FRONIUS TPS/i Push User manual

Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).

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TPS/i Robotics welding system

Push

Operating instructions

MIG/MAG robot welding system

42,0426,0183,EN 019-31032021

Contents

Safety rules 7

Explanation of safety notices 7

General 7

Intended use 8

Environmental conditions 8

Obligations of the operator 8

Obligations of personnel 8

Mains connection 8

Protecting yourself and others 9

Danger from toxic gases and vapours 9

Danger from flying sparks 10

Risks from mains current and welding current 10

Meandering welding currents 11

EMC Device Classifications 12

EMC measures 12

EMF measures 12

Specific hazards 13

Requirement for the shielding gas 14

Danger from shielding gas cylinders 14

Danger from escaping shielding gas 14

Safety measures at the installation location and during transport 15

Safety measures in normal operation 15

Commissioning, maintenance and repair 16

Safety inspection 16

Disposal 16

Safety symbols 17

Data protection 17

Description of the warning notices on the device 18

System configurations 21

System configurations - conventional robot 23

Push with wire drum 23

Push with wirespool 24

Push with 4-roller unreeling wirefeeder and wire drum 25

System configurations - PAP 26

Push with wire drum 26

Push with wirespool 27

Push with 4-roller unreeling wirefeeder and wire drum 28

System components 29

WF wire-feed unit 31

Device concept 31

Proper use 31

Safety 31

Warning notices on the device 32

WF 25i REEL R /4R, WF 30i REEL R /2R 34

Safety 34

Device concept 34

Application area 34

Proper use 34

Warning notices on the device 34

Interconnecting hosepack 37

General 37

Torch hosepack 38

General remarks 38

Scope of supply 38

Buttons on the Robacta MHP hosepack 38

CrashBox /i 39

General remarks 39

Also required for installation 39

Device concept 39

Application areas 40

Information on repairing CrashBoxes 40

Scope of supply 40

Clamp system scope of supply and options 41

Robot welding torch 42

Safety 42

General 42

Controls, connections and mechanical components 43

Control elements and mechanical components 45

Safety 45

Control elements and mechanical components 45

Gas test/wire threading control panel (optional) 45

WF 15i / 25i / 30i R 48

WF 15i R, WF 30i R connections 48

WF 30i R / L connections 48

WF 25i R connections 49

WF 25i R / L connections 50

WF 15i / 25i / 30i R PAP 51

WF 15i R PAP, WF 30i R PAP connections 51

WF 25i R PAP connections 51

WF 25i R / L PAP connections 52

WF 25i REEL R /4R, WF 30i REEL R /2R 53

Safety 53

Controls, connections and mechanical components 53

Control panel 55

Installation - conventional robot 59

Fitting the welding system to a conventional robot 61

Safety 61

Fitting the TPS/i welding system to a conventional robot 61

Fitting the wire-feed unit 62

Fitting the wirefeeder holder 62

Fitting the wirefeeder 62

Fitting the CrashBox /i to the robot 64

Installing the CrashBox/i Dummy on the robot 65

Fitting the clamp system 67

Special tilt angle for the welding torch 67

Fitting the clamp system 68

Fitting the clamp system with extension 68

Fitting the MHP G / W hosepack 69

Fitting the MHP G / W conventional hosepack - Standard 69

Optimum hosepack arrangement 69

Fitting the TPS/i torch neck 70

Safety 70

Fitting the TPS/i torch body - Standard 70

“OPT / i MHP WireBrake” option 70

Fitting the inner liner inside the torch hosepack 71

Fitting the interconnecting hosepack 73

Fitting the Standard interconnecting hosepack to the robot 73

Connecting the extension hosepack 73

Connecting the MHP W hosepack 75

Connecting wire-feed unit to system components 78

Safety 78

General 78

Connecting the wirefeeder to the system components 78

Fitting the OPT / i MHP WireBrake and torch body 81

Safety 81

Prerequisites for operation 81

Compressed air supply specifications 81

Remedying the clamping marks on the wire electrode 81

Technical data 82

Fitting the OPT/i MHP WireBrake 82

Removing the OPT / i MHP WireBrake and torch body 84

Safety 84

Removing the OPT / i MHP WireBrake and torch body 84

Fitting the unreeling wirefeeder 85

Installation - PAP 87

Fitting the welding system to a PAP robot 89

Safety 89

Fitting the TPS/i welding system to a PAP robot 89

Maximum axis rotation 89

Fitting the wire-feed unit 91

Fitting the WF 15i/25i/30i R PAP 91

Installing the CrashBox /i PAP on the robot 92

Installing the CrashBox/i Dummy on the robot 93

Fitting the MHPi/MHP S G/W PAP hosepack 95

Fitting the Robacta MHP G/W PAP hosepack 95

“OPT / i MHP WireBrake” option 96

Fitting the inner liner inside the torch hosepack 97

Fitting the MHPi/MHP S G/W PAP SM hosepack 99

Fitting the Robacta MHP G/W PAP SM hosepack 99

“OPT / i MHP WireBrake” option 100

Fitting the inner liner inside the torch hosepack 101

Fitting the interconnecting hosepack 103

Fitting the PAP interconnecting hosepack to the robot 103

Connecting the extension hosepack 104

Connecting the interconnecting hosepack 105

Connecting wire-feed unit to system components 106

Safety 106

General 106

Connecting the WF 15i/25i/30i R PAP to the system components 106

Start-up 109

Inserting/replacing feed rollers 111

General 111

WF 25i Reel 4R: inserting/replacing feed rollers for the 4-roller drive 111

WF 30i Reel 2R: inserting/replacing feed rollers for the 2-roller drive 112

Inserting/replacing feed rollers 113

Feeding in the wire electrode 115

Insulated routing of wire electrode to wirefeeder 115

Feeding in the wire electrode 115

Setting the contact pressure 117

Start-up 118

Requirements 118

General 118

Troubleshooting, maintenance and disposal 119

Troubleshooting 121

Safety 121

Fault diagnosis 121

Care, maintenance and disposal 124

General 124

Safety 124

Every start-up 124

Special care of O-rings 125

Whenever the welding torch or torch hosepack is changed 125

Every 6 months 125

Preparing the WF 15i/25i/30i R PAP for replacement of the welding torch inner liner 125

Recognising faulty wearing parts 126

MTG d, MTW d - Fitting wearing parts to the torch body 127

Fitting wearing parts to the torch body - MTW 700 i 128

Removing the CrashBox PAP from the robot (without mounting key) 128

Removing the CrashBox PAP from the robot (with mounting key) 130

Changing the torch hosepack, changing the interconnecting hosepack 132

Cleaning the welding torch 133

Disposal 133

Technical data 135

WF wire-feed unit 137

WF 15i R, WF 15i R PAP 137

WF 25i R, WF 25i R PAP, WF 25i R / L 137

WF 30i R, WF 30i R PAP, WF 30i R / L 138

Unreeling wirefeeder WF REEL 139

WF 25i REEL R /4R/G/W 139

WF 30i REEL R /2R/G/W 139

CrashBox /i 140

Technical data, triggering torques and weight/distance diagram 140

Torch hosepack 143

MHP 400i G / R 143

MHP 400i G / R / PAP 143

MHP 700i W / R (0.95 - 2.25 m / 3.12 - 7.38 ft.) 144

MHP 700i W / R (3.25 - 4.25 m / 10.66 - 13.12 ft.) 145

MHP 700i W / R / PAP 146

Robot welding torch 147

Gas-cooled robot welding torches 147

Water-cooled robot welding torches 148

Interconnecting hosepacks 150

HP 70i 150

HP 95i 150

HP 120i 150

HP 70i, HP PC Cable HD 70 150

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 recog-

nised 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 com-

pany,

- 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 operating

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 applic-

able and local regulations regarding accident prevention and environmental 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 section

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 intended

exclusively for automated MIG/MAG applications in conjunction with Fronius compon-

ents.

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 Instructions

- 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 section

"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 prevention

- 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 connection Devices with a higher rating may affect the energy quality of the mains due to their cur-

rent 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 matter 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 using car-

diac 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 protective 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 injury

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 vicinity:

- 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 current and welding

current, etc.)

- Provide suitable protective equipment

- Alternatively, erect suitable safety screens/curtains.

Danger from

toxic gases and

vapours

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.

Keep your face away from welding fumes and gases.

Fumes and hazardous gases

- must not be breathed in

- must be extracted from the working area using appropriate methods.

Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least

20 m³ per hour at all times.

Otherwise, a welding helmet with an air supply must be worn.

If there is any doubt about whether the extraction capacity is sufficient, the measured

toxic emission values should be compared with the permissible limit values.

The following components are responsible, amongst other things, for the degree of tox-

icity of welding fumes:

- Metals used for the workpiece

- Electrodes

- Coatings

- Cleaners, degreasers, etc.

- Welding process used

The relevant material safety data sheets and manufacturer's specifications for the listed

components should therefore be studied carefully.

Recommendations for trade fair scenarios, risk management measures and for identify-

ing working conditions can be found on the European Welding Association website under

Health & Safety (https://european-welding.org).

Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation

area.

Close the shielding gas cylinder valve or main gas supply if no welding is taking place.

Danger from fly-

ing sparks

Flying sparks may cause fires or explosions.

Never weld close to flammable materials.

Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the arc, or

alternatively covered with an approved cover.

A suitable, tested fire extinguisher must be available and ready for use.

Sparks and pieces of hot metal may also get into adjacent areas through small gaps or

openings. Take appropriate precautions to prevent any danger of injury or fire.

Welding must not be performed in areas that are subject to fire or explosion or near

sealed tanks, vessels or pipes unless these have been prepared in accordance with the

relevant national and international standards.

Do not carry out welding on containers that are being or have been used to store gases,

propellants, mineral oils or similar products. Residues pose an explosive hazard.

Risks from mains

current and weld-

ing current

An electric shock is potentially life threatening and can be fatal.

Do not touch live parts either inside or outside the device.

During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed

rollers and all pieces of metal that are in contact with the welding wire are live.

Always set the wirefeeder up on a sufficiently insulated surface or use a suitable, insu-

lated wirefeeder holder.

Make sure that you and others are protected with an adequately insulated, dry base or

cover for the earth or ground potential. This base or cover must extend over the entire

area between the body and the earth or ground potential.

All cables and leads must be secured, undamaged, insulated and adequately dimen-

sioned. Replace loose connections and scorched, damaged, or inadequately dimen-

sioned cables and leads immediately.

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