FRONIUS Pull User manual

Operating

instructions

TPS/i Robotics welding system

Pull

PushPull CMT

42,0426,0219,EN 021-15032022

EN Operating instructions

Contents

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

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

General 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

Connecting the SplitBox SB 500i R to the system components 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

Connecting the SplitBox SB 500i R PAP to the system components 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

Connecting the torch hosepack to the SplitBox SB 60i R 123

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

Fitting the inner liner (unreeling wirefeeder- WF Robacta Drive with external wirefeeding

hose)

135

Fitting the PowerLiner (unreeling wirefeeder - WF Robacta Drive with external wirefeed-

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

Feeding in the wire electrode 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

WF 30i REEL R /2R/G/W 190

Robot welding torch 191

Gas-cooled robot welding torches 191

Water-cooled robot welding torches 192

Interconnecting hosepacks 194

HP 70i 194

HP 95i 194

HP 120i 194

HP 70i, HP PC Cable HD 70 194

Safety rules

Explanation of

safety notices DANGER!

Indicates immediate danger.

▶If not avoided, death or serious injury will result.

WARNING!

Indicates a potentially hazardous situation.

▶If not avoided, death or serious injury may result.

CAUTION!

Indicates a situation where damage or injury could occur.

▶If not avoided, minor injury and/or damage to property may result.

NOTE!

Indicates a risk of ﬂawed results and possible damage to the equipment.

General The device is manufactured using state-of-the-art technology and according to

recognised safety standards. If used incorrectly or misused, however, it can

cause:

-injury or death to the operator or a third party,

-damage to the device and other material assets belonging to the operating

company,

-inefficient operation of the device.

All persons involved in commissioning, operating, maintaining and servicing the

device must:

-be suitably qualified,

-have sufficient knowledge of automated welding, and

-read and carefully follow these operating instructions as well as the operat-

ing instructions for all system components.

The operating instructions must always be at hand wherever the device is being

used. In addition to the operating instructions, attention must also be paid to any

generally applicable and local regulations regarding accident prevention and en-

vironmental protection.

All safety and danger notices on the device

-must be in a legible state,

-must not be damaged,

-must not be removed,

-must not be covered, pasted or painted over.

For the location of the safety and danger notices on the device, refer to the sec-

tion headed "General" in the operating instructions for the device.

Before commissioning the device, rectify any faults that could compromise

safety.

This is for your personal safety!

Intended use The devices and components described in these Operating Instructions are in-

tended exclusively for automated MIG/MAG applications in conjunction with

Fronius components.

Any use above and beyond this purpose is deemed improper. The manufacturer

shall not be held liable for any damage arising from such usage.

Proper use also includes:

-Carefully reading and following all the instructions given in the Operating In-

structions

-Studying and obeying all safety instructions and danger notices carefully

-Performing all stipulated inspection and servicing work

The manufacturer likewise accepts no liability for inadequate or incorrect results.

Environmental

conditions

Operation or storage of the device outside the stipulated area will be deemed as

not in accordance with the intended purpose. The manufacturer shall not be held

liable for any damage arising from such usage.

Ambient temperature range:

-during operation: -10 °C to + 40 °C (14 °F to 104 °F)

-during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)

Relative humidity:

-up to 50% at 40 °C (104 °F)

-up to 90% at 20 °C (68 °F)

The surrounding air must be free from dust, acids, corrosive gases or substances,

etc.

Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)

Obligations of

the operator

The operator must only allow persons to work with the device who:

-are familiar with the fundamental instructions regarding safety at work and

accident prevention and have been instructed in how to use the device

-have read and understood these operating instructions, especially the sec-

tion "safety rules", and have confirmed as much with their signatures

-are trained to produce the required results.

Checks must be carried out at regular intervals to ensure that operators are

working in a safety-conscious manner.

Obligations of

personnel

Before using the device, all persons instructed to do so undertake:

-to observe the basic instructions regarding safety at work and accident pre-

vention

-to read these operating instructions, especially the "Safety rules" section and

sign to confirm that they have understood them and will follow them.

Before leaving the workplace, ensure that people or property cannot come to any

harm in your absence.

Mains connec-

tion

Devices with a higher rating may affect the energy quality of the mains due to

their current consumption.

This may affect a number device types in terms of:

-Connection restrictions

-Criteria with regard to the maximum permissible mains impedance *)

-Criteria with regard to the minimum short-circuit power requirement *)

*) at the interface with the public grid

see "Technical data"

In this case, the plant operator or the person using the device should check

whether the device may be connected, where appropriate by discussing the mat-

ter with the power supply company.

IMPORTANT! Ensure that the mains connection is earthed properly

Protecting your-

self and others

Anyone working with the device exposes themselves to numerous risks, e.g.

-ﬂying sparks and hot pieces of metal

-Arc radiation, which can damage eyes and skin

-Hazardous electromagnetic fields, which can endanger the lives of those us-

ing cardiac pacemakers

-Risk of electrocution from mains current and welding current

-Greater noise pollution

-Harmful welding fumes and gases

Suitable protective clothing must be worn when working with the device. The

protective clothing must have the following properties:

-Flame-resistant

-Insulating and dry

-Covers the whole body, is undamaged and in good condition

-Safety helmet

-Trousers with no turn-ups

Protective clothing refers to a variety of different items. Operators should:

-Protect eyes and face from UV rays, heat and sparks using a protective visor

and regulation filter

-Wear regulation protective goggles with side protection behind the protect-

ive visor

-Wear stout footwear that provides insulation even in wet conditions

-Protect the hands with suitable gloves (electrically insulated and providing

protection against heat)

-Wear ear protection to reduce the harmful effects of noise and to prevent in-

jury

Keep all persons, especially children, out of the working area while any devices

are in operation or welding is in progress. If, however, there are people in the vi-

cinity:

-Make them aware of all the dangers (risk of dazzling by the arc, injury from

ﬂying sparks, harmful welding fumes, noise, possible risks from mains cur-

rent and welding current, etc.)

-Provide suitable protective equipment

-Alternatively, erect suitable safety screens/curtains.

Danger from tox-

ic gases and va-

pours

The fumes produced during welding contain harmful gases and vapours.

Welding fumes contain substances that cause cancer, as stated in Monograph

118 of the International Agency for Research on Cancer.

Use at-source extraction and a room extraction system.

If necessary, use a welding torch with an integrated extraction device.

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