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Fronius Pull User Manual

Fronius Pull
196 pages
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Op erating
instructions
TPS/i Robotics welding system
Pull
PushPull CMT
42,0426,0219,EN 021-15032022
EN
Operating instructions

Table of Contents

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Fronius Pull Specifications

General IconGeneral
BrandFronius
ModelPull
CategoryWelding System
LanguageEnglish

Summary

Safety Rules

Explanation of Safety Notices

Details the meaning of danger, warning, caution, and note symbols.

General Safety Information

Covers intended use, environmental conditions, and operator/personnel obligations.

Personal Safety and Hazard Awareness

Addresses risks from toxic gases, flying sparks, and electrical hazards.

Electrical and Fire Hazards

Details risks from mains current, welding current, and flying sparks.

EMC and EMF Measures

Explains EMC classifications and measures, plus EMF considerations.

Operational Safety and Requirements

Covers shielding gas, cylinder safety, installation, transport, and normal operation.

Maintenance, Inspection, and Disposal

Outlines commissioning, maintenance, safety inspections, disposal, and compliance.

Device Warning Notices

Describes the location and meaning of warning labels affixed to the device.

System Configurations

Conventional Robot Setups

Illustrates various system configurations for conventional robots.

PAP Robot Setups

Illustrates various system configurations for PAP robots.

System Components

SplitBox Series

Introduces the SplitBox SB 500i R and SB 60i R devices for welding media integration.

WF Robacta Drive

Details the WF 25i and WF 60i Robacta Drives for precise wirefeeding in welding systems.

CrashBox /i

Describes the CrashBox /i as a protection device for torch bodies and drive units.

Robot Welding Torch

Covers various robot welding torch models and their features for welding applications.

WireSense Functionality

Explains the WireSense system for measuring workpiece surfaces and edges using the wire electrode.

Controls and Connections

SplitBox Control Elements

Details the controls and connections for SplitBox SB 500i R and SB 60i R units.

Wirefeeder Control Panels

Describes the control panels for WF Robacta Drive and WF 25i/30i Reel wirefeeders.

Component Connections

Explains how to connect SplitBox SB 500i R and PAP to system components.

Assembling Conventional Robot Systems

SplitBox SB 500i R Installation

Provides step-by-step instructions for fitting the SplitBox SB 500i R to a robot.

CrashBox /i Installation

Details the procedure for fitting the CrashBox /i to the robot arm, including torque specifications.

WF Robacta Drive Mounting

Guides the mounting of the WF Robacta Drive onto a conventional robot.

Hosepack Connections

Explains how to fit the interconnecting hosepack and connect the SplitBox SB 500i R.

Assembling PAP Robot Systems

SplitBox SB 500i R PAP Installation

Outlines the installation steps for the SplitBox SB 500i R PAP onto a PAP robot.

CrashBox Drive /i PAP Installation

Details the procedure for fitting the CrashBox Drive /i PAP to the robot, including torque values.

WF Robacta Drive (PAP) Mounting

Guides the mounting of the WF Robacta Drive onto a PAP robot.

Hosepack Connections

Explains how to fit the PAP interconnecting hosepack and connect the SplitBox SB 500i R PAP.

Assembling Additional System Components

SplitBox SB 60i R Installation

Provides instructions for installing the SplitBox SB 60i R on robots and balancers.

TPSi Wire Buffer and Unreeling Wirefeeder

Covers the installation of the TPSi Wire Buffer and the unreeling wirefeeder.

Torch Body and Inner Liner Fitting

Details the process of fitting the torch body and inner liner for welding torches.

OPT/i Camera Mount Installation

Explains how to mount the OPT/i camera mount onto the robot welding torch.

Start-up Procedures

Start-up Requirements

Lists the necessary conditions to be met before commissioning the welding system.

General Start-up Process

Describes the general procedure for commissioning the device using a welding start signal.

Feed Roller Maintenance

General Feed Roller Information

Provides general information on feed rollers and their selection for optimal wire feed.

WF 25i Reel 4R Feed Roller Service

Details the process of inserting and replacing feed rollers for the WF 25i Reel 4R.

WF 30i Reel 2R Feed Roller Service

Details the process of inserting and replacing feed rollers for the WF 30i Reel 2R.

WF Robacta Drive Feed Roller Service

Explains how to insert and replace feed rollers for WF Robacta Drive units.

Wire Feeding Procedures

Insulated Wire Routing

Emphasizes the importance of insulated routing for wire electrodes to prevent hazards.

Wire Feeding Process

Outlines safety precautions and steps for feeding the wire electrode into the welding system.

Contact Pressure Adjustment

WF 25i Robacta Drive Contact Pressure

Guides on setting the correct contact pressure for WF 25i Robacta Drive feed rollers.

WF 60i Robacta Drive CMT Contact Pressure

Guides on setting the correct contact pressure for WF 60i Robacta Drive CMT feed rollers.

Troubleshooting, Maintenance, and Disposal

Troubleshooting Common Problems

Lists common issues and provides initial troubleshooting steps for the welding system.

Power Source and Welding Issues

Addresses problems related to power source function, welding current, and gas shield.

Wire Feed and Weld Quality Issues

Covers troubleshooting for irregular wire feed, buffer issues, and poor weld properties.

Routine Maintenance and Component Replacement

Details regular checks, O-ring care, component replacement, and disposal procedures.

Regular Checks and Replacements

Outlines routine checks for hosepacks, connections, and replacement of wearing parts.

Disposal Procedures

Provides instructions on how to properly dispose of the device according to regulations.

Technical Data

SplitBox Series Data

Provides technical specifications for SplitBox SB 500i R and SB 60i R models.

WF Robacta Drive Data

Lists technical specifications for WF 25i and WF 60i Robacta Drive models.

CrashBox /i Data

Details technical specifications for various CrashBox /i models, including torques and deflection.

PushPull Hosepack Data

Provides technical specifications for MHP 400i and MHP 500i PushPull hosepacks.

Robot Welding Torch Data

Lists technical specifications for various gas-cooled and water-cooled robot welding torches.

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