Fronius TPS/i Robotics PushPull CMT User Manual

7
EN
Safety.................................................................................................................................................... 74
General ................................................................................................................................................. 74
Connecting the SplitBox to the system components............................................................................. 74
Fitting the inner liner (unreeling wirefeeder - SplitBox SB 500i R)........................................................ 75
Fitting the inner liner (SplitBox - WF 25i with internal inner liner) ......................................................... 76
Fitting the inner liner (unreeling wirefeeder- WF Robacta Drive with external wirefeeding hose) ........ 77
Fitting the inner liner (wire buffer - WF Robacta Drive with external wirefeeding hose) ....................... 77
Fitting the inner liner (unreeling wirefeeder - wire buffer) ..................................................................... 78
Fitting the inner liner (unreeling wirefeeder - SplitBox SB60i) .............................................................. 79
Fitting the inner liner inside the torch hosepack.................................................................................... 80
Connecting the torch hosepack to the SplitBox SB 60i R ..................................................................... 81
Connecting the control line to the wire buffer........................................................................................ 82
Fitting the unreeling wirefeeder.................................................................................................................. 83
Fitting the unreeling wirefeeder............................................................................................................. 83
Installation - PAP 85
Fitting the welding system to a PAP robot ................................................................................................. 87
Safety.................................................................................................................................................... 87
Fitting the TPS/i welding system to a PAP robot .................................................................................. 87
Maximum axis rotation .......................................................................................................................... 87
Fitting the SplitBox ..................................................................................................................................... 88
Fitting the SB 500i R PAP..................................................................................................................... 88
Fitting the TPSi wire buffer......................................................................................................................... 89
Fitting the TPSi wire buffer.................................................................................................................... 89
Installing the CrashBox Drive /i PAP on the robot ..................................................................................... 90
Installing the CrashBox on the robot..................................................................................................... 90
Installing the CrashBox/i Dummy on the robot...................................................................................... 91
WF Robacta Drive...................................................................................................................................... 92
Fitting the gas-saver nozzle .................................................................................................................. 92
Fitting the hosepack to the WF 25i Robacta Drive................................................................................ 92
Fitting the WF Robacta Drive to the robot............................................................................................. 93
Fitting the inner liner inside the torch body ........................................................................................... 94
Fitting the welding torch to the WF Robacta Drive................................................................................ 96
Fitting the interconnecting hosepack ......................................................................................................... 97
Fitting the PAP interconnecting hosepack to the robot ......................................................................... 97
Connecting the extension hosepack ..................................................................................................... 97
Connecting the SplitBox to the system components..................................................................................
99
Safety.................................................................................................................................................... 99
General ................................................................................................................................................. 99
Connecting the SplitBox to the system components............................................................................. 99
Fitting the inner liner (unreeling wirefeeder - SplitBox SB 500i R)........................................................ 100
Fitting the inner liner (SplitBox - WF 25i with internal inner liner) ......................................................... 100
Fitting the inner liner (unreeling wirefeeder - wire buffer) ..................................................................... 101
Fitting the inner liner (wire buffer - WF Robacta Drive with internal wirefeeding hose) ........................ 102
Connecting the control line to the wire buffer........................................................................................ 103
Start-up 105
Inserting/replacing feed rollers................................................................................................................... 107
General ................................................................................................................................................. 107
4-roller drive: inserting/replacing feed rollers ........................................................................................ 107
2-roller drive: inserting/replacing feed rollers ........................................................................................ 108
Inserting/replacing the WF 25i Robacta Drive feed rollers.................................................................... 109
Inserting/replacing the WF 60i Robacta Drive CMT feed rollers........................................................... 111
Feeding in the wire electrode..................................................................................................................... 113
Insulated routing of wire electrode to wirefeeder .................................................................................. 113
Feeding in the wire electrode................................................................................................................ 113
Setting the contact pressure for the WF 25i Robacta Drive.................................................................. 114
Setting the contact pressure for the WF 60i Robacta Drive CMT ......................................................... 115
Start-up ...................................................................................................................................................... 116
Requirements........................................................................................................................................ 116
General ................................................................................................................................................. 116

Fronius TPS/i Robotics PushPull CMT Specifications

General

Brand	Fronius
Model	TPS/i Robotics PushPull CMT
Category	Welding System
Language	English

Summary

Safety Rules

General Safety Guidelines

General safety rules, operator duties, and proper device use.

Hazard Identification and Protection

Risks from gases, sparks, electricity, and required personal protective equipment.

Electrical, Fire, and Gas Cylinder Safety

Safety precautions for mains, welding current, fire, and gas cylinders.

Installation Procedures

Conventional Robot Installation

Steps for fitting the welding system to a conventional robot.

PAP Robot Installation

Fitting SplitBox and CrashBox Components

WF Robacta Drive and Torch Fitting

Hosepack and Cable Connections

Start-up and Operation

Feed Roller and Wire Electrode Setup

Instructions for inserting rollers, feeding wire, and related safety.

Contact Pressure Adjustment

Troubleshooting and Maintenance

Troubleshooting Common Issues

Diagnosing and resolving common welding system malfunctions.