
System Configurations - PAP
34
Powerdrive with Wire Drum
34
Pushpull with 4-Roller Unreeling Wirefeeder and Wire Drum
35
Pushpull with 4-Roller Unreeling Wirefeeder and Wirespool
36
Pushpull with 2-Roller Unreeling Wirefeeder and Wire Drum
37
Pushpull with Wire Buffer, 4-Roller Unreeling Wirefeeder and Wire Drum
38
Pushpull with Wire Buffer, 4-Roller Unreeling Wirefeeder and Wirespool
39
Pushpull with SB 500I, 4-Roller Unreeling Wirefeeder and Wire Drum
40
CMT with SB 60I, 4-Roller Unreeling Wirefeeder and Wire Drum
41
CMT with SB 500I, 4-Roller Unreeling Wirefeeder and Wire Drum
42
CMT with SB 500I, 4-Roller Unreeling Wirefeeder and Wirespool
43
Interconnecting Hosepack
44
General Remarks
44
General
44
Powerliner
45
General
45
WF 25I REEL R /4R, WF 30I REEL R /2R
46
Safety
46
Device Concept
46
Application Area
46
Proper Use
46
Warning Notices on the Device
47
Splitbox SB 500I R
49
Device Concept
49
Proper Use
49
Safety
49
Warning Notices on the Device
50
Splitbox SB 60I R
52
Device Concept
52
Proper Use
52
Safety
52
Warning Notices on the Device
53
Pushpull Hosepack
55
General
55
Scope of Supply
55
WF Robacta Drive
56
General
56
Warning Notices on the Device
56
Crashbox /I
57
General
57
Also Required for Installation
57
Device Concept
58
Areas of Utilisation
58
Scope of Supply
58
Robot Welding Torch
59
Safety
59
General
59
Tpsi Wire Buffer
60
General
60
Wiresense
61
General
61
Requirements
61
How It Works
61
Wiresense - Edge Detection
62
Wiresense - Contour Detection
63
Technical Details
64
Controls, Connections and Mechanical Components
65
Splitbox
67
Safety
67
General
67
Gas Test/Wire Threading Control Panel (Optional)
67
Control Elements, Connections and Mechanical Components of the Splitbox
69
Safety
69
Control Elements, Connections and Mechanical Components
69
SB 60I R:control Elements, Connections and Mechanical Components
70
SB 60I R /L:control Elements, Connections and Mechanical Components
71
SB 500I R PAP Control Elements, Connections and Mechanical Components
73
Safety
73
Control Elements, Connections and Mechanical Components
73
WF 25I Robacta Drive Control Panel / WF 60I Robacta Drive CMT
75
WF 25I Robacta Drive / WF 60I Robacta Drive CMT Control Panel
75
WF 25I REEL R /4R, WF 30I REEL R /2R
77
Safety
77
Controls, Connections and Mechanical Components
77
Control Panel
79
Installation - Conventional Robot
81
Fitting the Welding System to a Conventional Robot
83
Safety
83
Fitting the Tps/I Welding System to a Conventional Robot
83
Optimum Hosepack Arrangement
84
Fitting the Splitbox
85
Fitting the Wirefeeder Holder
85
Fitting the SB 500I R
85
Fitting the SB 500I R (Left Variant)
85
Fitting the SB 60I R to the Robot
86
Fitting the SB 60I R to the Balancer
86
Mounting the SB 60I R on the Wall
87
Fitting the Tpsi Wire Buffer
88
Fitting the Crashbox /I to the Robot
89
Installing the Crashbox/I Dummy on the Robot
90
Preparing the WF Robacta Drive and Fitting to a Conventional Robot
92
Fitting the Gas-Saver Nozzle
92
Fitting the Hosepack to the WF Robacta Drive (Conventional)
93
Fitting the WF Robacta Drive to the Crashbox (Conventional)
94
Fitting the Inner Liner Inside the Torch Body
94
Fitting the Welding Torch to the WF Robacta Drive (Conventional)
96
Fitting the Interconnecting Hosepack
97
Fitting the Standard Interconnecting Hosepack to the Robot
97
Connecting the Extension Hosepack
97
Connecting the Splitbox to the System Components
99
Safety
99
General
99
Fitting the Inner Liner (Unreeling Wirefeeder - Splitbox SB 500I R)
100
Fitting the Inner Liner (Splitbox - WF 25I with Internal Inner Liner)
101
Fitting the Inner Liner (Unreeling Wirefeeder- WF Robacta Drive with External Wirefeeding Hose)
102
Fitting the Inner Liner (Wire Buffer - WF Robacta Drive with External Wirefeeding Hose)
102
Fitting the Inner Liner (Unreeling Wirefeeder - Wire Buffer)
103
Fitting the Inner Liner (Unreeling Wirefeeder - Splitbox Sb60I)
104
Fitting the Inner Liner Inside the Torch Hosepack
105
Connecting the Torch Hosepack to the Splitbox SB 60I R
106
Connecting the Control Line to the Wire Buffer
107
Fitting the Unreeling Wirefeeder
108
Installation - PAP
109
Fitting the Welding System to a PAP Robot
111
Safety
111
Fitting the Tps/I Welding System to a PAP Robot
111
Maximum Axis Rotation
112
Fitting the Splitbox
113
Fitting the SB 500I R PAP
113
Fitting the Tpsi Wire Buffer
114
Installing the Crashbox Drive /I PAP on the Robot
115
Installing the Crashbox on the Robot
115
Installing the Crashbox/I Dummy on the Robot
116
WF Robacta Drive
118
Fitting the Gas-Saver Nozzle
118
Fitting the Hosepack to the WF Robacta Drive
118
Fitting the WF Robacta Drive to the Robot
119
Fitting the Inner Liner Inside the Torch Body
121
Fitting the Welding Torch to the WF Robacta Drive
122
Fitting the Interconnecting Hosepack
124
Fitting the PAP Interconnecting Hosepack to the Robot
124
Connecting the Extension Hosepack
125
Connecting the Splitbox to the System Components
126
Safety
126
General
126
Fitting the Inner Liner (Unreeling Wirefeeder - Splitbox SB 500I R)
127
Fitting the Inner Liner (Splitbox - WF 25I with Internal Inner Liner)
128
Fitting the Inner Liner (Unreeling Wirefeeder - Wire Buffer)
129
Fitting the Inner Liner (Wire Buffer - WF Robacta Drive with Internal Wirefeeding Hose)
130
Connecting the Control Line to the Wire Buffer
130
Start-Up
133
Inserting/Replacing Feed Rollers
135
General
135
4-Roller Drive: Inserting/Replacing Feed Rollers
135
2-Roller Drive: Inserting/Replacing Feed Rollers
136
Inserting/Replacing the WF 25I Robacta Drive Feed Rollers
137
Inserting/Replacing the WF 60I Robacta Drive CMT Feed Rollers
139
Feeding in the Wire Electrode
142
Insulated Routing of Wire Electrode to Wirefeeder
142
Setting the Contact Pressure for the WF 25I Robacta Drive
143
Setting the Contact Pressure for the WF 60I Robacta Drive CMT
144
Start-Up
145
Requirements
145
General
145
Troubleshooting, Maintenance and Disposal
147
Troubleshooting
149
Safety
149
Fault Diagnosis
149
Care, Maintenance and Disposal
153
General
153
Safety
153
Every Start-Up
153
Special Care of O-Rings
154
Whenever the Welding Torch or Torch Hosepack Is Changed
154
Changing the Torch Hosepack, Changing the Interconnecting Hosepack
154
Every 6 Months
154
Recognising Faulty Wearing Parts
155
Replacing the WF 25I Robacta Drive Clamping Lever
155
Replacing the WF 60I Robacta Drive CMT Clamping Lever
156
Replacing the WF Robacta Drive Gas-Saver Nozzle
156
Replacing the SB 60I R Inner Liner
157
Replacing the Tpsi Wire Buffer Wire Guide
159
Changing the Direction of Operation of the Tpsi Wire Buffer
160
Replacing the Tpsi Wire Buffer Lever
161
Fitting Wearing Parts to the Torch Body
162
Fitting Wearing Parts to the Torch Body - MTW 700 I
162
Removing the Crashbox PAP from the Robot
163
Disposal
164
Technical Data
165
SB 500I R, R Left Variant, PAP
167
SB 60I R
168
Crashbox /I
169
Pushpull Hosepack
171
General
171
Gas-Cooled Pushpull Hosepacks
171
Water-Cooled Pushpull Hosepacks
172
WF 25I Robacta Drive
174
WF 25I Robacta Drive /G
174
WF 25I Robacta Drive /W
174
WF 60I Robacta Drive CMT
175
WF 60I Robacta Drive CMT /G
175
WF 25I Robacta Drive /W
175
Robot Welding Torch
176
Gas-Cooled Robot Welding Torches
176
Water-Cooled Robot Welding Torches
177
Interconnecting Hosepacks
179
HP 70I, HP PC Cable HD 70
179
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Fronius MIG/MAG Specifications
General
Brand
Fronius
Model
MIG/MAG
Category
Welding System
Language
English
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