Fronius Pull - Controls and Connections

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Controls, connections and mechan-

ical components

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Table of Contents3
Safety Rules8
Explanation of Safety Notices8
General8
Intended Use9
Environmental Conditions9
Obligations of the Operator9
Obligations of Personnel9
Mains Connection9
Protecting Yourself and Others10
Danger from Toxic Gases and Vapours10
Danger from Flying Sparks11
Risks from Mains Current and Welding Current11
Meandering Welding Currents13
EMC Device Classifications13
EMC Measures13
EMF Measures14
Specific Hazards14
Requirement for the Shielding Gas15
Danger from Shielding Gas Cylinders15
Danger from Escaping Shielding Gas16
Safety Measures at the Installation Location and During Transport16
Safety Measures in Normal Operation17
Commissioning, Maintenance and Repair17
Safety Inspection18
Disposal18
Safety Symbols18
Data Protection18
Copyright18
Description of the Warning Notices on the Device19
System Configurations21
System Configurations - Conventional Robot23
Powerdrive with Wire Drum23
Powerdrive with Wire Drum and External Wirefeeding Hose24
Pushpull with 4-Roller Unreeling Wirefeeder and Wire Drum25
Pushpull with 4-Roller Unreeling Wirefeeder and Wirespool26
Pushpull with SB 60I, 4-Roller Unreeling Wirefeeder and Wirespool27
Pushpull with 2-Roller Unreeling Wirefeeder, Wire Drum and External Wirefeeding Hose28
CMT with SB 60I, 4-Roller Unreeling Wirefeeder and Wire Drum29
CMT with SB 500I, 4-Roller Unreeling Wirefeeder, Wire Drum and External Wirefeeding Hose30
CMT with SB 60I, 4-Roller Unreeling Wirefeeder and Wirespool31
System Configurations - PAP32
Powerdrive with Wire Drum32
Pushpull with 4-Roller Unreeling Wirefeeder and Wire Drum33
Pushpull with 4-Roller Unreeling Wirefeeder and Wirespool34
Pushpull with 2-Roller Unreeling Wirefeeder and Wire Drum35
Pushpull with Wire Buffer, 4-Roller Unreeling Wirefeeder and Wire Drum36
Pushpull with Wire Buffer, 4-Roller Unreeling Wirefeeder and Wirespool37
CMT with SB 60I, 4-Roller Unreeling Wirefeeder and Wire Drum38
CMT with SB 500I, 4-Roller Unreeling Wirefeeder and Wire Drum39
CMT with SB 500I, 4-Roller Unreeling Wirefeeder and Wirespool40
System Components41
Splitbox SB 500I R43
Device Concept43
Proper Use43
Safety43
Warning Notices on the Device44
Splitbox SB 60I R46
Device Concept46
Proper Use46
Safety46
Warning Notices on the Device47
Tpsi Wire Buffer49
General49
Crashbox /I50
General50
Also Required for Installation51
Device Concept52
Areas of Utilisation52
Information on Repairing Crashboxes52
Scope of Supply52
WF Robacta Drive53
General53
Warning Notices on the Device53
Pushpull Hosepack54
General54
Scope of Supply54
Robot Welding Torch55
Safety55
General55
WF 25I REEL R /4R, WF 30I REEL R /2R57
Safety57
Device Concept57
Application Area57
Proper Use57
Warning Notices on the Device58
Interconnecting Hosepack60
General60
Powerliner61
General61
Wiresense62
General62
Requirements62
How It Works62
Wiresense - Edge Detection63
Wiresense - Contour Detection64
Technical Details65
Opt/I Camera Mount66
General66
Drilling Template66
Controls, Connections and Mechanical Components67
General69
Safety69
Splitbox SB 500I R / SB 500I R PAP70
SB 500I R Control Elements, Connections and Mechanical Components70
SB 500I R PAP Control Elements, Connections and Mechanical Components71
Gas Test/Wire Threading Control Panel (Optional)72
Splitbox SB 60I R75
SB 60I R:control Elements, Connections and Mechanical Components75
SB 60I R /L:control Elements, Connections and Mechanical Components76
WF 25I Robacta Drive / WF 60I Robacta Drive CMT77
WF 25I Robacta Drive / WF 60I Robacta Drive CMT Control Panel77
Status Indicators79
WF 25I REEL R /4R, WF 30I REEL R /2R81
Controls, Connections and Mechanical Components81
Control Panel82
Assembling System Components - Conventional Robot85
General87
Safety87
Assembly Sequence, Conventional Robot87
Fitting the Splitbox SB 500I R88
Fitting the Wirefeeder Holder88
Fitting the SB 500I R88
Fitting the SB 500I R (Left Variant)88
Fitting the Crashbox /I to the Robot89
Installing the Crashbox/I Dummy on the Robot90
Fitting the WF Robacta Drive to a Conventional Robot92
Fitting the Hosepack to the WF Robacta Drive (Conventional)92
Fitting the WF Robacta Drive to the Robot (Conventional)93
Fitting the WF Robacta Drive to the Robot94
Optimum Hosepack Arrangement95
Fitting the Interconnecting Hosepack96
Fitting the Standard Interconnecting Hosepack to the Robot96
Connecting the MHP W Hosepack97
Connecting the Splitbox SB 500I R to the System Components100
Safety100
General100
Assembling System Components - PAP Robot103
General105
Safety105
Assembly Sequence, PAP Robot105
Maximum Axis Rotation106
Fitting the Splitbox SB 500I R PAP107
Fitting the SB 500I R PAP107
Installing the Crashbox Drive /I PAP on the Robot108
Installing the Crashbox Drive /I PAP Dummy on the Robot109
Fitting the WF Robacta Drive to a PAP Robot111
Fitting the Hosepack to the WF Robacta Drive (PAP)111
Fitting the WF Robacta Drive to the Robot (PAP)112
Fitting the Interconnecting Hosepack115
Fitting the PAP Interconnecting Hosepack to the Robot115
Connecting the Splitbox SB 500I R PAP to the System Components116
Safety116
General116
Assembling Further System Components119
Fitting the Splitbox SB 60I R121
Fitting the SB 60I R to the Robot121
Fitting the SB 60I R to the Balancer121
Mounting the SB 60I R on the Wall122
Fitting the Tpsi Wire Buffer124
Connecting the Control Line to the Wire Buffer125
Fitting the Unreeling Wirefeeder126
Connecting the Extension Hosepack127
Fitting the Torch Body to the WF Robacta Drive129
Fitting the Gas-Saver Nozzle129
Fitting the Inner Liner Inside the Torch Body130
Fitting the Torch Body to the WF Robacta Drive132
Fitting the Opt/I Camera Mount133
Load-Bearing Capacity of the Opt/I Camera Mount133
Safety133
Fitting the Opt/I Camera Mount134
Fitting the Inner Liner135
Fitting the Inner Liner (Unreeling Wirefeeder - Splitbox SB 500I R)135
Ing Hose)136
Fitting the Inner Liner (Unreeling Wirefeeder - Wire Buffer)137
Fitting the Inner Liner (Splitbox - WF 25I with Internal Inner Liner)138
Fitting the Inner Liner (Wire Buffer - WF Robacta Drive with Internal Wirefeeding Hose)139
Fitting the Inner Liner (Wire Buffer - WF Robacta Drive with External Wirefeeding Hose)140
Fitting the Inner Liner Inside the Torch Hosepack141
Start-Up143
Inserting/Replacing Feed Rollers145
General145
WF 25I Reel 4R: Inserting/Replacing Feed Rollers for the 4-Roller Drive145
WF 30I Reel 2R: Inserting/Replacing Feed Rollers for the 2-Roller Drive146
Inserting/Replacing the WF 25I Robacta Drive Feed Rollers147
Inserting/Replacing the WF 60I Robacta Drive CMT Feed Rollers149
Feeding in the Wire Electrode152
Insulated Routing of Wire Electrode to Wirefeeder152
Setting the Contact Pressure for the WF 25I Robacta Drive153
Setting the Contact Pressure for the WF 60I Robacta Drive CMT154
Start-Up155
Requirements155
General155
Troubleshooting, Maintenance and Disposal157
Troubleshooting159
Safety159
Fault Diagnosis159
Care, Maintenance and Disposal163
General163
Safety163
Every Start-Up163
Special Care of O-Rings163
Whenever the Welding Torch or Torch Hosepack Is Changed164
Changing the Torch Hosepack, Changing the Interconnecting Hosepack164
Every 6 Months164
Recognising Faulty Wearing Parts165
Replacing the WF 25I Robacta Drive Clamping Lever165
Replacing the WF 60I Robacta Drive CMT Clamping Lever166
Replacing the WF Robacta Drive Gas-Saver Nozzle166
Replacing the SB 60I R Inner Liner167
Replacing the Tpsi Wire Buffer Wire Guide169
Changing the Direction of Operation of the Tpsi Wire Buffer170
Replacing the Tpsi Wire Buffer Lever171
Fitting Wearing Parts to the Torch Body172
Fitting Wearing Parts to the Torch Body - MTW 700 I172
Removing the Crashbox PAP from the Robot173
Disposal174
Technical Data175
SB 500I R, R Left Variant, PAP177
SB 60I R178
Crashbox /I179
Pushpull Hosepack183
Gas-Cooled Pushpull Hosepacks183
Water-Cooled Pushpull Hosepacks184
WF 25I Robacta Drive186
WF 25I Robacta Drive /G186
WF 25I Robacta Drive /W186
WF 60I Robacta Drive CMT187
WF 60I Robacta Drive CMT /G187
WF 60I Robacta Drive /W CMT187
WF 25I REEL R /4R/G/W189
Robot Welding Torch191
Gas-Cooled Robot Welding Torches191
Water-Cooled Robot Welding Torches192
Interconnecting Hosepacks194
HP 70I, HP PC Cable HD194

Fronius Pull - Controls and Connections

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