MHP 500/700 S, MTB 500 S Operating Instructions

The MHP 500 S R/G, MHP 700 S R/W hosepack has been designed for gas-cooled/water-cooled robot applications. It connects the TransSteel Robotics wirefeeders to the robot welding torches of the TransSteel series.

MHP PAP hosepack

MHP conventional hosepack

(1)	MHP 500 S R/G, MHP 700 S R/W hosepack

Not supplied:

Inner liners
Inlet nozzles

CrashBox /i PAP fitted to robot arm

CrashBox /i fitted to robot arm with clamp system

The CrashBox /i is a protection device for the torch body, the drive unit, the wire brake and the torch body coupling. In the event of a collision, the CrashBox sends a signal to the robot control, which stops the robot immediately. The torch holder on the CrashBox protects the welding torch and the system components fitted from damage should a collision occur.

The clamp system is used for holding gas-cooled and water-cooled robot welding torches. With torch body curvatures of 22°, 36° and 45°, the clamp system positions the welding torch in such a way that the TCP is in the 6th axis or at a 45° angle to the 6th axis, depending on the torque angle gauge.

A robot-specific, isolated robot flange is required for fitting the CrashBox /i.

CrashBox /i PAP fitted to robot arm

CrashBox /i fitted to robot arm with clamp system

The CrashBox /i is a protection device for the torch body, the drive unit, the wire brake and the torch body coupling. In the event of a collision, the CrashBox sends a signal to the robot control, which stops the robot immediately. The torch holder on the CrashBox protects the welding torch and the system components fitted from damage should a collision occur.

The clamp system is used for holding gas-cooled and water-cooled robot welding torches. With torch body curvatures of 22°, 36° and 45°, the clamp system positions the welding torch in such a way that the TCP is in the 6th axis or at a 45° angle to the 6th axis, depending on the torque angle gauge.

A robot-specific, isolated robot flange is required for fitting the CrashBox /i.

Depending on the particular robot:

1 x robot flange with screws

Robot flange as per price list

The CrashBox /i is designed specifically for fitting to the robot arm and for holding gas-cooled and water-cooled robot hosepacks and robot drive units. For PAP systems, the torch hosepack runs through the CrashBox and then through the robot arm. In conventional robot systems the torch hosepack runs along the robot arm and is attached to the clamp. In the event of a crash, the magnetic coupling smoothly deflects the forces along a large deflection path.

The clamp system can be used for the following push robot hosepacks:

MHP i G / MHP i W TPS /i hosepacks
MTG/MTW TransSteel hosepacks

CrashBox /i PAP scope of supply

CrashBox /i Standard scope of supply

(1)	CrashBox /i holder	(4)	Bellows
(2)	1-ear clamp *	(5)	Cheese-head screws, M4 x 16 mm
(3)	Locking ring, 2-part *	(6)	Magnetic ring
* Delivered fitted to bellows (4)

Do not fit the CrashBox /i holder (1) and magnetic ring (4) together before fitting to the robot. The components become even more difficult to release due to the strong magnetism.

(1)	M8 hexagon nut
(2)	M8 washer
(3)	Clamp
(4)	Index disc
(5)	Allen screw, M8 x 40 mm

Optional (material for extension):

(6)	M8 x 40 mm screw
(7)	M8 washer
(8)	Extension
(9)	Index disc
(10)	M8 hexagon nut

CAUTION!

Risk of burns from hot torch body, hot torch body coupling and other hot welding torch components.

Before starting work on the torch body, the torch body coupling and all other welding torch components:

Allow the torch body, torch body coupling and all other welding torch components to cool down to room temperature (+25 °C, +77 °F)

Wear electrically insulated and heat protective gloves

Use a suitable tool

CAUTION!

Risk of burns from hot torch body, hot torch body coupling and other hot welding torch components.

Before starting work on the torch body, the torch body coupling and all other welding torch components:

Allow the torch body, torch body coupling and all other welding torch components to cool down to room temperature (+25 °C, +77 °F)

Wear electrically insulated and heat protective gloves

Use a suitable tool

The robot welding torch transmits the arc power to the workpiece. The gas-cooled or water-cooled TransSteel welding torch is designed for use with the CrashBox /i.
The torch body has an integrated lead for gas nozzle touch sensing.

Standard: with wearing parts, without contact tip

OVT: without wearing parts

WARNING!

Danger from work that is not carried out properly.

This can result in serious personal injury and damage to property.

Only trained and qualified personnel may carry out the activities described in the following.

Observe the operating instructions of the system components, in particular the chapter "Safety rules".

WARNING!

Danger of electric shock.

Could result in serious injury or death.

Before starting the work described below, switch the power switch on the welding machine to the position - O -.

Disconnect the welding machine from the grid.

Ensure that the welding machine remains disconnected from the grid until all work is complete.

WARNING!

Danger from falling objects.

This can result in serious personal injury and damage to property.

Check that all screw connections described below are tightly fastened after assembly

Check that screw connections are tightly fastened after abnormal operating situations (e.g., after a crash).

Check that screw connections are tightly fastened at regular intervals

WARNING!

Danger from electric current due to defective system components and incorrect operation.

This can result in serious personal injury and damage to property.

All cables, leads, and hosepacks must always be securely connected, undamaged, and correctly insulated.

Only use adequately dimensioned cables, leads, and hosepacks.

WARNING!

Danger from work that is not carried out properly.

This can result in serious personal injury and damage to property.

Only trained and qualified personnel may carry out the activities described in the following.

Observe the operating instructions of the system components, in particular the chapter "Safety rules".

WARNING!

Danger of electric shock.

Could result in serious injury or death.

Before starting the work described below, switch the power switch on the welding machine to the position - O -.

Disconnect the welding machine from the grid.

Ensure that the welding machine remains disconnected from the grid until all work is complete.

WARNING!

Danger from falling objects.

This can result in serious personal injury and damage to property.

Check that all screw connections described below are tightly fastened after assembly

Check that screw connections are tightly fastened after abnormal operating situations (e.g., after a crash).

Check that screw connections are tightly fastened at regular intervals

WARNING!

Danger from electric current due to defective system components and incorrect operation.

This can result in serious personal injury and damage to property.

All cables, leads, and hosepacks must always be securely connected, undamaged, and correctly insulated.

Only use adequately dimensioned cables, leads, and hosepacks.

WARNING!

Danger from work that is not carried out properly.

This can result in serious personal injury and damage to property.

Only trained and qualified personnel may carry out the activities described in the following.

Observe the operating instructions of the system components, in particular the chapter "Safety rules".

WARNING!

Danger of electric shock.

Could result in serious injury or death.

Before starting the work described below, switch the power switch on the welding machine to the position - O -.

Disconnect the welding machine from the grid.

Ensure that the welding machine remains disconnected from the grid until all work is complete.

WARNING!

Danger from falling objects.

This can result in serious personal injury and damage to property.

Check that all screw connections described below are tightly fastened after assembly

Check that screw connections are tightly fastened after abnormal operating situations (e.g., after a crash).

Check that screw connections are tightly fastened at regular intervals

WARNING!

Danger from electric current due to defective system components and incorrect operation.

This can result in serious personal injury and damage to property.

All cables, leads, and hosepacks must always be securely connected, undamaged, and correctly insulated.

Only use adequately dimensioned cables, leads, and hosepacks.

Individual components must be fitted to the robot in the following order:

Wirefeeder - the wirefeeder holder and the side arm holder must be fitted first
CrashBox /i
Clamp system
Torch hosepack
Robot welding torch
Interconnecting hosepack

1

Observe the torques when fitting the robot flange:

Tightening torque for screws of strength class 8.8

M4	2,3 - 3,3 Nm 1,70 - 2,43 lb·ft
M5	4,4 - 6,5 Nm 3,25 - 4,79 lb·ft
M6	7,70 - 11,3 Nm 5,68 - 8,33 lb·ft
M8	18,5 - 27,3 Nm 13,65 - 20,14 lb·ft
M10	36,0 - 54,0 Nm 26,55 - 39,83 lb·ft
M12	63,0 - 93,0 Nm 46,47 - 68,60 lb·ft

2

3

4

5

6

7

8

1

Observe the torques when fitting the robot flange:

Tightening torque for screws of strength class 8.8

M4	2,3 - 3,3 Nm 1,70 - 2,43 lb·ft
M5	4,4 - 6,5 Nm 3,25 - 4,79 lb·ft
M6	7,70 - 11,3 Nm 5,68 - 8,33 lb·ft
M8	18,5 - 27,3 Nm 13,65 - 20,14 lb·ft
M10	36,0 - 54,0 Nm 26,55 - 39,83 lb·ft
M12	63,0 - 93,0 Nm 46,47 - 68,60 lb·ft

2

3

4

5

6

7

8

The positioning of the welding torch in relation to the workpiece is divided into fixed angles by the index disc. Special angles are available on request.

1

2

1

Mount the index disc 45° from the scope of supply of the clamp extension

NOTE!

CB (for CrashBox) is stamped on one side of the clamp extension.

This side must be fitted to the index disc that has already been fitted.

2

Fit the clamp extension to the index disc that has already been fitted in such a way that the stamped 'CB' on the clamp extension faces the index disc!

3

1

2

3

4

1

2

3

4

CAUTION!

Risk of burns from hot torch body, hot torch body coupling and other hot welding torch components.

Before starting work on the torch body, the torch body coupling and all other welding torch components:

Allow the torch body, torch body coupling and all other welding torch components to cool down to room temperature (+25 °C, +77 °F)

Wear electrically insulated and heat protective gloves

Use a suitable tool

CAUTION!

Risk of burns from hot torch body, hot torch body coupling and other hot welding torch components.

Before starting work on the torch body, the torch body coupling and all other welding torch components:

Allow the torch body, torch body coupling and all other welding torch components to cool down to room temperature (+25 °C, +77 °F)

Wear electrically insulated and heat protective gloves

Use a suitable tool

Special tool required

1

2

1

Lay the welding torch out straight

2

Lay the inner liner out straight

3

Push the inner liner into the welding torch until it protrudes from the front of the welding torch

4

Mark the end of the torch connector on the inner liner

5

Cut off the inner liner at the marking and deburr; left inner liner made of steel, right inner liner made of plastic

6

Screw the clamping nipple onto the inner liner as far as it will go. The inner liner must be visible through the hole in the cap

7

Fit the extraction nozzle

Push the extraction nozzle on as far as it will go.

WARNING!

Danger from work that is not carried out properly.

This can result in serious personal injury and damage to property.

Only trained and qualified personnel may carry out the activities described in the following.

Observe the operating instructions of the system components, in particular the chapter "Safety rules".

WARNING!

Danger of electric shock.

Could result in serious injury or death.

Before starting the work described below, switch the power switch on the welding machine to the position - O -.

Disconnect the welding machine from the grid.

Ensure that the welding machine remains disconnected from the grid until all work is complete.

WARNING!

Danger from falling objects.

This can result in serious personal injury and damage to property.

Check that all screw connections described below are tightly fastened after assembly

Check that screw connections are tightly fastened after abnormal operating situations (e.g., after a crash).

Check that screw connections are tightly fastened at regular intervals

WARNING!

Danger from electric current due to defective system components and incorrect operation.

This can result in serious personal injury and damage to property.

All cables, leads, and hosepacks must always be securely connected, undamaged, and correctly insulated.

Only use adequately dimensioned cables, leads, and hosepacks.

WARNING!

Danger from work that is not carried out properly.

This can result in serious personal injury and damage to property.

Only trained and qualified personnel may carry out the activities described in the following.

Observe the operating instructions of the system components, in particular the chapter "Safety rules".

WARNING!

Danger of electric shock.

Could result in serious injury or death.

Before starting the work described below, switch the power switch on the welding machine to the position - O -.

Disconnect the welding machine from the grid.

Ensure that the welding machine remains disconnected from the grid until all work is complete.

WARNING!

Danger from falling objects.

This can result in serious personal injury and damage to property.

Check that all screw connections described below are tightly fastened after assembly

Check that screw connections are tightly fastened after abnormal operating situations (e.g., after a crash).

Check that screw connections are tightly fastened at regular intervals

WARNING!

Danger from electric current due to defective system components and incorrect operation.

This can result in serious personal injury and damage to property.

All cables, leads, and hosepacks must always be securely connected, undamaged, and correctly insulated.

Only use adequately dimensioned cables, leads, and hosepacks.

Individual components must be fitted to the robot in the following order:

Wirefeeder - the wirefeeder holder and the side arm holder must be fitted first
CrashBox /i
Torch hosepack
Robot welding torch
Interconnecting hosepack

1

Observe the torques when fitting the robot flange:

Max. tightening torque for screws 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

2

3

4

5

6

7

8

1

Observe the torques when fitting the robot flange:

Max. tightening torque for screws 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

2

3

4

5

6

7

8

Special tool required

1

2

3

4

5

6

7

8

9

10

Special tool required

1

2

3

4

5

6

7

8

9

10

1

Lay the welding torch out straight

2

Lay the inner liner out straight

3

Push the inner liner into the welding torch until it protrudes from the front of the welding torch

4

Mark the end of the torch connector on the inner liner

5

Cut off the inner liner at the marking and deburr; left inner liner made of steel, right inner liner made of plastic

6

Screw the clamping nipple onto the inner liner as far as it will go. The inner liner must be visible through the hole in the cap

7

Fit the extraction nozzle

Push the extraction nozzle on as far as it will go.

Under normal operating conditions, the device requires only a minimum of care and maintenance. However, it is vital to observe some important points to ensure the welding system remains in a usable condition for many years.

WARNING!

Danger due to incorrect operation and incorrectly performed work.

This can result in serious injury and damage to property.

All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

Fully read and understand this document.

Read and understand all safety rules and user documentation for this device and all system components.

WARNING!

Danger from electric current.

This can result in serious injury and damage to property.

Before starting maintenance or servicing work, switch off all the devices and components involved and disconnect them from the mains.

Secure all the devices and components involved to prevent unintentional restarting.

After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

CAUTION!

Danger due to hot system components and/or equipment.

This can result in burns or scalding.

Before starting work, allow all hot system components and/or equipment to cool to +25°C/+77°F (e.g., coolant, water-cooled system components, wirefeeder drive motor, etc.).

Wear suitable protective equipment if cooling down is not possible (e.g., heat-resistant gloves, safety goggles, etc.).

Check all hosepacks and the ground earth connection for damage. Replace any damaged components.
Check feed rollers and inner liners for signs of damage. Replace any damaged components.
Check the wirefeeding hoses for damage. Replace any damaged components.
Check contact pressure of feed rollers and adjust if necessary.
Check that all screw connections between the robot, wirefeeder holder and wire-feed unit are secure.

CAUTION!

Danger from compressed air at close range.

Electronic components may be damaged.

Do not bring the air nozzle too close to electronic components.

Open covers, remove device side panels and clean inside of device with dry reduced compressed air. After cleaning, restore device to its original state.

Insulating parts
- Burned-off outside edges, notches
Nozzle fittings
- Burned-off outside edges, notches
- Heavily covered in welding spatter
Spatter guard
- Burned-off outside edges, notches
Contact tips
- Worn-out (oval) wire entry and wire exit holes
- Heavily covered in welding spatter
- Penetration on the tip of the contact tip
Gas nozzles
- Heavily covered in welding spatter
- Burned-off outside edges
- Notches

1

2

3

**	Screw on and tighten the gas nozzle as far as it will go

1

2

1

2

Waste electrical and electronic equipment must be collected separately and recycled in an environmentally responsible manner in accordance with the EU Directive and national law. Used equipment must be returned to the distributor or through a local, authorised collection and disposal system. Proper disposal of the old device promotes sustainable recycling of material resources. Ignoring this may lead to potential health/environmental impacts.

Packaging materials
Collected separately. Check your municipality’s regulations. Reduce the volume of the box.

Welding current at 10 min/40° C M21 (EN ISO 14175) C1 (EN ISO 14175)	40 % ED* / 500 A 60 % ED* / 450 A 100 % ED* / 360 A 40 % ED* / 500 A 60 % ED* / 450 A 100 % ED* / 360 A
Wire diameter	0.8 - 1.6 mm 0.032 - 0.063 in.
Length	0.94 / 0.96 / 1.04 / 1.06 / 1.075 / 1.12 / 1.13 / 1.15 / 1.18 / 1.19 / 1.2 / 1.22 / 1.31 / 1.35 / 1.37 / 1.4 / 1.43 / 1.51 / 1.59 / 2.13 m 3.08 / 3.15 / 3.4 / 3.48 / 3.53 / 3.67 / 3.71 / 3.77 / 3.87 / 3.9 / 3.94 / 4.0 / 4.3 / 4.43 / 4.5 / 4.59 / 4.69 / 4.95 / 5.22 / 6.99 ft.
* ED = Duty cycle

Welding current at 10 min/40° C M21 (EN ISO 14175) C1 (EN ISO 14175)	40 % ED* / 500 A 60 % ED* / 450 A 100 % ED* / 360 A 40 % ED* / 500 A 60 % ED* / 450 A 100 % ED* / 360 A
Wire diameter	0.8 - 1.6 mm 0.032 - 0.063 in.
Length	0.94 / 0.96 / 1.04 / 1.06 / 1.075 / 1.12 / 1.13 / 1.15 / 1.18 / 1.19 / 1.2 / 1.22 / 1.31 / 1.35 / 1.37 / 1.4 / 1.43 / 1.51 / 1.59 / 2.13 m 3.08 / 3.15 / 3.4 / 3.48 / 3.53 / 3.67 / 3.71 / 3.77 / 3.87 / 3.9 / 3.94 / 4.0 / 4.3 / 4.43 / 4.5 / 4.59 / 4.69 / 4.95 / 5.22 / 6.99 ft.
* ED = Duty cycle

X / I_max (10 min/40 °C) M21 (EN ISO 14175)		- - 100% D.C.* 700
X / I_max (10 min/40 °C) C1 (EN ISO 14175)		- - 100% D.C.* 700
	[mm (in.)]	0.8-1.6 (0.032-0.063)
P_max	[m] ([W]) [ft.] ([W])	0.96 (1200) / 1.04 (1250) / 1.06 (1250) / 1.075 (1250) / 1.12 (1300) / 1.13 (1300) / 1.15 (1300) / 1.18 (1300) / 1.19 (1300) / 1.2 (1300) / 1.22 (1300) / 1.31 (1350) / 1.35 (1400) / 1.37 (1400) / 1.4 (1400) / 1.43 (1400) / 1.51 (1400) 3.15 (1200) / 3.41 (1250) / 3.48 (1250) / 3.53 (1250) / 3.67 (1300) / 3.71 (1300) / 3.77 (1300) / 3.87 (1300) / 3.9 (1300) / 3.94 (1300) / 4 (1300) / 4.3 (1350) / 4.43 (1400) / 4.5 (1400) / 4.59 (1400) / 4.69 (1400) / 4.95 (1400)
Q_min	[L/min] [gal./min]	1 0.26
p_min	[bar] [psi]	3 43
p_max	[bar] [psi]	5 72
* D.C. = Duty cycle

Gas-cooled robot welding torches

Welding current at 10 min/40° C M21 (EN ISO 14175) C1 (EN ISO 14175)	40 % ED* / 500 A 60 % ED* / 450 A 100 % ED* / 360 A 40 % ED* / 500 A 60 % ED* / 450 A 100 % ED* / 360 A
Wire diameter	0.8 - 1.6 mm 0.032 - 0.063 in.

* ED = Duty cycle

Gas-cooled robot welding torches

Welding current at 10 min/40° C M21 (EN ISO 14175) C1 (EN ISO 14175)	40 % ED* / 500 A 60 % ED* / 450 A 100 % ED* / 360 A 40 % ED* / 500 A 60 % ED* / 450 A 100 % ED* / 360 A
Wire diameter	0.8 - 1.6 mm 0.032 - 0.063 in.

* ED = Duty cycle

MHP 500/700 S, MTB 500 S

General information

Torch hosepack

General

Torch hosepack

General

General

Scope of supply

CrashBox /i

General

General

Also required for installation

Device concept

Application areas

Scope of supply

Clamp system scope of supply and options

Robot welding torch

Safety

CAUTION!

Safety

CAUTION!

General

Installation and commissioning

Fitting the welding system to a conventional robot

Safety

WARNING!

WARNING!

WARNING!

WARNING!

Fitting the welding system to a conventional robot

Safety

WARNING!

WARNING!

WARNING!

WARNING!

Safety

WARNING!

WARNING!

WARNING!

WARNING!

Fitting the TransSteel welding system to a conventional robot

Fitting the CrashBox /i to the robot

Fitting the CrashBox /i to the robot

Fitting the CrashBox /i to the robot

Fitting the clamp system

Special tilt angle for the welding torch

Special tilt angle for the welding torch

Fitting the clamp system

Fitting the clamp system with extension

NOTE!

Fitting the MHP G / W hosepack

Fitting the MHP G / W conventional hosepack - standard

Fitting the MHP G / W conventional hosepack - standard

Fitting the TransSteel torch body

Safety

CAUTION!

Safety

CAUTION!

Fitting the TransSteel torch body - Standard

Fitting the inner liner inside the torch hosepack

Fitting the welding system to a PAP robot

Safety

WARNING!

WARNING!

WARNING!

WARNING!

Safety

WARNING!

WARNING!

WARNING!

WARNING!

Fitting the TransSteel welding system to a PAP robot

Installing the CrashBox /i PAP on the robot

Installing the CrashBox /i PAP on the robot

Installing the CrashBox /i PAP on the robot

Fitting the MHPi/MHP S G/W PAP hosepack

Fitting the Robacta MHP G/W PAP hosepack

Fitting the Robacta MHP G/W PAP hosepack

Fitting the inner liner inside the torch hosepack

Appendix