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Fronius
Welding System
Pull
Fronius Pull User Manual
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6
7
8
Installing the
CrashBo
x/i
Dummy on the
robot
1
Observe the torques when fitting the
robot
flange:
Max. tightening t
orque for scre
ws of
strength class 8.8
M4
3.3 Nm / 2.43 lb-ft
M5
5.0 Nm / 3.69 lb-ft
M6
6.0 Nm / 4.43 lb-ft
M8
27.3 Nm / 20.14 lb-ft
M10
54 Nm / 39.83 lb-ft
M12
93 Nm / 68.60 lb-ft
90
89
91
Table of Contents
Table of Contents
3
Safety Rules
8
Explanation of Safety Notices
8
General
8
Intended Use
9
Environmental Conditions
9
Obligations of the Operator
9
Obligations of Personnel
9
Mains Connection
9
Protecting Yourself and Others
10
Danger from Toxic Gases and Vapours
10
Danger from Flying Sparks
11
Risks from Mains Current and Welding Current
11
Meandering Welding Currents
13
EMC Device Classifications
13
EMC Measures
13
EMF Measures
14
Specific Hazards
14
Requirement for the Shielding Gas
15
Danger from Shielding Gas Cylinders
15
Danger from Escaping Shielding Gas
16
Safety Measures at the Installation Location and During Transport
16
Safety Measures in Normal Operation
17
Commissioning, Maintenance and Repair
17
Safety Inspection
18
Disposal
18
Safety Symbols
18
Data Protection
18
Copyright
18
Description of the Warning Notices on the Device
19
System Configurations
21
System Configurations - Conventional Robot
23
Powerdrive with Wire Drum
23
Powerdrive with Wire Drum and External Wirefeeding Hose
24
Pushpull with 4-Roller Unreeling Wirefeeder and Wire Drum
25
Pushpull with 4-Roller Unreeling Wirefeeder and Wirespool
26
Pushpull with SB 60I, 4-Roller Unreeling Wirefeeder and Wirespool
27
Pushpull with 2-Roller Unreeling Wirefeeder, Wire Drum and External Wirefeeding Hose
28
CMT with SB 60I, 4-Roller Unreeling Wirefeeder and Wire Drum
29
CMT with SB 500I, 4-Roller Unreeling Wirefeeder, Wire Drum and External Wirefeeding Hose
30
CMT with SB 60I, 4-Roller Unreeling Wirefeeder and Wirespool
31
System Configurations - PAP
32
Powerdrive with Wire Drum
32
Pushpull with 4-Roller Unreeling Wirefeeder and Wire Drum
33
Pushpull with 4-Roller Unreeling Wirefeeder and Wirespool
34
Pushpull with 2-Roller Unreeling Wirefeeder and Wire Drum
35
Pushpull with Wire Buffer, 4-Roller Unreeling Wirefeeder and Wire Drum
36
Pushpull with Wire Buffer, 4-Roller Unreeling Wirefeeder and Wirespool
37
CMT with SB 60I, 4-Roller Unreeling Wirefeeder and Wire Drum
38
CMT with SB 500I, 4-Roller Unreeling Wirefeeder and Wire Drum
39
CMT with SB 500I, 4-Roller Unreeling Wirefeeder and Wirespool
40
System Components
41
Splitbox SB 500I R
43
Device Concept
43
Proper Use
43
Safety
43
Warning Notices on the Device
44
Splitbox SB 60I R
46
Device Concept
46
Proper Use
46
Safety
46
Warning Notices on the Device
47
Tpsi Wire Buffer
49
General
49
Crashbox /I
50
General
50
Also Required for Installation
51
Device Concept
52
Areas of Utilisation
52
Information on Repairing Crashboxes
52
Scope of Supply
52
WF Robacta Drive
53
General
53
Warning Notices on the Device
53
Pushpull Hosepack
54
General
54
Scope of Supply
54
Robot Welding Torch
55
Safety
55
General
55
WF 25I REEL R /4R, WF 30I REEL R /2R
57
Safety
57
Device Concept
57
Application Area
57
Proper Use
57
Warning Notices on the Device
58
Interconnecting Hosepack
60
General
60
Powerliner
61
General
61
Wiresense
62
General
62
Requirements
62
How It Works
62
Wiresense - Edge Detection
63
Wiresense - Contour Detection
64
Technical Details
65
Opt/I Camera Mount
66
General
66
Drilling Template
66
Controls, Connections and Mechanical Components
67
General
69
Safety
69
Splitbox SB 500I R / SB 500I R PAP
70
SB 500I R Control Elements, Connections and Mechanical Components
70
SB 500I R PAP Control Elements, Connections and Mechanical Components
71
Gas Test/Wire Threading Control Panel (Optional)
72
Splitbox SB 60I R
75
SB 60I R:control Elements, Connections and Mechanical Components
75
SB 60I R /L:control Elements, Connections and Mechanical Components
76
WF 25I Robacta Drive / WF 60I Robacta Drive CMT
77
WF 25I Robacta Drive / WF 60I Robacta Drive CMT Control Panel
77
Status Indicators
79
WF 25I REEL R /4R, WF 30I REEL R /2R
81
Controls, Connections and Mechanical Components
81
Control Panel
82
Assembling System Components - Conventional Robot
85
General
87
Safety
87
Assembly Sequence, Conventional Robot
87
Fitting the Splitbox SB 500I R
88
Fitting the Wirefeeder Holder
88
Fitting the SB 500I R
88
Fitting the SB 500I R (Left Variant)
88
Fitting the Crashbox /I to the Robot
89
Installing the Crashbox/I Dummy on the Robot
90
Fitting the WF Robacta Drive to a Conventional Robot
92
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 Robot
94
Optimum Hosepack Arrangement
95
Fitting the Interconnecting Hosepack
96
Fitting the Standard Interconnecting Hosepack to the Robot
96
Connecting the MHP W Hosepack
97
Connecting the Splitbox SB 500I R to the System Components
100
Safety
100
General
100
Assembling System Components - PAP Robot
103
General
105
Safety
105
Assembly Sequence, PAP Robot
105
Maximum Axis Rotation
106
Fitting the Splitbox SB 500I R PAP
107
Fitting the SB 500I R PAP
107
Installing the Crashbox Drive /I PAP on the Robot
108
Installing the Crashbox Drive /I PAP Dummy on the Robot
109
Fitting the WF Robacta Drive to a PAP Robot
111
Fitting the Hosepack to the WF Robacta Drive (PAP)
111
Fitting the WF Robacta Drive to the Robot (PAP)
112
Fitting the Interconnecting Hosepack
115
Fitting the PAP Interconnecting Hosepack to the Robot
115
Connecting the Splitbox SB 500I R PAP to the System Components
116
Safety
116
General
116
Assembling Further System Components
119
Fitting the Splitbox SB 60I R
121
Fitting the SB 60I R to the Robot
121
Fitting the SB 60I R to the Balancer
121
Mounting the SB 60I R on the Wall
122
Fitting the Tpsi Wire Buffer
124
Connecting the Control Line to the Wire Buffer
125
Fitting the Unreeling Wirefeeder
126
Connecting the Extension Hosepack
127
Fitting the Torch Body to the WF Robacta Drive
129
Fitting the Gas-Saver Nozzle
129
Fitting the Inner Liner Inside the Torch Body
130
Fitting the Torch Body to the WF Robacta Drive
132
Fitting the Opt/I Camera Mount
133
Load-Bearing Capacity of the Opt/I Camera Mount
133
Safety
133
Fitting the Opt/I Camera Mount
134
Fitting the Inner Liner
135
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 Hosepack
141
Start-Up
143
Inserting/Replacing Feed Rollers
145
General
145
WF 25I Reel 4R: Inserting/Replacing Feed Rollers for the 4-Roller Drive
145
WF 30I Reel 2R: Inserting/Replacing Feed Rollers for the 2-Roller Drive
146
Inserting/Replacing the WF 25I Robacta Drive Feed Rollers
147
Inserting/Replacing the WF 60I Robacta Drive CMT Feed Rollers
149
Feeding in the Wire Electrode
152
Insulated Routing of Wire Electrode to Wirefeeder
152
Setting the Contact Pressure for the WF 25I Robacta Drive
153
Setting the Contact Pressure for the WF 60I Robacta Drive CMT
154
Start-Up
155
Requirements
155
General
155
Troubleshooting, Maintenance and Disposal
157
Troubleshooting
159
Safety
159
Fault Diagnosis
159
Care, Maintenance and Disposal
163
General
163
Safety
163
Every Start-Up
163
Special Care of O-Rings
163
Whenever the Welding Torch or Torch Hosepack Is Changed
164
Changing the Torch Hosepack, Changing the Interconnecting Hosepack
164
Every 6 Months
164
Recognising Faulty Wearing Parts
165
Replacing the WF 25I Robacta Drive Clamping Lever
165
Replacing the WF 60I Robacta Drive CMT Clamping Lever
166
Replacing the WF Robacta Drive Gas-Saver Nozzle
166
Replacing the SB 60I R Inner Liner
167
Replacing the Tpsi Wire Buffer Wire Guide
169
Changing the Direction of Operation of the Tpsi Wire Buffer
170
Replacing the Tpsi Wire Buffer Lever
171
Fitting Wearing Parts to the Torch Body
172
Fitting Wearing Parts to the Torch Body - MTW 700 I
172
Removing the Crashbox PAP from the Robot
173
Disposal
174
Technical Data
175
SB 500I R, R Left Variant, PAP
177
SB 60I R
178
Crashbox /I
179
Pushpull Hosepack
183
Gas-Cooled Pushpull Hosepacks
183
Water-Cooled Pushpull Hosepacks
184
WF 25I Robacta Drive
186
WF 25I Robacta Drive /G
186
WF 25I Robacta Drive /W
186
WF 60I Robacta Drive CMT
187
WF 60I Robacta Drive CMT /G
187
WF 60I Robacta Drive /W CMT
187
WF 25I REEL R /4R/G/W
189
Robot Welding Torch
191
Gas-Cooled Robot Welding Torches
191
Water-Cooled Robot Welding Torches
192
Interconnecting Hosepacks
194
HP 70I, HP PC Cable HD
194
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Fronius Pull Specifications
General
Brand
Fronius
Model
Pull
Category
Welding System
Language
English
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