LogoTPS/i Robotics Push welding system
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    • Imprint
    • Terms and Conditions
    • Data privacy statement
    • Cookie Policy
    • 027-19032025
    • Safety rules
      • Explanation of safety notices
      • General
      • Intended use
      • Environmental conditions
      • Obligations of the operator
      • Obligations of personnel
      • Mains connection
      • Protecting yourself and others
      • Danger from toxic gases and vapours
      • Danger from flying sparks
      • Risks from mains current and welding current
      • Meandering welding currents
      • EMC Device Classifications
      • EMC measures
      • EMF measures
      • Specific hazards
      • Requirement for the shielding gas
      • Danger from shielding gas cylinders
      • Danger from escaping shielding gas
      • Safety measures at the installation location and during transport
      • Safety measures in normal operation
      • Commissioning, maintenance and repair
      • Safety inspection
      • Disposal
      • Sicherheitskennzeichnung
      • Data security
      • Copyright
      • Description of the warning notices on the device
    • System configurations
      • System configurations - conventional robot
        • Push with wire drum
        • Push with wirespool
        • Push with 4-roller unreeling wirefeeder and wire drum
      • System configurations - PAP
        • Push with wire drum
        • Push with wirespool
        • Push with 4-roller unreeling wirefeeder and wire drum
    • System components
      • WF wire-feed unit
        • Device concept
        • Proper use
        • Safety
        • Warning notices on the device
      • WF 25i REEL R /4R, WF 30i REEL R /2R
        • Safety
        • Device concept
        • Application area
        • Proper use
        • Warning notices on the device
      • Interconnecting hosepack
        • General
      • Torch hosepack
        • General remarks
        • Scope of supply
        • Buttons on the Robacta MHP hosepack
      • CrashBox /i
        • General
        • Note on the correct operation of CrashBoxes
        • Also required for installation
        • Device concept
        • Application areas
        • Information on repairing CrashBoxes
        • Scope of supply
        • Clamp system scope of supply and options
      • Robot welding torch
        • Safety
        • General
      • OPT/i camera mount
        • General
        • Drilling template
    • Controls, connections and mechanical components
      • WFi R control elements and mechanical components
        • Safety
        • WFi R control elements and mechanical components
      • WF 15i / 25i / 30i R
        • WF 15i R, WF 30i R connections
        • WF 30i R / L connections
        • WF 25i R connections
        • WF 25i R / L connections
      • WF 15i / 25i / 30i R PAP
        • WF 15i R PAP, WF 30i R PAP connections
        • WF 25i R PAP connections
        • WF 25i R / L PAP connections
      • WF 25i REEL R /4R, WF 30i REEL R /2R
        • Safety
        • Control elements, connections and mechanical components
      • Function of the gas-test, wire retract and wire threading buttons
        • Function of the gas-test, wire retract and wire threading buttons
    • Installation - conventional robot
      • Fitting the welding system to a conventional robot
        • Safety
        • Fitting the TPS/i welding system to a conventional robot
      • Fitting the wire-feed unit
        • Fitting the wirefeeder holder
        • Fitting the wirefeeder
      • Fitting the CrashBox /i to the robot
        • Fitting the CrashBox /i to the robot
        • Installing the CrashBox/i Dummy on the robot
      • Fitting the clamp system
        • Special tilt angle for the welding torch
        • Fitting the clamp system
        • Fitting the clamp system with extension
      • Fitting the MHP G / W hosepack
        • Fitting the MHP G / W conventional hosepack - Standard
        • Optimum hosepack arrangement
      • Fitting the TPS/i torch neck
        • Safety
        • Fitting the TPS/i torch body - Standard
        • “OPT / i MHP WireBrake” option
        • Fitting the inner liner inside the torch hosepack
      • Fitting the interconnecting hosepack
        • Fitting the Standard interconnecting hosepack to the robot
        • Connecting the extension hosepack
      • Connecting the MHP W hosepack
        • Connecting the MHP W hosepack
      • Connecting wire-feed unit to system components
        • Safety
        • General
        • Connecting the wirefeeder to the system components
      • Fitting the OPT / i MHP WireBrake and torch body
        • Safety
        • Prerequisites for operation
        • Compressed air supply specifications
        • Remedying the clamping marks on the wire electrode
        • Technical data
        • Fitting the OPT/i MHP WireBrake
      • Removing the OPT / i MHP WireBrake and torch body
        • Safety
        • Removing the OPT / i MHP WireBrake and torch body
      • Fitting the unreeling wirefeeder
        • Fitting the unreeling wirefeeder
      • Fitting the OPT/i camera mount
        • Load-bearing capacity of the OPT/i camera mount
        • Safety
        • Fitting the OPT/i camera mount
    • Installation - PAP
      • Axis rotation and service life of the torch hosepack
        • General
        • Recommended axis rotation
        • Maximum axis rotation
        • Hosepack service life depending on the axis rotation in the fifth and sixth robot axis
      • Fitting the welding system to a PAP robot
        • Safety
        • Fitting the TPS/i welding system to a PAP robot
      • Fitting the wire-feed unit
        • Fitting the WF 15i/25i/30i R PAP
      • Installing the CrashBox /i PAP on the robot
        • Installing the CrashBox /i PAP on the robot
        • Installing the CrashBox/i Dummy on the robot
      • Fitting the MHPi/MHP S G/W PAP hosepack
        • Fitting the Robacta MHP G/W PAP hosepack
        • “OPT / i MHP WireBrake” option
        • Fitting the inner liner inside the torch hosepack
      • Fitting the MHPi/MHP S G/W PAP SM hosepack
        • Fitting the Robacta MHP G/W PAP SM hosepack
        • “OPT / i MHP WireBrake” option
        • Fitting the inner liner inside the torch hosepack
      • Fitting the interconnecting hosepack
        • Fitting the PAP interconnecting hosepack to the robot
        • Connecting the extension hosepack
        • Connecting the interconnecting hosepack
      • Connecting wire-feed unit to system components
        • Safety
        • General
        • Connecting the WF 15i/25i/30i R PAP to the system components
    • Start-up
      • Inserting/replacing feed rollers
        • General
        • WF 25i Reel 4R: inserting/replacing feed rollers for the 4-roller drive
        • WF 30i Reel 2R: Inserting/replacing feed rollers for the 2-roller drive
        • Inserting/replacing feed rollers
      • Feeding in the wire electrode
        • Insulated routing of wire electrode to wirefeeder
        • Feeding in the wire electrode
        • Setting the contact pressure
      • Start-up
        • Requirements
        • General
    • Troubleshooting, maintenance and disposal
      • Troubleshooting
        • Safety
        • Fault diagnosis
      • Care, maintenance and disposal
        • General
        • Safety
        • Every start-up
        • Special care of O-rings
        • Whenever the welding torch or torch hosepack is changed
        • Every 6 months
        • "Stop" coolant pump service position - Working mode 17
        • Preparing the WF 15i/25i/30i R PAP for replacement of the welding torch inner liner
        • Recognising faulty wearing parts
        • MTG d, MTW d - Fitting wearing parts to the torch body
        • MTG d, MTW d, MTB - Fitting wear parts to the burner body
        • Fitting wearing parts to the torch body - MTW 700 i
        • Removing the CrashBox PAP from the robot (without mounting key)
        • Removing the CrashBox PAP from the robot (with mounting key)
        • Changing the torch hosepack, changing the interconnecting hosepack
        • Cleaning the welding torch
        • Disposal
    • Technical data
      • WF wire-feed unit
        • WF 15i R,
          WF 15i R
        • WF 15i R,
          WF 15i R PAP
        • WF 25i R,
          WF 25i R,
          WF 25i R / L
        • WF 25i R,
          WF 25i R PAP,
          WF 25i R / L
        • WF 30i R,
          WF 30i R,
          WF 30i R / L
        • WF 30i R,
          WF 30i R PAP,
          WF 30i R / L
      • Unreeling wirefeeder WF REEL
        • WF 25i REEL R /4R/G/W
        • WF 30i REEL R /2R/G/W
      • CrashBox /i
        • Technical data, triggering torques and weight/distance diagram
      • Torch hosepack
        • MHP 400i G / R
        • MHP 400i G / R / PAP
        • MHP 500 S R / G / PAP
        • MHP 700i W / R (0.95 - 2.25 m / 3.12 - 7.38 ft.)
        • MHP 700i W / R (3.25 - 4.25 m / 10.66 - 13.12 ft.)
        • MHP 700i W / R / PAP
      • Robot welding torch
        • Gas-cooled robot welding torches
        • MTB 500S G R, MTB 500S G R TD
        • Water-cooled robot welding torches
        • MTB 350i W R
      • Interconnecting hosepacks
        • HP 70i
        • HP 95i
        • HP 120i
        • HP 70i, HP PC Cable HD 70

    TPS/i Robotics Push welding system Operating Instructions

    Overview of the TPS/i Standard
    Overview of the TPS/i PAP
    Fitting to conventional robots
    Fitting to PAP robots
    Commissioning
    Troubleshooting
    Maintenance
    Changing the hosepack
    Technical data
    Spare parts

    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.

    1. 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.

    1. Safety rules

    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 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 applicable 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!

    1. Safety rules

    Intended use

    The devices and components described in these Operating Instructions are intended 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 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.

    1. Safety rules

    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.)

    1. Safety rules

    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.

    1. Safety rules

    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.

    1. Safety rules

    Mains connection

    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 matter with the power supply company.

    IMPORTANT! Ensure that the mains connection is earthed properly

    1. Safety rules

    Protecting yourself 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 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 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.
    1. Safety rules

    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 toxicity 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 identifying 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.

    1. Safety rules

    Danger from flying 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.

    1. Safety rules

    Risks from mains current and welding 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 wire spool, 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, insulated 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 dimensioned. Replace loose connections and scorched, damaged, or inadequately dimensioned cables and leads immediately.
    Use the handle to ensure the power connections are tight before every use.
    In the case of power cables with a bayonet connector, rotate the power cable around the longitudinal axis by at least 180° and pretension.

    Do not wrap cables or leads around the body or parts of the body.

    The electrode (rod electrode, tungsten electrode, welding wire, etc.) must
    • never be immersed in liquid for cooling
    • never be touched when the welding system is switched on.

    Double the open circuit voltage of a welding system can occur between the welding electrodes of two welding systems. Touching the potentials of both electrodes at the same time may be fatal under certain circumstances.

    Arrange for the mains cable to be checked regularly by a qualified electrician to ensure the ground conductor is functioning properly.

    Protection class I devices require a mains supply with ground conductor and a connector system with ground conductor contact for proper operation.

    Operation of the device on a mains supply without ground conductor and on a socket without ground conductor contact is only permitted if all national regulations for protective separation are observed.
    Otherwise, this is considered gross negligence. The manufacturer shall not be held liable for any damage arising from such usage.

    If necessary, provide adequate earthing for the workpiece.

    Switch off unused devices.

    Wear a safety harness if working at height.

    Before working on the device, switch it off and pull out the mains plug.

    Attach a clearly legible and easy-to-understand warning sign to the device to prevent anyone from plugging the mains plug back in and switching it on again.

    After opening the device:
    • Discharge all live components
    • Ensure that all components in the device are de-energised.

    If work on live parts is required, have a second person switch off the main switch at the right moment.

    1. Safety rules

    Meandering welding currents

    If the following instructions are ignored, meandering welding currents can develop with the following consequences:
    • Fire hazard
    • Overheating of parts connected to the workpiece
    • Damage to ground conductors
    • Damage to device and other electrical equipment

    Ensure that the workpiece is held securely by the workpiece clamp.

    Attach the workpiece clamp as close as possible to the area that is to be welded.

    Position the device with sufficient insulation against electrically conductive environments, such as insulation against conductive floor or insulation to conductive racks.

    If power distribution boards, twin-head mounts, etc., are being used, note the following: The electrode of the welding torch / electrode holder that is not used is also live. Make sure that the welding torch / electrode holder that is not used is kept sufficiently insulated.

    In the case of automated MIG/MAG applications, ensure that only an insulated wire electrode is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeeder.

    1. Safety rules

    EMC Device Classifications

    Devices in emission class A:
    • Are only designed for use in industrial settings
    • Can cause line-bound and radiated interference in other areas
    Devices in emission class B:
    • Satisfy the emissions criteria for residential and industrial areas. This is also true for residential areas in which the energy is supplied from the public low-voltage mains.

    EMC device classification as per the rating plate or technical data.

    1. Safety rules

    EMC measures

    In certain cases, even though a device complies with the standard limit values for emissions, it may affect the application area for which it was designed (e.g. when there is sensitive equipment at the same location, or if the site where the device is installed is close to either radio or television receivers).
    If this is the case, then the operator is obliged to take appropriate action to rectify the situation.

    Check and evaluate the immunity to interference of nearby devices according to national and international regulations. Examples of equipment that may be susceptible to interference from the device include:
    • Safety devices
    • Network, signal and data transfer lines
    • IT and telecommunications devices
    • Measuring and calibrating devices
    Supporting measures for avoidance of EMC problems:
    1. Mains supply
      • If electromagnetic interference arises despite the correct mains connection, additional measures are necessary (e.g. use of a suitable line filter)
    2. Welding power-leads
      • must be kept as short as possible
      • must be laid close together (to avoid EMF problems)
      • must be kept well apart from other leads
    3. Equipotential bonding
    4. Earthing of the workpiece
      • If necessary, establish an earth connection using suitable capacitors.
    5. Shield, if necessary
      • Shield other devices nearby
      • Shield the entire welding installation
    1. Safety rules

    EMF measures

    Electromagnetic fields may pose as yet unknown risks to health:
    • Effects on the health of persons in the vicinity, e.g. those with pacemakers and hearing aids
    • Individuals with pacemakers must seek advice from their doctor before approaching the device or any welding that is in progress
    • For safety reasons, maintain as large a distance as possible between the welding power-leads and the head/torso of the welder
    • Do not carry welding power-leads and hosepacks over the shoulders or wind them around any part of the body
    1. Safety rules

    Specific hazards

    Keep hands, hair, clothing and tools away from moving parts. For example:
    • Fans
    • Cogs
    • Rollers
    • Shafts
    • Wire spools and welding wires

    Do not reach into the rotating cogs of the wire drive or into rotating drive components.

    Covers and side panels may only be opened/removed while maintenance or repair work is being carried out.

    During operation
    • Ensure that all covers are closed and all side panels are fitted properly.
    • Keep all covers and side panels closed.

    The welding wire emerging from the welding torch poses a high risk of injury (piercing of the hand, injuries to the face and eyes, etc.).
    Therefore, always keep the welding torch facing away from the body (devices with wirefeeder) and wear suitable protective goggles.

    Never touch the workpiece during or after welding - risk of burns.

    Slag can jump off cooling workpieces. The specified protective equipment must therefore also be worn when reworking workpieces, and steps must be taken to ensure that other people are also adequately protected.

    Welding torches and other parts with a high operating temperature must be allowed to cool down before handling.

    Special provisions apply in areas at risk of fire or explosion
    - observe relevant national and international regulations.

    Welding machines for work in areas with increased electrical risk (e.g. near boilers) must carry the 'Safety' sign. However, the welding machine must not be located in such areas.

    Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting coolant flow or return lines.

    Observe the information on the coolant safety data sheet when handling coolant. The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer's website.

    Use only suitable load-carrying equipment supplied by the manufacturer when transporting devices by crane.

    • Hook chains or ropes onto all suspension points provided on the suitable load-carrying equipment.
    • Chains or ropes must be at the smallest angle possible to the vertical.
    • Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).

    If the wirefeeder is attached to a crane holder during welding, always use a suitable, insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).

    Welding with the device during crane transport is only permitted if this is clearly stated in the intended use of the device.

    If the device has a carrying strap or handle, this is intended solely for carrying by hand. The carrying strap is not to be used if transporting with a crane, counterbalanced lift truck or other mechanical hoist.

    All lifting tackle (straps, handles, chains, etc.) used in connection with the device or its components must be tested regularly (e.g. for mechanical damage, corrosion or changes caused by other environmental factors).
    The testing interval and scope of testing must comply with applicable national standards and directives as a minimum.

    Odourless and colourless shielding gas may escape unnoticed if an adapter is used for the shielding gas connection. Prior to assembly, seal the device-side thread of the adapter for the shielding gas connection using suitable Teflon tape.

    1. Safety rules

    Requirement for the shielding gas

    Especially with ring lines, contaminated shielding gas can cause damage to equipment and reduce welding quality.
    Meet the following requirements regarding shielding gas quality:
    • Solid particle size < 40 µm
    • Pressure condensation point < -20 °C
    • Max. oil content < 25 mg/m³

    Use filters if necessary.

    1. Safety rules

    Danger from shielding gas cylinders

    Shielding gas cylinders contain gas under pressure and can explode if damaged. As the shielding gas cylinders are part of the welding equipment, they must be handled with the greatest of care.

    Protect shielding gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked flames, sparks and arcs.

    Mount the shielding gas cylinders vertically and secure according to instructions to prevent them falling over.

    Keep the shielding gas cylinders well away from any welding or other electrical circuits.

    Never hang a welding torch on a shielding gas cylinder.

    Never touch a shielding gas cylinder with an electrode.

    Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.

    Only use shielding gas cylinders suitable for the application in hand, along with the correct and appropriate accessories (regulator, hoses and fittings). Only use shielding gas cylinders and accessories that are in good condition.

    Turn your face to one side when opening the valve of a shielding gas cylinder.

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

    If the shielding gas cylinder is not connected, leave the valve cap in place on the cylinder.

    The manufacturer's instructions must be observed as well as applicable national and international regulations for shielding gas cylinders and accessories.

    1. Safety rules

    Danger from escaping shielding gas

    Risk of suffocation from the uncontrolled escape of shielding gas

    Shielding gas is colourless and odourless and, in the event of a leak, can displace the oxygen in the ambient air.

    • Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/hour.
    • Observe safety and maintenance instructions on the shielding gas cylinder or the main gas supply.
    • Close the shielding gas cylinder valve or main gas supply if no welding is taking place.
    • Check the shielding gas cylinder or main gas supply for uncontrolled gas leakage before every start-up.
    1. Safety rules

    Safety measures at the installation location and during transport

    A device toppling over could easily kill someone. Place the device on a solid, level surface such that it remains stable
    • The maximum permissible tilt angle is 10°.
    Special regulations apply in rooms at risk of fire or explosion
    • Observe relevant national and international regulations.

    Use internal directives and checks to ensure that the workplace environment is always clean and clearly laid out.

    Only set up and operate the device in accordance with the degree of protection shown on the rating plate.

    When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft. 7.69 in.) to ensure that cooling air can flow in and out freely.

    When transporting the device, observe the relevant national and local guidelines and accident prevention regulations. This applies especially to guidelines regarding the risks arising during transport.

    Do not lift or transport operational devices. Switch off and disconnect devices from the grid before transport or lifting.

    Before transporting the device, allow coolant to drain completely and detach the following components:
    • Wirefeeder
    • Wirespool
    • Shielding gas cylinder

    After transporting the device, the device must be visually inspected for damage before commissioning. Any damage must be repaired by trained service technicians before commissioning the device.

    1. Safety rules

    Safety measures in normal operation

    Only operate the device when all safety devices are fully functional. If the safety devices are not fully functional, there is a risk of
    • injury or death to the operator or a third party
    • damage to the device and other material assets belonging to the operator
    • inefficient operation of the device

    Any safety devices that are not functioning properly must be repaired before switching on the device.

    Never bypass or disable safety devices.

    Before switching on the device, ensure that no one is likely to be endangered.

    Check the device at least once a week for obvious damage and proper functioning of safety devices.

    Always fasten the shielding gas cylinder securely and remove it beforehand if the device is to be transported by crane.

    Only the manufacturer's original coolant is suitable for use with our devices due to its properties (electrical conductibility, anti-freeze agent, material compatibility, flammability, etc.).

    Only use suitable original coolant from the manufacturer.

    Do not mix the manufacturer's original coolant with other coolants.

    Only connect the manufacturer's system components to the cooling circuit.

    The manufacturer accepts no liability for damage resulting from use of other system components or a different coolant. In addition, all warranty claims will be forfeited.

    Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under certain conditions. Transport the coolant only in its original, sealed containers and keep well away from any sources of ignition.

    Used coolant must be disposed of properly in accordance with the relevant national and international regulations. The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer's website.

    Check the coolant level before starting to weld, while the system is still cool.

    1. Safety rules

    Commissioning, maintenance and repair

    It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made of them, or that they satisfy safety requirements.

    • Use only original spare and wearing parts (also applies to standard parts).
    • Do not carry out any modifications, alterations, etc. to the device without the manufacturer's consent.
    • Components that are not in perfect condition must be replaced immediately.
    • When ordering, please give the exact designation and part number as shown in the spare parts list, as well as the serial number of your device.

    The housing screws provide the ground conductor connection for earthing the housing parts.
    Only use original housing screws in the correct number and tightened to the specified torque.

    1. Safety rules

    Safety inspection

    The manufacturer recommends that a safety inspection of the device be performed at least once every 12 months.

    The manufacturer recommends that the welding system be calibrated during the same 12-month period.

    A safety inspection should be carried out by a qualified electrician
    • after any changes are made
    • after any additional parts are installed, or after any conversions
    • after repair, care and maintenance are carried out
    • at least every twelve months.

    For safety inspections, follow the appropriate national and international standards and directives.

    Further details on safety inspection and calibration can be obtained from your service centre. They will provide you with any documents you may require, on request.

    1. Safety rules

    Disposal

    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. Correct disposal of the used device promotes sustainable recycling of resources and prevents negative effects on health and the environment.

    Packaging materials
    • Collect separately
    • Observe locally valid regulations
    • Compress the cardboard box to reduce volume
    1. Safety rules

    Sicherheitskennzeichnung

    Geräte mit CE-Kennzeichnung erfüllen die Anforderungen aller gültigen EU-Richtlinien, wie z. B.
    • Richtlinie 2014/30/EU über die elektromagnetische Verträglichkeit
    • Richtlinie 2014/35/EU Niederspannungs-Richtlinie
    • Richtlinie 2014/53/EU Funkanlagen-Richtlinie
    • EN IEC 60974 Lichtbogen-Schweißeinrichtungen
    • und weitere

    Der vollständige Text der EU-Konformitätserklärung ist unter
    https://www.fronius.com verfügbar.

    Geräte mit CSA-Kennzeichnung erfüllen die Anforderungen der relevanten Normen für Kanada und USA.

    1. Safety rules

    Data security

    With regard to data security, the user is responsible for:
    • backing up any changes made to the factory settings
    • saving and retaining personal settings
    1. Safety rules

    Copyright

    Copyright of these operating instructions remains with the manufacturer.

    Text and illustrations were accurate at the time of printing, subject to change.
    We are grateful for suggestions for improvement and information regarding any discrepancies in the operating instructions.

    1. Safety rules

    Description of the warning notices on the device

    For certain device versions, warning notices are affixed to the device.

    The arrangement of the symbols may vary.

    !
    Warning! Attention!
    The symbols represent possible dangers.
    A
    Drive rollers can injure fingers.
    B
    The welding wire and drive parts are live during operation.
    Keep hands and metal objects away!
    1.
    An electric shock can be fatal.
    1.1
    Wear dry, insulating gloves. Do not touch the wire electrode with bare hands. Do not wear wet or damaged gloves.
    1.2
    Use a base that is insulated from the floor and work area to protect against electric shock.
    1.3
    Before working on the device, switch off the device and pull out the mains plug or disconnect it from the power supply.
    2.
    Inhalation of welding fumes can be harmful to health.
    2.1
    Keep your face away from any welding fumes.
    2.2
    Use forced-air ventilation or a local extraction system to remove welding fumes.
    2.3
    Remove welding fumes with a fan.
    3
    Welding sparks can cause an explosion or fire.
    3.1
    Keep flammable materials away from the welding process. Never weld close to flammable materials.
    3.2
    Welding sparks can cause a fire. Have fire extinguishers to hand. If necessary, have a supervisor ready who can operate the fire extinguisher.
    3.3
    Do not weld on drums or closed containers.
    4.
    Arc rays can burn the eyes and injure the skin.
    4.1
    Wear headgear and protective goggles. Use ear protection and a shirt collar with button. Use a welding helmet with the correct tinting. Wear suitable protective clothing over the entire body.
    5.
    Before working on the system or welding:
    undertake training on the device and read the instructions!
    6.
    Do not remove or paint over the warning sticker.
    *
    Manufacturer order number of the sticker

    System configurations

    System configurations - conventional robot

    Push with wire drum

    (1)
    Wirefeeding hose with inner liner
    (2)
    TPSi welding machine
    (3)
    CU cooling unit
    (4)
    Upright console
    (5)
    HP interconnecting hosepack
    (6)
    Wirefeeder WF 15i R / WF 25i R / WF 30i R
    (7)
    MHP /i R torch hosepack
    (8)
    MTB /i R robot welding torch

    Maximum wirefeed length:
    max. 8 m between wire drum and wirefeeder
    (max. 10 m with PowerLiner)

    Possible wire diameters:
    0.8 - 2.0 mm

    Welding process:
    Standard, Puls, LSC, PMC

    *
    Use the largest inner liner (incl. basic kit)
    **
    Use the inner liner corresponding to the wire diameter (incl. basic kit)
    1. System configurations

    System configurations - conventional robot

    Push with wire drum

    (1)
    Wirefeeding hose with inner liner
    (2)
    TPSi welding machine
    (3)
    CU cooling unit
    (4)
    Upright console
    (5)
    HP interconnecting hosepack
    (6)
    Wirefeeder WF 15i R / WF 25i R / WF 30i R
    (7)
    MHP /i R torch hosepack
    (8)
    MTB /i R robot welding torch

    Maximum wirefeed length:
    max. 8 m between wire drum and wirefeeder
    (max. 10 m with PowerLiner)

    Possible wire diameters:
    0.8 - 2.0 mm

    Welding process:
    Standard, Puls, LSC, PMC

    *
    Use the largest inner liner (incl. basic kit)
    **
    Use the inner liner corresponding to the wire diameter (incl. basic kit)
    1. System configurations
    2. System configurations - conventional robot

    Push with wire drum

    (1)
    Wirefeeding hose with inner liner
    (2)
    TPSi welding machine
    (3)
    CU cooling unit
    (4)
    Upright console
    (5)
    HP interconnecting hosepack
    (6)
    Wirefeeder WF 15i R / WF 25i R / WF 30i R
    (7)
    MHP /i R torch hosepack
    (8)
    MTB /i R robot welding torch

    Maximum wirefeed length:
    max. 8 m between wire drum and wirefeeder
    (max. 10 m with PowerLiner)

    Possible wire diameters:
    0.8 - 2.0 mm

    Welding process:
    Standard, Puls, LSC, PMC

    *
    Use the largest inner liner (incl. basic kit)
    **
    Use the inner liner corresponding to the wire diameter (incl. basic kit)
    1. System configurations
    2. System configurations - conventional robot

    Push with wirespool

    (1)
    TPSi welding machine
    (2)
    CU cooling unit
    (3)
    Upright console
    (4)
    HP interconnecting hosepack
    (5)
    Wirefeeding hose with inner liner
    (6)
    Wirefeeder WF 15i R / WF 25i R / WF 30i R
    (7)
    MHP /i R torch hosepack
    (8)
    MTB /i R robot welding torch

    Maximum wirefeed length:
    max. 2 m between wirefeeder and wirespool

    Possible wire diameters:
    0.8 - 2.0 mm

    Welding process:
    Standard, Puls, LSC, PMC

    *
    Use the largest inner liner (incl. basic kit)
    **
    Use the inner liner corresponding to the wire diameter (incl. basic kit)
    1. System configurations
    2. System configurations - conventional robot

    Push with 4-roller unreeling wirefeeder and wire drum

    (1)
    Wirefeeding hose with inner liner
    (2)
    SpeedNet cable COM
    (3)
    Unreeling wirefeeder WV 25i Reel 4R
    (4)
    TPSi welding machine
    (5)
    CU cooling unit
    (6)
    Upright console
    (7)
    HP interconnecting hosepack
    (8)
    Wirefeeder WF 15i R / WF 25i R / WF 30i R
    (9)
    MHP /i R torch hosepack
    (10)
    MTB /i R robot welding torch
    Maximum wirefeed length:
    • max. 20 m between wirefeeder and unreeling wirefeeder
      (max. 30 m with PowerLiner)
    • max. 8 m between wire drum and unreeling wirefeeder
      (max. 10 m with PowerLiner)

    Possible wire diameters:
    0.8 - 2.0 mm

    Welding process:
    Standard, Puls, LSC, PMC

    *
    Use the largest inner liner (incl. basic kit)
    **
    Use the inner liner corresponding to the wire diameter (incl. basic kit)
    1. System configurations

    System configurations - PAP

    Push with wire drum

    (1)
    Wirefeeding hose with inner liner
    (2)
    TPSi welding machine
    (3)
    CU cooling unit
    (4)
    Upright console
    (5)
    HP interconnecting hosepack
    (6)
    Wirefeeder WF 15i R / WF 25i R / WF 30i R
    (7)
    MHP /i R torch hosepack
    (8)
    MTB /i R robot welding torch

    Maximum wirefeed length:
    max. 8 m between wire drum and wirefeeder
    (max. 10 m with PowerLiner)

    Possible wire diameters:
    0.8 - 2.0 mm

    Welding process:
    Standard, Puls, LSC, PMC

    *
    Use the largest inner liner (incl. basic kit)
    **
    Use the inner liner corresponding to the wire diameter (incl. basic kit)
    1. System configurations
    2. System configurations - PAP

    Push with wire drum

    (1)
    Wirefeeding hose with inner liner
    (2)
    TPSi welding machine
    (3)
    CU cooling unit
    (4)
    Upright console
    (5)
    HP interconnecting hosepack
    (6)
    Wirefeeder WF 15i R / WF 25i R / WF 30i R
    (7)
    MHP /i R torch hosepack
    (8)
    MTB /i R robot welding torch

    Maximum wirefeed length:
    max. 8 m between wire drum and wirefeeder
    (max. 10 m with PowerLiner)

    Possible wire diameters:
    0.8 - 2.0 mm

    Welding process:
    Standard, Puls, LSC, PMC

    *
    Use the largest inner liner (incl. basic kit)
    **
    Use the inner liner corresponding to the wire diameter (incl. basic kit)
    1. System configurations
    2. System configurations - PAP

    Push with wirespool

    (1)
    TPSi welding machine
    (2)
    CU cooling unit
    (3)
    Upright console
    (4)
    HP interconnecting hosepack
    (5)
    Wirefeeding hose with inner liner
    (6)
    Wirefeeder WF 15i R / WF 25i R / WF 30i R
    (7)
    MHP /i R torch hosepack
    (8)
    MTB /i R robot welding torch

    Maximum wirefeed length:
    max. 2 m between wirefeeder and wirespool

    Possible wire diameters:
    0.8 - 2.0 mm

    Welding process:
    Standard, Puls, LSC, PMC

    *
    Use the largest inner liner (incl. basic kit)
    **
    Use the inner liner corresponding to the wire diameter (incl. basic kit)
    1. System configurations
    2. System configurations - PAP

    Push with 4-roller unreeling wirefeeder and wire drum

    (1)
    Wirefeeding hose with inner liner
    (2)
    SpeedNet cable COM
    (3)
    Unreeling wirefeeder WV 25i Reel 4R
    (4)
    TPSi welding machine
    (5)
    CU cooling unit
    (6)
    Upright console
    (7)
    HP interconnecting hosepack
    (8)
    Wirefeeder WF 15i R / WF 25i R / WF 30i R
    (9)
    MHP /i R torch hosepack
    (10)
    MTB /i R robot welding torch
    Maximum wirefeed length:
    • max. 20 m between wirefeeder and unreeling wirefeeder
      (max. 30 m with PowerLiner)
    • max. 8 m between wire drum and unreeling wirefeeder
      (max. 10 m with PowerLiner)

    Possible wire diameters:
    0.8 - 2.0 mm

    Welding process:
    Standard, Puls, LSC, PMC

    *
    Use the largest inner liner (incl. basic kit)
    **
    Use the inner liner corresponding to the wire diameter (incl. basic kit)

    System components

    WF wire-feed unit

    Device concept

    The robot wirefeeders of the WF 15i/25i/30i R and R PAP series have been specifically designed for robot mounting.
    The wirefeeders are available in several different versions:

    WF 15i/25i/30i R:
    For applications in which the hosepack is externally mounted on the robot.

    WF 15i/25i/30i R PAP:
    For applications in which the hosepack is mounted in the robot arm.

    WF 25i R / L and 30i R / L:
    For applications in which the torch hosepack is connected to the wirefeeder from the left.

    1. System components

    WF wire-feed unit

    Device concept

    The robot wirefeeders of the WF 15i/25i/30i R and R PAP series have been specifically designed for robot mounting.
    The wirefeeders are available in several different versions:

    WF 15i/25i/30i R:
    For applications in which the hosepack is externally mounted on the robot.

    WF 15i/25i/30i R PAP:
    For applications in which the hosepack is mounted in the robot arm.

    WF 25i R / L and 30i R / L:
    For applications in which the torch hosepack is connected to the wirefeeder from the left.

    1. System components
    2. WF wire-feed unit

    Device concept

    The robot wirefeeders of the WF 15i/25i/30i R and R PAP series have been specifically designed for robot mounting.
    The wirefeeders are available in several different versions:

    WF 15i/25i/30i R:
    For applications in which the hosepack is externally mounted on the robot.

    WF 15i/25i/30i R PAP:
    For applications in which the hosepack is mounted in the robot arm.

    WF 25i R / L and 30i R / L:
    For applications in which the torch hosepack is connected to the wirefeeder from the left.

    1. System components
    2. WF wire-feed unit

    Proper use

    The device is designed exclusively for wirefeeding in automated MIG/MAG welding applications in conjunction with Fronius system 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.

    Utilisation in accordance with the intended purpose also comprises:

    • carefully reading these operating instructions
    • following all the instructions and safety rules in these operating instructions
    • performing all stipulated inspection and maintenance work
    1. System components
    2. WF wire-feed unit

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal 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.

    Read and understand this document in full.

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

    1. System components
    2. WF wire-feed unit

    Warning notices on the device

    The device is fitted with safety symbols and a rating plate. The safety symbols and rating plate must not be removed or painted over. The safety symbols warn against operating the equipment incorrectly, as this may result in serious injury and damage.

    Do not use the functions described here until you have fully read and understood the following documents:

    • These Operating Instructions
    • All the Operating Instructions for the system components, especially the safety rules

    Welding is dangerous. The following basic requirements must be met to ensure the equipment is used properly:

    • Anyone performing automated welding must be sufficiently qualified
    • Suitable protective equipment must be used
    • All persons not involved must be kept at a safe distance from the wirefeeder and the welding process

    Do not dispose of used devices with domestic waste. Dispose of them according to the safety rules.

    Keep hands, hair, clothing and tools away from moving parts. For example:

    • Cogs
    • Feed rollers
    • Wirespools and wire electrodes

    Do not reach into the rotating cogs of the wire drive or into rotating drive components.

    Covers and side panels may only be opened/removed while maintenance or repair work is being carried out.

    During operation
    • Ensure that all covers are closed and all side panels are fitted properly.
    • Keep all covers and side panels closed.
    1. System components

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

    Safety

    WARNING!

    Danger due to incorrect operation and incorrectly performed work.

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

    Fully read and understand these operating instructions before commissioning the unreeling wirefeeder.

    Fully read and understand the operating instructions of the welding machine being used.

    Fully read and understand the operating instructions for all other system components.

    Read and adhere to all safety rules and safety instructions in the above-mentioned documents.

    CAUTION!

    Danger from rotating drive parts if covers are open.

    This can result in injuries.

    When performing maintenance or set-up work, make sure that the drive components of the unreeling wirefeeder cannot be started by the welding machine, by a wirefeeder or by any other system extensions.

    1. System components
    2. WF 25i REEL R /4R, WF 30i REEL R /2R

    Safety

    WARNING!

    Danger due to incorrect operation and incorrectly performed work.

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

    Fully read and understand these operating instructions before commissioning the unreeling wirefeeder.

    Fully read and understand the operating instructions of the welding machine being used.

    Fully read and understand the operating instructions for all other system components.

    Read and adhere to all safety rules and safety instructions in the above-mentioned documents.

    CAUTION!

    Danger from rotating drive parts if covers are open.

    This can result in injuries.

    When performing maintenance or set-up work, make sure that the drive components of the unreeling wirefeeder cannot be started by the welding machine, by a wirefeeder or by any other system extensions.

    1. System components
    2. WF 25i REEL R /4R, WF 30i REEL R /2R

    Device concept

    The unreeling wirefeeder is an extra drive unit for ensuring constant and precision wirefeeding over large wirefeeding distances between the welding wire drum and the robot wirefeeder.
    While in operation, the unreeling wirefeeder is synchronised with the welding machine.
    It is supplied with power and controlled by the welding machine in the welding system.

    The unreeling wirefeeder is available in two versions:
    • WF 25i REEL R /4R
      Integrated version with 4-roller drive
    • WF 30i REEL R /2R
      Integrated version with 2-roller drive - not permitted in conjunction with a basket-type spool
    1. System components
    2. WF 25i REEL R /4R, WF 30i REEL R /2R

    Application area

    All indoor and automated MIG/MAG applications.

    1. System components
    2. WF 25i REEL R /4R, WF 30i REEL R /2R

    Proper use

    The device is designed exclusively for wirefeeding in automated MIG/MAG welding applications in conjunction with Fronius system 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.

    Utilisation in accordance with the intended purpose also comprises:

    • carefully reading these operating instructions
    • following all the instructions and safety rules in these operating instructions
    • performing all stipulated inspection and maintenance work
    1. System components
    2. WF 25i REEL R /4R, WF 30i REEL R /2R

    Warning notices on the device

    The device is fitted with safety symbols and a rating plate. The safety symbols and rating plate must not be removed or painted over. The safety symbols warn against operating the equipment incorrectly, as this may result in serious injury and damage.

    Example: WF 30i REEL R /2R/G/W

    Do not dispose of used devices with domestic waste. Dispose of them according to the safety rules.

    Welding is dangerous. The following basic requirements must be met to ensure the equipment is used properly:

    • Anyone performing automated welding must be sufficiently qualified
    • Suitable protective equipment must be used
    • All persons not involved must be kept at a safe distance from the wirefeeder and the welding process

    Do not use the functions described here until you have fully read and understood the following documents:

    • These Operating Instructions
    • All the Operating Instructions for the system components, especially the safety rules

    Keep hands, hair, clothing and tools away from moving parts. For example:

    • Cogs
    • Feed rollers
    • Wirespools and welding wires

    Do not reach into the rotating cogs of the wire drive or into rotating drive components.

    Covers and side panels may only be opened / removed while maintenance or repair work is being carried out.

    Wear eye protection

    1. System components

    Interconnecting hosepack

    General

    The interconnecting hosepack connects the welding machine to the wirefeeder. With the TPS/i welding system the interconnecting hosepack is available in two versions - one split and one standard variant.

    • 3 / 5 / 10 / 15 m (extension - split variant)
    • CON hosepacks 4 / 5.5 / 8 / 10 / 15 / 16 m (continuous variant)
    1. System components
    2. Interconnecting hosepack

    General

    The interconnecting hosepack connects the welding machine to the wirefeeder. With the TPS/i welding system the interconnecting hosepack is available in two versions - one split and one standard variant.

    • 3 / 5 / 10 / 15 m (extension - split variant)
    • CON hosepacks 4 / 5.5 / 8 / 10 / 15 / 16 m (continuous variant)
    1. System components

    Torch hosepack

    General remarks

    The Robacta MHP hosepack is designed for gas-cooled and water-cooled robot applications. It connects the TPS/i robot wirefeeders to the Robacta MTB robot welding torches.

    1. System components
    2. Torch hosepack

    General remarks

    The Robacta MHP hosepack is designed for gas-cooled and water-cooled robot applications. It connects the TPS/i robot wirefeeders to the Robacta MTB robot welding torches.

    1. System components
    2. Torch hosepack

    Scope of supply

    Robacta MHP PAP hosepack
    Robacta MHP conventional hosepack
    (1)
    Robacta MHP hosepack
    Not supplied:
    • Inner liners
    • Inlet nozzles
    1. System components
    2. Torch hosepack

    Buttons on the Robacta MHP hosepack

    Buttons on the Robacta MHP hosepack

    "Wire threading" and "wire retract" buttons are located on the Robacta MHP hosepack

    1. System components

    CrashBox /i

    General

    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 index disc.

    NOTE!

    Always adjust the holding force of the CrashBox to the system weight.

    Select the CrashBox size according to the following criteria:

    L:
    for push systems with a torch body length of up to 249 mm.

    XL:
    for push systems with a torch body length of up to 249 mm and with extension;
    for push systems with a torch body length of 250-391 mm;
    for push/pull systems with a torch body length of up to 249 mm.

    XXL:
    for push/pull systems with a torch body length of 250-391 mm;
    for push/pull systems with a torch body length of up to 249 mm and with extension.

    If there is a TX/i torch body change system or WireBrake in the welding system, select the next larger CrashBox.

    When cleaning the welding torch with the TC 2000, also select the next larger CrashBox.

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

    1. System components
    2. CrashBox /i

    General

    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 index disc.

    NOTE!

    Always adjust the holding force of the CrashBox to the system weight.

    Select the CrashBox size according to the following criteria:

    L:
    for push systems with a torch body length of up to 249 mm.

    XL:
    for push systems with a torch body length of up to 249 mm and with extension;
    for push systems with a torch body length of 250-391 mm;
    for push/pull systems with a torch body length of up to 249 mm.

    XXL:
    for push/pull systems with a torch body length of 250-391 mm;
    for push/pull systems with a torch body length of up to 249 mm and with extension.

    If there is a TX/i torch body change system or WireBrake in the welding system, select the next larger CrashBox.

    When cleaning the welding torch with the TC 2000, also select the next larger CrashBox.

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

    1. System components
    2. CrashBox /i

    Note on the correct operation of CrashBoxes

    NOTE!

    To avoid damage to the welding torch or the torch hosepack, or to prevent false triggering of the CrashBox, consider the following points:

    Avoid strong accelerations and maximum speeds during robot movements.

    Ensure the free movement of the torch hosepack during all robot movements;
    The torch hosepack must not tighten in any position and thus exert a strain on the CrashBox.

    The torch hosepack must not whip around or get stuck when moving.

    If possible, clarify all movement situations with Fronius system components in a simulation as early as the concept phase.

    1. System components
    2. CrashBox /i

    Also required for installation

    Depending on the particular robot:
    • 1 x robot flange with screws

    Robot flange as per price list

    Observe torques:

    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
    1. System components
    2. CrashBox /i

    Device concept

    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.

    1. System components
    2. CrashBox /i

    Application areas

    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
    1. System components
    2. CrashBox /i

    Information on repairing CrashBoxes

    NOTE!

    Only send complete CrashBoxes for repair!

    Incomplete CrashBoxes (e.g. without a magnetic ring) cannot be checked in the course of a repair.

    1. System components
    2. CrashBox /i

    Scope of supply

    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. System components
    2. CrashBox /i

    Clamp system scope of supply and options

    (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
    1. System components

    Robot welding torch

    Safety

    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

    1. System components
    2. Robot welding torch

    Safety

    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

    1. System components
    2. Robot welding torch

    General

    * Optional (no torch body)

    The robot welding torch transmits the arc power to the workpiece. The gas-cooled or water-cooled TPS /i 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

    TXi:
    Automatic torch body changeover

    TXM:
    Manual torch body changeover

    OPT CAM:
    Prepared for the camera mount option

    1. System components

    OPT/i camera mount

    General

    Application example of a mounted OPT/i camera mount (44,0350,0080)

    The OPT/i camera mount can be used to mount seam tracking systems, cameras or similar on the robot welding torch.
    The camera mount is fitted instead of the torch body union nut; the TCP remains the same.

    The seam tracking system or camera is protected by the CrashBox.
    The position of the mounted seam tracking system or camera is reproducible, as it is positioned with a dowel pin.

    Seam tracking system or camera can be mounted in six different places.

    The scope of supply of the OPT/i camera mount includes a mounting key (size 60 mm).

    1. System components
    2. OPT/i camera mount

    General

    Application example of a mounted OPT/i camera mount (44,0350,0080)

    The OPT/i camera mount can be used to mount seam tracking systems, cameras or similar on the robot welding torch.
    The camera mount is fitted instead of the torch body union nut; the TCP remains the same.

    The seam tracking system or camera is protected by the CrashBox.
    The position of the mounted seam tracking system or camera is reproducible, as it is positioned with a dowel pin.

    Seam tracking system or camera can be mounted in six different places.

    The scope of supply of the OPT/i camera mount includes a mounting key (size 60 mm).

    1. System components
    2. OPT/i camera mount

    Drilling template

    The following holes are provided as standard on the six surfaces of the OPT/i camera mount:
    • 4 M4 threaded holes with a depth of 9 mm
    • 2 holes Ø 4 mm G7, depth = 6 mm

    Controls, connections and mechanical components

    WFi R control elements and mechanical components

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal 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.

    Read and understand this document in full.

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

    1. Controls, connections and mechanical components

    WFi R control elements and mechanical components

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal 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.

    Read and understand this document in full.

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

    1. Controls, connections and mechanical components
    2. WFi R control elements and mechanical components

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal 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.

    Read and understand this document in full.

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

    1. Controls, connections and mechanical components
    2. WFi R control elements and mechanical components

    WFi R control elements and mechanical components

    No.Function
    (1)
    Cover
    (2)
    Clamping lever
    for setting the contact pressure of the feed rollers
    (3)
    4-roller drive
    (4)
    Protective cover for the 4-roller drive
    (5)
    Operating status LED +
    Gas-test / wire threading / wire retract buttons
    (option)

    The function of the wire retract, wire threading and gas-test buttons is described from page (→) onwards.

    1. Controls, connections and mechanical components

    WF 15i / 25i / 30i R

    WF 15i R, WF 30i R connections

    No.Function
    (1)
    Welding torch connection
    (2)
    Coolant connection
    For connecting the coolant connection socket from the interconnecting hosepack
    (3)
    Coolant connection socket
    For connecting to the torch hosepack
    (4)
    SpeedNet connection
    For connecting the SpeedNet cable from the interconnecting hosepack
    (5)
    Shielding gas connection
    (6)
    (+) current socket
    For connecting the power cable from the interconnecting hosepack
    (7)
    Wire infeed
    1. Controls, connections and mechanical components
    2. WF 15i / 25i / 30i R

    WF 15i R, WF 30i R connections

    No.Function
    (1)
    Welding torch connection
    (2)
    Coolant connection
    For connecting the coolant connection socket from the interconnecting hosepack
    (3)
    Coolant connection socket
    For connecting to the torch hosepack
    (4)
    SpeedNet connection
    For connecting the SpeedNet cable from the interconnecting hosepack
    (5)
    Shielding gas connection
    (6)
    (+) current socket
    For connecting the power cable from the interconnecting hosepack
    (7)
    Wire infeed
    1. Controls, connections and mechanical components
    2. WF 15i / 25i / 30i R

    WF 30i R / L connections

    No.Function
    (1)
    Wire infeed
    (2)
    (+) current socket
    For connecting the power cable from the interconnecting hosepack
    (3)
    Shielding gas connection
    (4)
    SpeedNet connection
    For connecting the SpeedNet cable from the interconnecting hosepack
    (5)
    Coolant connection socket
    For connecting to the torch hosepack
    (6)
    Coolant connection
    For connecting the coolant connection socket from the interconnecting hosepack
    (7)
    Welding torch connection
    1. Controls, connections and mechanical components
    2. WF 15i / 25i / 30i R

    WF 25i R connections

    No.Function
    (1)
    Welding torch connection
    (2)
    SpeedNet connection
    For connecting the SpeedNet cable from the interconnecting hosepack
    (3)
    Shielding gas connection
    (4)
    (+) current socket
    For connecting the power cable from the interconnecting hosepack
    (5)
    Wire infeed
    1. Controls, connections and mechanical components
    2. WF 15i / 25i / 30i R

    WF 25i R / L connections

    No.Function
    (1)
    Wire infeed
    (2)
    (+) current socket
    For connecting the power cable from the interconnecting hosepack
    (3)
    Shielding gas connection
    (4)
    SpeedNet connection
    For connecting the SpeedNet cable from the interconnecting hosepack
    (5)
    Welding torch connection
    1. Controls, connections and mechanical components

    WF 15i / 25i / 30i R PAP

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

    No.Function
    (1)
    Welding torch connection
    (2)
    (+) current socket
    For connecting the power cable from the interconnecting hosepack
    (3)
    Shielding gas connection
    (4)
    SpeedNet connection
    For connecting the SpeedNet cable from the interconnecting hosepack
    (5)
    Coolant connection
    For connecting the coolant connection socket from the interconnecting hosepack
    (6)
    Coolant connection socket
    For connecting to the torch hosepack
    (7)
    Wire infeed
    1. Controls, connections and mechanical components
    2. WF 15i / 25i / 30i R PAP

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

    No.Function
    (1)
    Welding torch connection
    (2)
    (+) current socket
    For connecting the power cable from the interconnecting hosepack
    (3)
    Shielding gas connection
    (4)
    SpeedNet connection
    For connecting the SpeedNet cable from the interconnecting hosepack
    (5)
    Coolant connection
    For connecting the coolant connection socket from the interconnecting hosepack
    (6)
    Coolant connection socket
    For connecting to the torch hosepack
    (7)
    Wire infeed
    1. Controls, connections and mechanical components
    2. WF 15i / 25i / 30i R PAP

    WF 25i R PAP connections

    No.Function
    (1)
    Welding torch connection
    (2)
    (+) current socket
    For connecting the power cable from the interconnecting hosepack
    (3)
    Shielding gas connection
    (4)
    SpeedNet connection
    For connecting the SpeedNet cable from the interconnecting hosepack
    (5)
    Wire infeed
    1. Controls, connections and mechanical components
    2. WF 15i / 25i / 30i R PAP

    WF 25i R / L PAP connections

    No.Function
    (1)
    SpeedNet connection
    For connecting the SpeedNet cable from the interconnecting hosepack
    (2)
    Shielding gas connection
    (3)
    (+) current socket
    For connecting the power cable from the interconnecting hosepack
    (4)
    Welding torch connection
    (5)
    Wire infeed
    1. Controls, connections and mechanical components

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

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal 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.

    Read and understand this document in full.

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

    1. Controls, connections and mechanical components
    2. WF 25i REEL R /4R, WF 30i REEL R /2R

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal 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.

    Read and understand this document in full.

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

    1. Controls, connections and mechanical components
    2. WF 25i REEL R /4R, WF 30i REEL R /2R

    Control elements, connections and mechanical components

    Front of WF 25i REEL R /4R/G/W
    Front of WF 30i REEL R /2R/G/W
    Left side
    Rear
    Top/underside
    No.Function
    (1)
    Cover
    (2)
    Protective cover for the 4-roller drive
    (3)
    4-roller drive
    (4)
    Protective cover for the 2-roller drive
    (5)
    2-roller drive
    (6)
    Opening for optional sash lock
    (7)
    Operating status LED + Gas-test / wire threading / wire retract buttons
    The function of the wire retract, wire threading and gas-test buttons is described from page (→) onwards.
    (8)
    SpeedNet connection
    (9)
    Blanking cover for optional component
    (10)
    Blanking cover for optional component
    (11)
    Blanking cover for optional component
    (12)
    M20 thread
    for connecting QuickConnect option
    (13)
    Wire infeed/outfeed tube
    Wire infeed (underside)
    Wire outfeed (upper side)

     

    1. Controls, connections and mechanical components

    Function of the gas-test, wire retract and wire threading buttons

    Function of the gas-test, wire retract and wire threading buttons

    Operating status LED

    Shows steady green when the device is ready for use

    Gas-test button

    After pressing the gas-test button, gas flows out for 30 seconds. Press the button again to stop the gas flow prematurely.

    Wire retract button

    The wire electrode can be retracted using one of two methods:

    Method 1
    Retracting the wire electrode at the preset wire retract speed:

    • Press and hold the wire retract button
    • The wire electrode will be retracted 1 mm (0.039 in.) after the wire retract button is pressed
    • After a short pause, the wirefeeder continues to retract the wire electrode. If the wire retract button remains pressed, the speed will increase every second at a rate of 10 m/min (393.70 ipm) until the preset wire retract speed is reached

    Method 2
    Retracting the wire electrode in 1 mm increments (0.039 in. increments)

    • Do not hold the wire retract button for more than 1 second (tap it)

    NOTE!

    Do not allow long lengths of wire electrode to be retracted, as the wire electrode is not wound onto the wirespool when retracted.

    NOTE!

    If there was a ground earth connection with the contact tip before the wire retract button was pressed, the wire electrode will be retracted when the button is pressed until it is short-circuit-free - it retracts by no more 10 mm (0.39 in.) with each press of the button.

    If the wire electrode still needs to be retracted, press the wire retract button again.

    Wire threading button

    Wire threading can be performed using one of two methods:

    Method 1
    Threading the wire electrode using the preset feeder inching speed:

    • Press and hold the wire threading button
    • The wire electrode will be threaded 1 mm (0.039 in.) after the wire threading button is pressed
    • After a short pause, the wirefeeder continues to thread the wire electrode. If the wire threading button remains pressed, the speed will increase every second at a rate of 10 m/min (393.70 ipm) until the preset feeder inching speed is reached
    • If the wire electrode comes into contact with a ground earth connection, the wirefeeding will be stopped and the wire electrode will be retracted again by 1 mm (0.039 in.)

    Method 2
    Threading the wire electrode in 1 mm increments (0.039 in. increments)

    • Do not press the wire threading button for more than 1 second (tap it)
    • If the wire electrode comes into contact with a ground earth connection, the wirefeeding will be stopped and the wire electrode will be retracted again by 1 mm (0.039 in.)

    NOTE!

    If there is a ground earth connection with the contact tip before the wire threading button is pressed, the wire electrode will be retracted when the button is pressed until it is short-circuit-free – it retracts by no more than 10 mm (0.39 in.) with each press of the button.

    If there is still a ground earth connection with the contact tip after 10 mm (0.39 in.) of wire retraction, pressing the wire threading button again will cause the wire electrode to be retracted again by a maximum of 10 mm (0.39 in.). The process will be repeated until there is no longer a ground earth connection with the contact tip.

    1. Controls, connections and mechanical components
    2. Function of the gas-test, wire retract and wire threading buttons

    Function of the gas-test, wire retract and wire threading buttons

    Operating status LED

    Shows steady green when the device is ready for use

    Gas-test button

    After pressing the gas-test button, gas flows out for 30 seconds. Press the button again to stop the gas flow prematurely.

    Wire retract button

    The wire electrode can be retracted using one of two methods:

    Method 1
    Retracting the wire electrode at the preset wire retract speed:

    • Press and hold the wire retract button
    • The wire electrode will be retracted 1 mm (0.039 in.) after the wire retract button is pressed
    • After a short pause, the wirefeeder continues to retract the wire electrode. If the wire retract button remains pressed, the speed will increase every second at a rate of 10 m/min (393.70 ipm) until the preset wire retract speed is reached

    Method 2
    Retracting the wire electrode in 1 mm increments (0.039 in. increments)

    • Do not hold the wire retract button for more than 1 second (tap it)

    NOTE!

    Do not allow long lengths of wire electrode to be retracted, as the wire electrode is not wound onto the wirespool when retracted.

    NOTE!

    If there was a ground earth connection with the contact tip before the wire retract button was pressed, the wire electrode will be retracted when the button is pressed until it is short-circuit-free - it retracts by no more 10 mm (0.39 in.) with each press of the button.

    If the wire electrode still needs to be retracted, press the wire retract button again.

    Wire threading button

    Wire threading can be performed using one of two methods:

    Method 1
    Threading the wire electrode using the preset feeder inching speed:

    • Press and hold the wire threading button
    • The wire electrode will be threaded 1 mm (0.039 in.) after the wire threading button is pressed
    • After a short pause, the wirefeeder continues to thread the wire electrode. If the wire threading button remains pressed, the speed will increase every second at a rate of 10 m/min (393.70 ipm) until the preset feeder inching speed is reached
    • If the wire electrode comes into contact with a ground earth connection, the wirefeeding will be stopped and the wire electrode will be retracted again by 1 mm (0.039 in.)

    Method 2
    Threading the wire electrode in 1 mm increments (0.039 in. increments)

    • Do not press the wire threading button for more than 1 second (tap it)
    • If the wire electrode comes into contact with a ground earth connection, the wirefeeding will be stopped and the wire electrode will be retracted again by 1 mm (0.039 in.)

    NOTE!

    If there is a ground earth connection with the contact tip before the wire threading button is pressed, the wire electrode will be retracted when the button is pressed until it is short-circuit-free – it retracts by no more than 10 mm (0.39 in.) with each press of the button.

    If there is still a ground earth connection with the contact tip after 10 mm (0.39 in.) of wire retraction, pressing the wire threading button again will cause the wire electrode to be retracted again by a maximum of 10 mm (0.39 in.). The process will be repeated until there is no longer a ground earth connection with the contact tip.

    Installation - conventional robot

    Fitting the welding system to a conventional robot

    Safety

    WARNING!

    Danger due to work that has been carried out incorrectly.

    This can result in serious injury and damage to property.

    The activities described below may only be carried out by trained and qualified personnel.

    The operating instructions for system components, particularly the chapter entitled "Safety rules", must be observed.

    WARNING!

    Danger from electric shocks.

    These can result in serious injury and death.

    Before starting the work described below, turn the mains switch on the welding machine to the "O" position.

    Disconnect the welding machine from the grid.

    Ensure that the welding machine remains disconnected from the grid until all work has been completed.

    WARNING!

    Danger from falling objects.

    This can result in serious injury and damage to property.

    Check all the screw connections described below after fitting to ensure they are tight.

    Check after abnormal operating situations (e.g. after a crash) to ensure screw connections are tight.

    Check screw connections regularly to ensure they are tight.

    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.

    CAUTION!

    Danger from escaping coolant.

    This can result in damage to property.

    Switch off the cooling unit during maintenance activities or when replacing components and wear parts.

    The cooling system must be depressurised while the maintenance work is being carried out.

    NOTE!

    Performing maintenance on the active robot welding system is only permitted in Working mode 17 .

     

    Move the robot to a suitable position to allow water-cooled components and wear parts to be changed.

    1. Installation - conventional robot

    Fitting the welding system to a conventional robot

    Safety

    WARNING!

    Danger due to work that has been carried out incorrectly.

    This can result in serious injury and damage to property.

    The activities described below may only be carried out by trained and qualified personnel.

    The operating instructions for system components, particularly the chapter entitled "Safety rules", must be observed.

    WARNING!

    Danger from electric shocks.

    These can result in serious injury and death.

    Before starting the work described below, turn the mains switch on the welding machine to the "O" position.

    Disconnect the welding machine from the grid.

    Ensure that the welding machine remains disconnected from the grid until all work has been completed.

    WARNING!

    Danger from falling objects.

    This can result in serious injury and damage to property.

    Check all the screw connections described below after fitting to ensure they are tight.

    Check after abnormal operating situations (e.g. after a crash) to ensure screw connections are tight.

    Check screw connections regularly to ensure they are tight.

    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.

    CAUTION!

    Danger from escaping coolant.

    This can result in damage to property.

    Switch off the cooling unit during maintenance activities or when replacing components and wear parts.

    The cooling system must be depressurised while the maintenance work is being carried out.

    NOTE!

    Performing maintenance on the active robot welding system is only permitted in Working mode 17 .

     

    Move the robot to a suitable position to allow water-cooled components and wear parts to be changed.

    1. Installation - conventional robot
    2. Fitting the welding system to a conventional robot

    Safety

    WARNING!

    Danger due to work that has been carried out incorrectly.

    This can result in serious injury and damage to property.

    The activities described below may only be carried out by trained and qualified personnel.

    The operating instructions for system components, particularly the chapter entitled "Safety rules", must be observed.

    WARNING!

    Danger from electric shocks.

    These can result in serious injury and death.

    Before starting the work described below, turn the mains switch on the welding machine to the "O" position.

    Disconnect the welding machine from the grid.

    Ensure that the welding machine remains disconnected from the grid until all work has been completed.

    WARNING!

    Danger from falling objects.

    This can result in serious injury and damage to property.

    Check all the screw connections described below after fitting to ensure they are tight.

    Check after abnormal operating situations (e.g. after a crash) to ensure screw connections are tight.

    Check screw connections regularly to ensure they are tight.

    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.

    CAUTION!

    Danger from escaping coolant.

    This can result in damage to property.

    Switch off the cooling unit during maintenance activities or when replacing components and wear parts.

    The cooling system must be depressurised while the maintenance work is being carried out.

    NOTE!

    Performing maintenance on the active robot welding system is only permitted in Working mode 17 .

     

    Move the robot to a suitable position to allow water-cooled components and wear parts to be changed.

    1. Installation - conventional robot
    2. Fitting the welding system to a conventional robot

    Fitting the TPS/i welding system to a conventional robot

    Individual components must be fitted to the robot in the following order:
    1. Wire-feed unit - the wirefeeder holder and the side arm holder must be fitted first
    2. CrashBox /i
    3. Clamp system
    4. Torch hosepack
    5. Robot welding torch
    6. Interconnecting hosepack
    1. Installation - conventional robot

    Fitting the wire-feed unit

    Fitting the wirefeeder holder

    NOTE!

    Depending on the robot, please also note the instructions and information on installing the wirefeeder in the User Information.

    1. Installation - conventional robot
    2. Fitting the wire-feed unit

    Fitting the wirefeeder holder

    NOTE!

    Depending on the robot, please also note the instructions and information on installing the wirefeeder in the User Information.

    1. Installation - conventional robot
    2. Fitting the wire-feed unit

    Fitting the wirefeeder

    1
    2
    3
    Example: WF 25i R

    NOTE!

    The coolant line must be routed under the wirefeeder.

    To do so, the wirefeeder must be removed from the holder and re-fitted after the line has been routed.



    1. Installation - conventional robot

    Fitting the CrashBox /i to the robot

    Fitting the CrashBox /i to the robot

    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. Installation - conventional robot
    2. Fitting the CrashBox /i to the robot

    Fitting the CrashBox /i to the robot

    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. Installation - conventional robot
    2. Fitting the CrashBox /i to the robot

    Installing the CrashBox/i Dummy on the robot

    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
    1. Installation - conventional robot

    Fitting the clamp system

    Special tilt angle for the welding torch

    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. Installation - conventional robot
    2. Fitting the clamp system

    Special tilt angle for the welding torch

    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. Installation - conventional robot
    2. Fitting the clamp system

    Fitting the clamp system

    1
    2
    1. Installation - conventional robot
    2. Fitting the clamp system

    Fitting the clamp system with extension

    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. Installation - conventional robot

    Fitting the MHP G / W hosepack

    Fitting the MHP G / W conventional hosepack - Standard

    1
    2
    3
    4
    1. Installation - conventional robot
    2. Fitting the MHP G / W hosepack

    Fitting the MHP G / W conventional hosepack - Standard

    1
    2
    3
    4
    1. Installation - conventional robot
    2. Fitting the MHP G / W hosepack

    Optimum hosepack arrangement

    1. Installation - conventional robot

    Fitting the TPS/i torch neck

    Safety

    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

    1. Installation - conventional robot
    2. Fitting the TPS/i torch neck

    Safety

    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

    1. Installation - conventional robot
    2. Fitting the TPS/i torch neck

    Fitting the TPS/i torch body - Standard

    Special tool required


    NOTE!

    Performing maintenance on the active robot welding system is only permitted in the "Stop" coolant pump service position - Working mode 17.

     

    Move the robot to a suitable position to allow water-cooled components and wear parts to be changed.

    IMPORTANT! Whenever the welding torch is fitted or removed, ensure that the coupling point is clean and dry. Remove any coolant that has escaped from the coupling point.

    1
    2
    1. Installation - conventional robot
    2. Fitting the TPS/i torch neck

    “OPT / i MHP WireBrake” option

    If you would like to fit the “OPT / i MHP WireBrake” option, read the “Fitting the OPT / i MHP WireBrake and torch body” chapter.

    1. Installation - conventional robot
    2. Fitting the TPS/i torch neck

    Fitting the inner liner inside the torch hosepack

    NOTE!

    Ensure that the hosepack is straight when fitting the inner liner, otherwise the liner might not be inserted correctly.

    1
    2
    3
    4
    5
    1. Installation - conventional robot

    Fitting the interconnecting hosepack

    Fitting the Standard interconnecting hosepack to the robot

    1
    2
    1. Installation - conventional robot
    2. Fitting the interconnecting hosepack

    Fitting the Standard interconnecting hosepack to the robot

    1
    2
    1. Installation - conventional robot
    2. Fitting the interconnecting hosepack

    Connecting the extension hosepack

    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.

    Check that they are tight at least every three months.

    1
    *
    Only on water-cooled hosepack
    CON
    = Interconnecting hosepack
    EXT
    = Extension hosepack

    Connect all connections so they are hand-tight.
    Check for tightness.

    Tightening the power connection hand-tight corresponds to 7-8 Nm.



    2

    If the components are not bundled in the protective bag, all interfaces must be fixed so they are immovable.

    NOTE!

    Reduced service life at a bending radius of r < 200 mm.

    Note the bending radius.

    Do not use a bending radius smaller than r = 200 mm.

    NOTE!

    Note the current load.

    Dimensioning of the correct hosepack according to the following table:

    Welding current
    40% d.c. / 40 °C

    Cross-section up to 10 m

    Cross-section up to 50 m

     

     

     

    150 A

    16 mm²

    25 mm²

    200 A

    25 mm²

    35 mm²

    250 A

    35 mm²

    50 mm²

    300 A

    50 mm²

    70 mm²

    400 A

    70 mm²

    95 mm²

    500 A

    95 mm²

    120 mm²

    600 A

    120 mm²

    120 mm²

    1. Installation - conventional robot

    Connecting the MHP W hosepack

    Connecting the MHP W hosepack

    IMPORTANT! Whenever the torch hosepack is fitted or removed, ensure that the coupling point is clean and dry. Remove any coolant that has escaped from the coupling point.

    1
    2
    3
    4
    * Push in hosepack as far as it will go
    5
    6

    IMPORTANT! Always route coolant hoses below the hosepack and then guide them to the connection socket:

    WFi R / SB 500i
    SB 60i
    7
    (1)
    Coolant return (red)
    (2)
    Coolant flow (blue)

    IMPORTANT! Connect the coolant hoses to the cooling unit correctly!

    Disconnecting the coolant hoses

    1
    2
    3
    1. Installation - conventional robot
    2. Connecting the MHP W hosepack

    Connecting the MHP W hosepack

    IMPORTANT! Whenever the torch hosepack is fitted or removed, ensure that the coupling point is clean and dry. Remove any coolant that has escaped from the coupling point.

    1
    2
    3
    4
    * Push in hosepack as far as it will go
    5
    6

    IMPORTANT! Always route coolant hoses below the hosepack and then guide them to the connection socket:

    WFi R / SB 500i
    SB 60i
    7
    (1)
    Coolant return (red)
    (2)
    Coolant flow (blue)

    IMPORTANT! Connect the coolant hoses to the cooling unit correctly!

    Disconnecting the coolant hoses

    1
    2
    3
    1. Installation - conventional robot

    Connecting wire-feed unit to system components

    Safety

    WARNING!

    Danger from electric current.

    This can result in serious injury and damage to property.

    Before starting the work described below, turn the mains switch on the welding machine to the "O" position.

    Disconnect the welding machine from the grid.

    Ensure that the welding machine remains disconnected from the grid until all work has been completed.

    CAUTION!

    Risk of injury and damage from loose connections.

    All cables, leads and hosepacks must be properly connected, undamaged, correctly insulated and adequately dimensioned.

    1. Installation - conventional robot
    2. Connecting wire-feed unit to system components

    Safety

    WARNING!

    Danger from electric current.

    This can result in serious injury and damage to property.

    Before starting the work described below, turn the mains switch on the welding machine to the "O" position.

    Disconnect the welding machine from the grid.

    Ensure that the welding machine remains disconnected from the grid until all work has been completed.

    CAUTION!

    Risk of injury and damage from loose connections.

    All cables, leads and hosepacks must be properly connected, undamaged, correctly insulated and adequately dimensioned.

    1. Installation - conventional robot
    2. Connecting wire-feed unit to system components

    General

    NOTE!

    Also follow the instructions and information in the documents 42,0410,1946 and 42,0410,2010 when connecting the wirefeeder to the system components.

    1. Installation - conventional robot
    2. Connecting wire-feed unit to system components

    Connecting the wirefeeder to the system components

    IMPORTANT! The coolant line must be routed under the wirefeeder.
    To do so, the wirefeeder must be removed from the holder and re-fitted after the line has been routed.

    IMPORTANT! Whenever the torch hosepack is fitted or removed, ensure that the coupling point is clean and dry. Remove any coolant that has escaped from the coupling point.

    WF 15i / 25i / 30i R:

    1
    2
    WF 15i / 30i R
    2
    WF 25i R

    WF 25i / 30i R/L:

    1
    2
    WF 30i R / L
    2
    WF 25i R / L
    3
    4

    IMPORTANT! After disconnecting the coolant connection from the hosepack, close the coolant connections on the hosepack using the hosepack's seal cap.

    1. Installation - conventional robot

    Fitting the OPT / i MHP WireBrake and torch body

    Safety

    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

    1. Installation - conventional robot
    2. Fitting the OPT / i MHP WireBrake and torch body

    Safety

    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

    1. Installation - conventional robot
    2. Fitting the OPT / i MHP WireBrake and torch body

    Prerequisites for operation

    NOTE!

    OPT/i MHP WireBrake only secures a wire electrode if a torch body is correctly fitted to the OPT/i MHP WireBrake.

    System requirements:
    The wirefeeder of the WF 15i / 25i / 30i R (PAP) series
    +
    OPT/i WF 16 bar gas purging option (4,100,867,CK).

    The OPT/i MHP WireBrake option operates at 6 or 16 bar.

    NOTE!

    To ensure that the WireBrake option functions correctly, wait for 4 seconds after deactivating the "WireBrake on" signal before activating another signal.

    1. Installation - conventional robot
    2. Fitting the OPT / i MHP WireBrake and torch body

    Compressed air supply specifications

    The compressed air supply of the OPT/i MHP WireBrake is provided through the hosepack.

    Observe the following specifications:

    • Compressed air supply of at least 5 bar (72 psi)
    • Compressed air supply for aluminium max. 7 bar (102 psi), for all other materials max. 16 bar (232 psi)
    • Compressed air is free of oil
    • Compressed air is free of dust – no dirt particles larger than 5 mm
    • Compressed air is free of water

    Recommendation: use a filter unit with a pressure regulator.

    1. Installation - conventional robot
    2. Fitting the OPT / i MHP WireBrake and torch body

    Remedying the clamping marks on the wire electrode

    NOTE!

    When securing the wire electrode in the OPT/i MHP WireBrake, small clamping marks can occur on the wire electrode.

    To remedy the clamping marks, cut off the wire electrode after securing.

    Calculation of the cut-off point = torch body length + 50 mm (1.97 in.)

    1. Installation - conventional robot
    2. Fitting the OPT / i MHP WireBrake and torch body

    Technical data

    TCP offset

    47 mm
    1.85 in.

    Wire diameter

    0.8 - 1.6 mm
    0.03 - 0.06 in.

    Weight

    450 g
    0.99 Ib.

    1. Installation - conventional robot
    2. Fitting the OPT / i MHP WireBrake and torch body

    Fitting the OPT/i MHP WireBrake

    1
    2
    3
    4

    NOTE!

    The front O-ring must only be removed at a system pressure of > 5.5 bar / 79.74 psi (step 3).

    At a system pressure of < 5.5 bar / 79.74 psi, the second O-ring remains on the WireBrake option.

    For steel inner liners:
    5
    6
    For plastic inner liners:
    5
    6
    1. Installation - conventional robot

    Removing the OPT / i MHP WireBrake and torch body

    Safety

    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

    1. Installation - conventional robot
    2. Removing the OPT / i MHP WireBrake and torch body

    Safety

    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

    1. Installation - conventional robot
    2. Removing the OPT / i MHP WireBrake and torch body

    Removing the OPT / i MHP WireBrake and torch body

    1
    2
    3
    1. Installation - conventional robot

    Fitting the unreeling wirefeeder

    Fitting the unreeling wirefeeder

    WARNING!

    Danger from electric current.

    This can result in serious injury and damage to property.

    Before starting the work described below, turn the mains switch on the welding machine to the "O" position.

    Disconnect the welding machine from the grid.

    Ensure that the welding machine remains disconnected from the grid until all work has been completed.

    Ensure that the unreeling wirefeeder is fitted in the correct direction. The threading direction of the wire electrode is marked with an arrow.

    The unreeling wirefeeder is designed exclusively for vertical installation on the following mounts:

    • WF Mounting WALL 4,100,846
    • WF Mounting Drum 4,100,845

    Operating a 2-roller WF30i REEL R /2R unreeling wirefeeder with a basket-type spool is not permitted.

    1In accordance with the installation instructions, mount the unreeling wirefeeder onto the wall bracket or the wire drum mount
    2Use the QuickConnect option to connect the wirefeeding hose to the unreeling wirefeeder
    3Use Fronius SpeedNet to connect the unreeling wirefeeder to the welding machine in the welding system
    1. Installation - conventional robot
    2. Fitting the unreeling wirefeeder

    Fitting the unreeling wirefeeder

    WARNING!

    Danger from electric current.

    This can result in serious injury and damage to property.

    Before starting the work described below, turn the mains switch on the welding machine to the "O" position.

    Disconnect the welding machine from the grid.

    Ensure that the welding machine remains disconnected from the grid until all work has been completed.

    Ensure that the unreeling wirefeeder is fitted in the correct direction. The threading direction of the wire electrode is marked with an arrow.

    The unreeling wirefeeder is designed exclusively for vertical installation on the following mounts:

    • WF Mounting WALL 4,100,846
    • WF Mounting Drum 4,100,845

    Operating a 2-roller WF30i REEL R /2R unreeling wirefeeder with a basket-type spool is not permitted.

    1In accordance with the installation instructions, mount the unreeling wirefeeder onto the wall bracket or the wire drum mount
    2Use the QuickConnect option to connect the wirefeeding hose to the unreeling wirefeeder
    3Use Fronius SpeedNet to connect the unreeling wirefeeder to the welding machine in the welding system
    1. Installation - conventional robot

    Fitting the OPT/i camera mount

    Load-bearing capacity of the OPT/i camera mount

    CAUTION!

    Danger due to mechanical overload of the system components

    This can result in injury and damage to property.

    Load the OPT/i camera mount with a maximum of 1.5 kg.

    Always observe the relationship between weight and mounting distance shown below.

    1. Installation - conventional robot
    2. Fitting the OPT/i camera mount

    Load-bearing capacity of the OPT/i camera mount

    CAUTION!

    Danger due to mechanical overload of the system components

    This can result in injury and damage to property.

    Load the OPT/i camera mount with a maximum of 1.5 kg.

    Always observe the relationship between weight and mounting distance shown below.

    1. Installation - conventional robot
    2. Fitting the OPT/i camera mount

    Safety

    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

    1. Installation - conventional robot
    2. Fitting the OPT/i camera mount

    Fitting the OPT/i camera mount

    1
    2
    3
    4

    Installation - PAP

    Axis rotation and service life of the torch hosepack

    General

    In addition to environmental and operating conditions, the service life of the PAP welding torch hosepack is heavily influenced by the axis rotation in the fifth and sixth robot axis.

    For details, see the following sections:

    • Recommended axis rotation
    • Maximum axis rotation
    • Hosepack service life depending on the axis rotation in the fifth and sixth robot axis
    1. Installation - PAP

    Axis rotation and service life of the torch hosepack

    General

    In addition to environmental and operating conditions, the service life of the PAP welding torch hosepack is heavily influenced by the axis rotation in the fifth and sixth robot axis.

    For details, see the following sections:

    • Recommended axis rotation
    • Maximum axis rotation
    • Hosepack service life depending on the axis rotation in the fifth and sixth robot axis
    1. Installation - PAP
    2. Axis rotation and service life of the torch hosepack

    General

    In addition to environmental and operating conditions, the service life of the PAP welding torch hosepack is heavily influenced by the axis rotation in the fifth and sixth robot axis.

    For details, see the following sections:

    • Recommended axis rotation
    • Maximum axis rotation
    • Hosepack service life depending on the axis rotation in the fifth and sixth robot axis
    1. Installation - PAP
    2. Axis rotation and service life of the torch hosepack

    Recommended axis rotation

    NOTE!

    The PAP welding torch hosepack reaches its optimal service life when operated within the recommended axis rotations.

    Any axis rotation beyond these limits accelerates wear and thus reduces the service life of the PAP torch hosepack.

    The expected hosepack service life is shown in the diagram "Hosepack service life depending on the axis rotation in the fifth and sixth robot axis" starting on page (→).

    (4)
    Fourth robot axis: +/- 175°
    (5)
    Fifth robot axis: +/- 90°
    (6)
    Sixth robot axis: +/- 200°
    (4)+(6)
    Fourth + sixth robot axis: +/- 360° in total.
    1. Installation - PAP
    2. Axis rotation and service life of the torch hosepack

    Maximum axis rotation

    NOTE!

    Operating at the maximum values of the axis rotations reduces the service life of the PAP welding torch hosepack.

    The expected hosepack service life is shown in the diagram "Hosepack service life depending on the axis rotation in the fifth and sixth robot axis" starting on page (→).

    Operating outside the limits invalidates any warranty claim.

       Maximum axis rotations reduce the hosepack service life.

    (4)
    Fourth robot axis: +/- 175°
    (5)
    Fifth robot axis: +/- 120°
    (6)
    Sixth robot axis: +/- 360°
    (4)+(6)
    Fourth + sixth robot axis: max. +/- 535° in total.
    1. Installation - PAP
    2. Axis rotation and service life of the torch hosepack

    Hosepack service life depending on the axis rotation in the fifth and sixth robot axis

    RLT = relative service life [%], ± AR6 = axis rotation in the sixth robot axis [°]

       = recommended axis rotation in the sixth robot axis

    Example:
    With an axis rotation in the sixth robot axis of 280° and at a tilt angle of 90° in the fifth robot axis, the relative service life of the hosepack is 76-77%.

    IMPORTANT! The values specified in the diagram are standard values that may vary depending on the environmental and operating conditions.
    The values were determined at an axis rotation of 0° in the fourth robot axis.

    1. Installation - PAP

    Fitting the welding system to a PAP robot

    Safety

    WARNING!

    Danger due to work that has been carried out incorrectly.

    This can result in serious injury and damage to property.

    The activities described below may only be carried out by trained and qualified personnel.

    The operating instructions for system components, particularly the chapter entitled "Safety rules", must be observed.

    WARNING!

    Danger from electric shocks.

    These can result in serious injury and death.

    Before starting the work described below, turn the mains switch on the welding machine to the "O" position.

    Disconnect the welding machine from the grid.

    Ensure that the welding machine remains disconnected from the grid until all work has been completed.

    WARNING!

    Danger from falling objects.

    This can result in serious injury and damage to property.

    Check all the screw connections described below after fitting to ensure they are tight.

    Check after abnormal operating situations (e.g. after a crash) to ensure screw connections are tight.

    Check screw connections regularly to ensure they are tight.

    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.

    CAUTION!

    Danger from escaping coolant.

    This can result in damage to property.

    Switch off the cooling unit during maintenance activities or when replacing components and wear parts.

    The cooling system must be depressurised while the maintenance work is being carried out.

    NOTE!

    Performing maintenance on the active robot welding system is only permitted in Working mode 17 .

     

    Move the robot to a suitable position to allow water-cooled components and wear parts to be changed.

    1. Installation - PAP
    2. Fitting the welding system to a PAP robot

    Safety

    WARNING!

    Danger due to work that has been carried out incorrectly.

    This can result in serious injury and damage to property.

    The activities described below may only be carried out by trained and qualified personnel.

    The operating instructions for system components, particularly the chapter entitled "Safety rules", must be observed.

    WARNING!

    Danger from electric shocks.

    These can result in serious injury and death.

    Before starting the work described below, turn the mains switch on the welding machine to the "O" position.

    Disconnect the welding machine from the grid.

    Ensure that the welding machine remains disconnected from the grid until all work has been completed.

    WARNING!

    Danger from falling objects.

    This can result in serious injury and damage to property.

    Check all the screw connections described below after fitting to ensure they are tight.

    Check after abnormal operating situations (e.g. after a crash) to ensure screw connections are tight.

    Check screw connections regularly to ensure they are tight.

    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.

    CAUTION!

    Danger from escaping coolant.

    This can result in damage to property.

    Switch off the cooling unit during maintenance activities or when replacing components and wear parts.

    The cooling system must be depressurised while the maintenance work is being carried out.

    NOTE!

    Performing maintenance on the active robot welding system is only permitted in Working mode 17 .

     

    Move the robot to a suitable position to allow water-cooled components and wear parts to be changed.

    1. Installation - PAP
    2. Fitting the welding system to a PAP robot

    Fitting the TPS/i welding system to a PAP robot

    Individual components must be fitted to the robot in the following order:
    1. Wire-feed unit - the wirefeeder holder and the side arm holder must be fitted first
    2. CrashBox /i
    3. Torch hosepack
    4. Robot welding torch
    5. Interconnecting hosepack
    1. Installation - PAP

    Fitting the wire-feed unit

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

    1
    2
    3
    4
    1. Installation - PAP
    2. Fitting the wire-feed unit

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

    1
    2
    3
    4
    1. Installation - PAP

    Installing the CrashBox /i PAP on the robot

    Installing the CrashBox /i PAP on the robot

    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. Installation - PAP
    2. Installing the CrashBox /i PAP on the robot

    Installing the CrashBox /i PAP on the robot

    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. Installation - PAP
    2. Installing the CrashBox /i PAP on the robot

    Installing the CrashBox/i Dummy on the robot

    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
    1. Installation - PAP

    Fitting the MHPi/MHP S G/W PAP hosepack

    Fitting the Robacta MHP G/W PAP hosepack

    Special tool required


    IMPORTANT! Whenever the welding torch is fitted or removed, ensure that the coupling point is clean and dry. Remove any coolant that has escaped from the coupling point.

    1
    2
    3
    4
    5
    6
    7
    8
    9
    10
    1. Installation - PAP
    2. Fitting the MHPi/MHP S G/W PAP hosepack

    Fitting the Robacta MHP G/W PAP hosepack

    Special tool required


    IMPORTANT! Whenever the welding torch is fitted or removed, ensure that the coupling point is clean and dry. Remove any coolant that has escaped from the coupling point.

    1
    2
    3
    4
    5
    6
    7
    8
    9
    10
    1. Installation - PAP
    2. Fitting the MHPi/MHP S G/W PAP hosepack

    “OPT / i MHP WireBrake” option

    If you would like to fit the “OPT / i MHP WireBrake” option, read the “Fitting the OPT / i MHP WireBrake and torch body” chapter.

    1. Installation - PAP
    2. Fitting the MHPi/MHP S G/W PAP hosepack

    Fitting the inner liner inside the torch hosepack

    NOTE!

    Ensure that the hosepack is straight when fitting the inner liner, otherwise the liner might not be inserted correctly.

    1
    2
    3
    4
    5
    1. Installation - PAP

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

    Fitting the Robacta MHP G/W PAP SM hosepack

    Special tool required


    IMPORTANT! Whenever the welding torch is fitted or removed, ensure that the coupling point is clean and dry. Remove any coolant that has escaped from the coupling point.

    1
    2
    3
    4
    5
    6
    7
    8
    9
    1. Installation - PAP
    2. Fitting the MHPi/MHP S G/W PAP SM hosepack

    Fitting the Robacta MHP G/W PAP SM hosepack

    Special tool required


    IMPORTANT! Whenever the welding torch is fitted or removed, ensure that the coupling point is clean and dry. Remove any coolant that has escaped from the coupling point.

    1
    2
    3
    4
    5
    6
    7
    8
    9
    1. Installation - PAP
    2. Fitting the MHPi/MHP S G/W PAP SM hosepack

    “OPT / i MHP WireBrake” option

    If you would like to fit the “OPT / i MHP WireBrake” option, read the “Fitting the OPT / i MHP WireBrake and torch body” chapter.

    1. Installation - PAP
    2. Fitting the MHPi/MHP S G/W PAP SM hosepack

    Fitting the inner liner inside the torch hosepack

    NOTE!

    Ensure that the hosepack is straight when fitting the inner liner, otherwise the liner might not be inserted correctly.

    1
    2
    3
    4
    5
    1. Installation - PAP

    Fitting the interconnecting hosepack

    Fitting the PAP interconnecting hosepack to the robot

    NOTE!

    The mounting of the holder for the interconnecting hosepack depends on the robot manufacturer and robot type.

    Mount the holder for the interconnecting hosepack according to the Installation Instructions for the respective robot.

    1
    2
    3Lay the interconnecting hosepack in the clamps
    4Close the clamps
    1. Installation - PAP
    2. Fitting the interconnecting hosepack

    Fitting the PAP interconnecting hosepack to the robot

    NOTE!

    The mounting of the holder for the interconnecting hosepack depends on the robot manufacturer and robot type.

    Mount the holder for the interconnecting hosepack according to the Installation Instructions for the respective robot.

    1
    2
    3Lay the interconnecting hosepack in the clamps
    4Close the clamps
    1. Installation - PAP
    2. Fitting the interconnecting hosepack

    Connecting the extension hosepack

    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.

    Check that they are tight at least every three months.

    1
    *
    Only on water-cooled hosepack
    CON
    = Interconnecting hosepack
    EXT
    = Extension hosepack

    Connect all connections so they are hand-tight.
    Check for tightness.

    Tightening the power connection hand-tight corresponds to 7-8 Nm.



    2

    If the components are not bundled in the protective bag, all interfaces must be fixed so they are immovable.

    NOTE!

    Reduced service life at a bending radius of r < 200 mm.

    Note the bending radius.

    Do not use a bending radius smaller than r = 200 mm.

    NOTE!

    Note the current load.

    Dimensioning of the correct hosepack according to the following table:

    Welding current
    40% d.c. / 40 °C

    Cross-section up to 10 m

    Cross-section up to 50 m

     

     

     

    150 A

    16 mm²

    25 mm²

    200 A

    25 mm²

    35 mm²

    250 A

    35 mm²

    50 mm²

    300 A

    50 mm²

    70 mm²

    400 A

    70 mm²

    95 mm²

    500 A

    95 mm²

    120 mm²

    600 A

    120 mm²

    120 mm²

    1. Installation - PAP
    2. Fitting the interconnecting hosepack

    Connecting the interconnecting hosepack



    1. Installation - PAP

    Connecting wire-feed unit to system components

    Safety

    WARNING!

    Danger from electric current.

    This can result in serious injury and damage to property.

    Before starting the work described below, turn the mains switch on the welding machine to the "O" position.

    Disconnect the welding machine from the grid.

    Ensure that the welding machine remains disconnected from the grid until all work has been completed.

    CAUTION!

    Risk of injury and damage from loose connections.

    All cables, leads and hosepacks must be properly connected, undamaged, correctly insulated and adequately dimensioned.

    1. Installation - PAP
    2. Connecting wire-feed unit to system components

    Safety

    WARNING!

    Danger from electric current.

    This can result in serious injury and damage to property.

    Before starting the work described below, turn the mains switch on the welding machine to the "O" position.

    Disconnect the welding machine from the grid.

    Ensure that the welding machine remains disconnected from the grid until all work has been completed.

    CAUTION!

    Risk of injury and damage from loose connections.

    All cables, leads and hosepacks must be properly connected, undamaged, correctly insulated and adequately dimensioned.

    1. Installation - PAP
    2. Connecting wire-feed unit to system components

    General

    NOTE!

    Also follow the instructions and information in the documents 42,0410,1946 and 42,0410,2010 when connecting the wirefeeder to the system components.

    1. Installation - PAP
    2. Connecting wire-feed unit to system components

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

    IMPORTANT! Whenever the torch hosepack is fitted or removed, ensure that the coupling point is clean and dry. Remove any coolant that has escaped from the coupling point.

    1
    2
    3
    4

    Start-up

    Inserting/replacing feed rollers

    General

    The feed rollers are not installed in the device when it is first delivered.

    In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the diameter and alloy of the wire being welded.

    NOTE!

    Risk from inadequate feed rollers.

    This can result in poor weld properties.

    Only use feed rollers that match the wire electrode.

    An overview of the feed rollers available and their possible areas of use can be found in the Spare Parts Lists.

    1. Start-up

    Inserting/replacing feed rollers

    General

    The feed rollers are not installed in the device when it is first delivered.

    In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the diameter and alloy of the wire being welded.

    NOTE!

    Risk from inadequate feed rollers.

    This can result in poor weld properties.

    Only use feed rollers that match the wire electrode.

    An overview of the feed rollers available and their possible areas of use can be found in the Spare Parts Lists.

    1. Start-up
    2. Inserting/replacing feed rollers

    General

    The feed rollers are not installed in the device when it is first delivered.

    In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the diameter and alloy of the wire being welded.

    NOTE!

    Risk from inadequate feed rollers.

    This can result in poor weld properties.

    Only use feed rollers that match the wire electrode.

    An overview of the feed rollers available and their possible areas of use can be found in the Spare Parts Lists.

    1. Start-up
    2. Inserting/replacing feed rollers

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

    CAUTION!

    Risk of injury if the feed roller holders fly upwards.

    When unlocking the clamping lever, keep fingers away from the area to the left and right of the lever.

    1
    2

    CAUTION!

    Risk of crushing due to exposed feed rollers.

    Always fit the protective cover of the 4-roller drive after changing feed rollers.

    3
    4
    1. Start-up
    2. Inserting/replacing feed rollers

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

    1
    2
    3
    4
    5
    6
    7

    CAUTION!

    Danger from exposed feed rollers.

    Risk of crushing.

    Always fit the protective cover of the 2-roller drive after changing feed rollers.

    1. Start-up
    2. Inserting/replacing feed rollers

    Inserting/replacing feed rollers

    CAUTION!

    Danger from feed roller holders flying upwards.

    This can result in injuries.

    When unlocking the clamping lever, keep fingers away from the area to the left and right of the lever.

    1
    2

    CAUTION!

    Danger from exposed feed rollers.

    This can result in injuries.

    Always fit the protective cover of the 4-roller drive after inserting or replacing a feed roller.

    3
    4
    1. Start-up

    Feeding in the wire electrode

    Insulated routing of wire electrode to wirefeeder

    CAUTION!

    Danger due to uninsulated wire electrode.

    This can result in personal injury, damage to property and impaired welding results.

    In the case of automated applications, ensure that only an insulated wire electrode is routed from the welding wire drum, large wirefeeder spool or wire spool to the wirefeeder (e.g. by using a wirefeeding hose).

    An earth contact or short-circuit can be caused by:

    • a non-insulated, exposed length of wire electrode coming into contact with a conductive object during the welding process
    • missing insulation between the wire electrode and the earthed enclosure of a robot cell
    • chafed wirefeeding hoses, exposing the wire electrode

    To avoid earth contact or short-circuit:

    • Use wirefeeding hoses for insulated routing of wire electrode to the wirefeeder
    • To prevent chafing, do not route the wirefeeding hoses over sharp edges
    • Use hose holders or hose protectors where necessary
    • Coupling pieces and hoods for welding wire drums are recommended to ensure safe transport of the wire electrode
    1. Start-up
    2. Feeding in the wire electrode

    Insulated routing of wire electrode to wirefeeder

    CAUTION!

    Danger due to uninsulated wire electrode.

    This can result in personal injury, damage to property and impaired welding results.

    In the case of automated applications, ensure that only an insulated wire electrode is routed from the welding wire drum, large wirefeeder spool or wire spool to the wirefeeder (e.g. by using a wirefeeding hose).

    An earth contact or short-circuit can be caused by:

    • a non-insulated, exposed length of wire electrode coming into contact with a conductive object during the welding process
    • missing insulation between the wire electrode and the earthed enclosure of a robot cell
    • chafed wirefeeding hoses, exposing the wire electrode

    To avoid earth contact or short-circuit:

    • Use wirefeeding hoses for insulated routing of wire electrode to the wirefeeder
    • To prevent chafing, do not route the wirefeeding hoses over sharp edges
    • Use hose holders or hose protectors where necessary
    • Coupling pieces and hoods for welding wire drums are recommended to ensure safe transport of the wire electrode
    1. Start-up
    2. Feeding in the wire electrode

    Feeding in the wire electrode

    CAUTION!

    Risk of injury and damage from the welding current and accidental ignition of an arc.

    Before starting work, disconnect the ground earth connection between the welding system and the workpiece.

    CAUTION!

    Risk of injury and damage from wire electrode emerging.

    While working:

    Hold the welding torch with the end directed away from the face and body

    Wear suitable protective goggles

    Do not point the welding torch at people

    Make sure that the wire electrode does not touch any conductive or earthed parts (e.g. housing)

    Ensure that all covers are closed, all side panels are in place and that all safety devices are intact and in their proper place (e.g. protection devices).

    CAUTION!

    Risk of damage to the welding torch from sharp end of wire electrode.

    Deburr the end of the wire electrode well before threading in.

    CAUTION!

    Risk of injury due to springiness of spooled wire electrode.

    When inserting the wire electrode into the 4-roller drive, hold the end of the wire electrode firmly to avoid injuries caused by the wire springing back.

    CAUTION!

    Risk of injury from moving or rotating parts in the welding system.

    Ensure that all covers are closed and that all parts are fitted properly and remain in place during operation.

    1
    2


    1. Start-up
    2. Feeding in the wire electrode

    Setting the contact pressure

    NOTE!

    Set the contact pressure in such a way that the wire electrode is not deformed but nevertheless ensures proper wirefeeding.

    1

    The standard contact pressure values can be found on the sticker on the 4-roller drive



    1. Start-up

    Start-up

    Requirements

    When commissioning the welding system, the following requirements must be met:
    • All components are installed and connected as described in the "Installation" chapter
    • All appropriate welding media is connected
    • Feed rollers are inserted in wirefeeders or drive unit
    • Wire electrode is threaded in
    • Feed roller contact pressure is set
    • Motor adjustment completed
    • All covers closed, all side panels in place, all safety devices intact and in their proper place (e.g. protective covers)
    1. Start-up
    2. Start-up

    Requirements

    When commissioning the welding system, the following requirements must be met:
    • All components are installed and connected as described in the "Installation" chapter
    • All appropriate welding media is connected
    • Feed rollers are inserted in wirefeeders or drive unit
    • Wire electrode is threaded in
    • Feed roller contact pressure is set
    • Motor adjustment completed
    • All covers closed, all side panels in place, all safety devices intact and in their proper place (e.g. protective covers)
    1. Start-up
    2. Start-up

    General

    The device is commissioned by means of an active welding start signal.

    Troubleshooting, maintenance and disposal

    Troubleshooting

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal 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.

    Read and understand this document in full.

    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 personal injury and damage to property.

    Before starting work, switch off all the devices and components involved and disconnect them from the grid.

    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.).

    CAUTION!

    Danger from escaping coolant.

    This can result in damage to property.

    Switch off the cooling unit during maintenance activities or when replacing components and wear parts.

    The cooling system must be depressurised while the maintenance work is being carried out.

    1. Troubleshooting, maintenance and disposal

    Troubleshooting

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal 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.

    Read and understand this document in full.

    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 personal injury and damage to property.

    Before starting work, switch off all the devices and components involved and disconnect them from the grid.

    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.).

    CAUTION!

    Danger from escaping coolant.

    This can result in damage to property.

    Switch off the cooling unit during maintenance activities or when replacing components and wear parts.

    The cooling system must be depressurised while the maintenance work is being carried out.

    1. Troubleshooting, maintenance and disposal
    2. Troubleshooting

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal 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.

    Read and understand this document in full.

    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 personal injury and damage to property.

    Before starting work, switch off all the devices and components involved and disconnect them from the grid.

    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.).

    CAUTION!

    Danger from escaping coolant.

    This can result in damage to property.

    Switch off the cooling unit during maintenance activities or when replacing components and wear parts.

    The cooling system must be depressurised while the maintenance work is being carried out.

    1. Troubleshooting, maintenance and disposal
    2. Troubleshooting

    Fault diagnosis

    Make a note of the serial number and configuration of the device and contact our After-Sales Service team with a detailed description of the error, if

    • errors occur that are not listed below
    • the troubleshooting measures listed are unsuccessful

    Welding machine does not function
    Mains switch is on, but indicators are not lit up
    Cause:There is a break in the mains lead; the mains plug is not plugged in
    Remedy:Check the mains lead, ensure that the mains plug is plugged in
    Cause:Mains socket or mains plug faulty
    Remedy:Replace faulty parts
    Cause:Mains fuse protection
    Remedy:Change the mains fuse protection
    Cause:Short circuit on the 24 V supply of SpeedNet connection socket or external sensor
    Remedy:Unplug connected components
    No response after setting a welding start signal
    Welding machine mains switch is on and indicators are lit
    Cause:Welding torch or welding torch control line is faulty
    Remedy:Replace welding torch
    Cause:Interconnecting hosepack is faulty or not connected properly
    Remedy:Check the interconnecting hosepack
    No welding current
    Welding machine mains switch is on and indicators are lit
    Cause:Grounding (earthing) connection is incorrect
    Remedy:Check the grounding (earthing) connection for correct polarity
    Cause:There is a break in the power cable in the welding torch
    Remedy:Replace welding torch
    No protective gas shield
    All other functions are OK
    Cause:Gas cylinder is empty
    Remedy:Change the gas cylinder
    Cause:The gas pressure regulator is faulty
    Remedy:Replace the gas pressure regulator
    Cause:Gas hose is not fitted or is damaged
    Remedy:Fit or change the gas hose
    Cause:Welding torch is faulty
    Remedy:Change the welding torch
    Cause:Gas solenoid valve is faulty
    Remedy:Contact After-Sales Service
    Irregular wire feed speed
    Cause:Hole in the contact tip is too narrow
    Remedy:Use a suitable contact tip
    Cause:Faulty inner liner in welding torch
    Remedy:Check the inner liner for kinks, dirt, etc.
    Cause:The feed rollers are not suitable for the wire electrode being used
    Remedy:Use suitable feed rollers
    Cause:Feed rollers have the wrong contact pressure
    Remedy:Optimise the contact pressure
    Wirefeed problems
    when using long hosepacks
    Cause:Incorrect arrangement of hosepack
    Remedy:Arrange the hosepack in as straight a line as possible, avoid tight bends
    Welding torch becomes very hot
    Cause:Welding torch is inadequately dimensioned
    Remedy:Observe the duty cycle and loading limits
    Cause:Only on water-cooled systems: inadequate coolant flow
    Remedy:Check coolant level, coolant flow, for coolant contamination, etc. For further information refer to the cooling unit Operating Instructions
    Poor weld properties
    Cause:Incorrect welding parameters
    Remedy:Check the settings
    Cause:Poor ground earth connection
    Remedy:Ensure good contact to workpiece
    Cause:Inadequate or no protective gas shield
    Remedy:Check the pressure regulator, gas hose, gas solenoid valve, torch gas connection, etc.
    Cause:Welding torch is leaking
    Remedy:Change the welding torch
    Cause:Wrong contact tip, or contact tip is worn out
    Remedy:Replace the contact tip
    Cause:Wrong wire alloy or wrong wire diameter
    Remedy:Check the wire electrode that has been inserted
    Cause:Wrong wire alloy or wrong wire diameter
    Remedy:Check weldability of the base material
    Cause:The shielding gas is not suitable for this wire alloy
    Remedy:Use the correct shielding gas
    1. Troubleshooting, maintenance and disposal

    Care, maintenance and disposal

    General

    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.

    1. Troubleshooting, maintenance and disposal
    2. Care, maintenance and disposal

    General

    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.

    1. Troubleshooting, maintenance and disposal
    2. Care, maintenance and disposal

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal 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.

    Read and understand this document in full.

    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 personal injury and damage to property.

    Before starting work, switch off all the devices and components involved and disconnect them from the grid.

    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.).

    CAUTION!

    Danger from escaping coolant.

    This can result in damage to property.

    Switch off the cooling unit during maintenance activities or when replacing components and wear parts.

    The cooling system must be depressurised while the maintenance work is being carried out.

    1. Troubleshooting, maintenance and disposal
    2. Care, maintenance and disposal

    Every start-up

    • 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.
    1. Troubleshooting, maintenance and disposal
    2. Care, maintenance and disposal

    Special care of O-rings

    IMPORTANT! When replacing O-rings, grease the new O-ring before fitting it.

    When repeatedly connecting and disconnecting the coolant hoses on the torch hosepack, grease the O-rings regularly.

    Unless a special grease is specified for the O-rings, use the O-ring grease from Fronius with item number 40,0009,0044.

    1. Troubleshooting, maintenance and disposal
    2. Care, maintenance and disposal

    Whenever the welding torch or torch hosepack is changed

    Whenever the welding torch or torch hosepack is changed, ensure that the coupling point is clean and dry. Remove any coolant that has escaped from the coupling point.
    Ensure that the cooling unit is switched off.

    1. Troubleshooting, maintenance and disposal
    2. Care, maintenance and disposal

    Every 6 months

    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.
    1. Troubleshooting, maintenance and disposal
    2. Care, maintenance and disposal

    "Stop" coolant pump service position - Working mode 17

    Prerequisites:

    • Min. welding machine firmware V3.2.30
    • Min. firmware RI FB PRO/I interface RI FB PRO/I 1.9.0

    Description:
    In Working mode 17, switch the coolant pump to "stop". The cooling circuit is interrupted, while all other functions of the welding machine remain active. The "Cooling circuit mode" process parameter on the welding machine does not need to be changed.
    Once Working mode 17 has ended, the robot controller continues from the last active program step
    Working mode 17 only works in automatic mode via the robot controller.

    NOTE!

    Performing maintenance on the active robot welding system is only permitted in Working mode 17 .

     

    Move the robot to a suitable position to allow water-cooled components and wear parts to be changed.

    NOTE!

    Detailed information can be found in the operating instructions 42,0426,0227 ... Description of TPS/i interface signals

    1. Troubleshooting, maintenance and disposal
    2. Care, maintenance and disposal

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

    1
    2

    WARNING!

    Toppling or falling devices can cause life-threatening injuries.

    Robot movements may not take place until:

    The wirefeeder has been retracted and locked

    All cables, leads and hosepacks are securely connected to the wirefeeder

    After replacing the inner liner:

    3
    4
    5
    6

    CAUTION!

    Risk of injury and damage from loose connections.

    All cables, leads and hosepacks must be properly connected, undamaged, correctly insulated and adequately dimensioned.

    1. Troubleshooting, maintenance and disposal
    2. Care, maintenance and disposal

    Recognising faulty wearing parts

    1. Insulating parts
      • Burned-off outside edges, notches
    2. Nozzle fittings
      • Burned-off outside edges, notches
      • Heavily covered in welding spatter
    3. Spatter guard
      • Burned-off outside edges, notches
    4. Contact tips
      • Worn-out (oval) wire entry and wire exit holes
      • Heavily covered in welding spatter
      • Penetration on the tip of the contact tip
    5. Gas nozzles
      • Heavily covered in welding spatter
      • Burned-off outside edges
      • Notches
    1. Troubleshooting, maintenance and disposal
    2. Care, maintenance and disposal

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

    1
    2
    3
    **
    Screw on and tighten the gas nozzle as far as it will go
    1. Troubleshooting, maintenance and disposal
    2. Care, maintenance and disposal

    MTG d, MTW d, MTB - Fitting wear parts to the burner body

    1

    Tightening torques:

    • Contact tube M5 3 Nm / 2.21 ft lb
    • Nozzle holder M5
    • Clamping nut M12 8 Nm / 5.9 ft lb
    2
    3
    1. Troubleshooting, maintenance and disposal
    2. Care, maintenance and disposal

    Fitting wearing parts to the torch body - MTW 700 i

    1
    2
    1. Troubleshooting, maintenance and disposal
    2. Care, maintenance and disposal

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

    1
    2
    3
    4
    5
    6
    7
    8
    9
    10
    11
    1. Troubleshooting, maintenance and disposal
    2. Care, maintenance and disposal

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

    1
    2
    3
    4
    5
    6
    7
    8
    9
    10
    11
    1. Troubleshooting, maintenance and disposal
    2. Care, maintenance and disposal

    Changing the torch hosepack, changing the interconnecting hosepack

    If a robot wirefeeder or a media splitter is mounted in the third robot axis, take the following into account when changing the torch hosepack or interconnecting hosepack:

    CAUTION!

    Risk of damage to the robot wirefeeder or media splitter from escaping coolant.

    After disconnecting the coolant hoses on the torch hosepack, immediately seal off the coolant connections with the covers provided.

    Position the robot in such a way that escaping coolant cannot flow back into the robot wirefeeder or the media splitter.

    NOTE!

    Performing maintenance on the active robot welding system is only permitted in the"Stop" coolant pump service position - Working mode 17.

     

    Move the robot to a suitable position to allow water-cooled components and wear parts to be changed.

    1. Troubleshooting, maintenance and disposal
    2. Care, maintenance and disposal

    Cleaning the welding torch

    1
    2
    1. Troubleshooting, maintenance and disposal
    2. Care, maintenance and disposal

    Disposal

    Dispose of in accordance with the applicable national and local regulations.

    Technical data

    WF wire-feed unit

    WF 15i R,
    WF 15i R

    Supply voltage

    24 V DC / 60 V DC

    Nominal current

    0.5 A / 1 A

    Welding current at 10 min/40 °C (104 °F)

    40 % ED* 650 A
    60 % ED* 600 A
    100 % ED* 500 A

    Maximum shielding gas pressure

    7 bar / 101.53 psi

    Coolant

    Original Fronius

    Maximum coolant pressure

    5 bar / 72.53 psi

    Wire speed

    0.5 - 15 m/min / 19.68 - 590.55 ipm

    Wire drive

    4-roller drive

    Recommended wire diameter

    0.8 - 2.4 mm / 0.03 - 0.09 in.

    Protection class

    IP 43

    Mark of conformity

    CE, CSA

    Dimensions l x w x h

    274 x 276 x 229 mm
    10.79 x 10.87 x 9.02 in.

    Weight

    5.8 kg / 12.79 Ib.


    * ED = Duty cycle

     

    1. Technical data

    WF wire-feed unit

    WF 15i R,
    WF 15i R

    Supply voltage

    24 V DC / 60 V DC

    Nominal current

    0.5 A / 1 A

    Welding current at 10 min/40 °C (104 °F)

    40 % ED* 650 A
    60 % ED* 600 A
    100 % ED* 500 A

    Maximum shielding gas pressure

    7 bar / 101.53 psi

    Coolant

    Original Fronius

    Maximum coolant pressure

    5 bar / 72.53 psi

    Wire speed

    0.5 - 15 m/min / 19.68 - 590.55 ipm

    Wire drive

    4-roller drive

    Recommended wire diameter

    0.8 - 2.4 mm / 0.03 - 0.09 in.

    Protection class

    IP 43

    Mark of conformity

    CE, CSA

    Dimensions l x w x h

    274 x 276 x 229 mm
    10.79 x 10.87 x 9.02 in.

    Weight

    5.8 kg / 12.79 Ib.


    * ED = Duty cycle

     

    1. Technical data
    2. WF wire-feed unit

    WF 15i R,
    WF 15i R

    Supply voltage

    24 V DC / 60 V DC

    Nominal current

    0.5 A / 1 A

    Welding current at 10 min/40 °C (104 °F)

    40 % ED* 650 A
    60 % ED* 600 A
    100 % ED* 500 A

    Maximum shielding gas pressure

    7 bar / 101.53 psi

    Coolant

    Original Fronius

    Maximum coolant pressure

    5 bar / 72.53 psi

    Wire speed

    0.5 - 15 m/min / 19.68 - 590.55 ipm

    Wire drive

    4-roller drive

    Recommended wire diameter

    0.8 - 2.4 mm / 0.03 - 0.09 in.

    Protection class

    IP 43

    Mark of conformity

    CE, CSA

    Dimensions l x w x h

    274 x 276 x 229 mm
    10.79 x 10.87 x 9.02 in.

    Weight

    5.8 kg / 12.79 Ib.


    * ED = Duty cycle

     

    1. Technical data
    2. WF wire-feed unit

    WF 15i R,
    WF 15i R PAP

    Supply voltage

    24 V DC / 60 V DC

    Nominal current

    0.5 A / 1 A

    Welding current at 10 min/40 °C (104 °F)

    40 % ED* 650 A
    60 % ED* 600 A
    100 % ED* 500 A

    Maximum shielding gas pressure

    7 bar / 101.53 psi

    Coolant

    Original Fronius

    Maximum coolant pressure

    5 bar / 72.53 psi

    Wire speed

    0.5 - 15 m/min / 19.68 - 590.55 ipm

    Wire drive

    4-roller drive

    Recommended wire diameter

    0.8 - 2.4 mm / 0.03 - 0.09 in.

    Protection class

    IP 43

    Mark of conformity

    CE, CSA

    Dimensions l x w x h

    274 x 252 x 229 mm
    10.79 x 9.92 x 9.02 in.

    Weight

    5.8 kg / 12.79 Ib.


    * ED = Duty cycle

     

    1. Technical data
    2. WF wire-feed unit

    WF 25i R,
    WF 25i R,
    WF 25i R / L

    Supply voltage

    24 V DC / 60 V DC

    Nominal current

    0.5 A / 1.2 A

    Welding current at 10 min/40 °C (104 °F)

    40 % ED* 500 A
    60 % ED* 450 A
    100 % ED* 360 A

    Maximum shielding gas pressure

    7 bar / 101.53 psi

    Coolant

    Original Fronius

    Maximum coolant pressure

    5 bar / 72.53 psi

    Wire speed

    1 - 25 m/min / 39.37 - 984.25 ipm

    Wire drive

    4-roller drive

    Recommended wire diameter

    0.8 - 1.6 mm / 0.03 - 0.06 in.

    Protection class

    IP 43

    Mark of conformity

    CE, CSA

    Dimensions l x w x h

    274 x 276 x 229 mm
    10.79 x 10.87 x 9.02 in.

    Weight

    4.8 kg / 10.58 Ib.


    * ED = Duty cycle

     

    1. Technical data
    2. WF wire-feed unit

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

    Supply voltage

    24 V DC / 60 V DC

    Nominal current

    0.5 A / 1.2 A

    Welding current at 10 min/40 °C (104 °F)

    40 % ED* 500 A
    60 % ED* 450 A
    100 % ED* 360 A

    Maximum shielding gas pressure

    7 bar / 101.53 psi

    Coolant

    Original Fronius

    Maximum coolant pressure

    5 bar / 72.53 psi

    Wire speed

    1 - 25 m/min / 39.37 - 984.25 ipm

    Wire drive

    4-roller drive

    Recommended wire diameter

    0.8 - 1.6 mm / 0.03 - 0.06 in.

    Protection class

    IP 43

    Mark of conformity

    CE, CSA

    Dimensions l x w x h

    274 x 252 x 229 mm
    10.79 x 9.92 x 9.02 in.

    Weight

    4.8 kg / 10.58 Ib.


    * ED = Duty cycle

     

    1. Technical data
    2. WF wire-feed unit

    WF 30i R,
    WF 30i R,
    WF 30i R / L

    Supply voltage

    24 V DC / 60 V DC

    Nominal current

    0.5 A / 1.4 A

    Welding current at 10 min/40 °C (104 °F)

    40 % ED* 650 A
    60 % ED* 600 A
    100 % ED* 500 A

    Maximum shielding gas pressure

    7 bar / 101.53 psi

    Coolant

    Original Fronius

    Maximum coolant pressure

    5 bar / 72.53 psi

    Wire speed

    1 - 30 m/min / 39.37 - 1181.10 ipm

    Wire drive

    4-roller drive

    Recommended wire diameter

    0.8 - 1.6 mm / 0.03 - 0.06 in.

    Protection class

    IP 43

    Mark of conformity

    CE, CSA

    Dimensions l x w x h

    274 x 276 x 229 mm
    10.79 x 10.87 x 9.02 in.

    Weight

    5.4 kg / 11.9 Ib.


    * ED = Duty cycle

     

    1. Technical data
    2. WF wire-feed unit

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

    Supply voltage

    24 V DC / 60 V DC

    Nominal current

    0.5 A / 1.4 A

    Welding current at 10 min/40 °C (104 °F)

    40 % ED* 650 A
    60 % ED* 600 A
    100 % ED* 500 A

    Maximum shielding gas pressure

    7 bar / 101.53 psi

    Coolant

    Original Fronius

    Maximum coolant pressure

    5 bar / 72.53 psi

    Wire speed

    1 - 30 m/min / 39.37 - 1181.10 ipm

    Wire drive

    4-roller drive

    Recommended wire diameter

    0.8 - 1.6 mm / 0.03 - 0.06 in.

    Protection class

    IP 43

    Mark of conformity

    CE, CSA

    Dimensions l x w x h

    274 x 252 x 229 mm
    10.79 x 9.92 x 9.02 in.

    Weight

    5.4 kg / 11.9 Ib.


    * ED = Duty cycle

     

    1. Technical data

    Unreeling wirefeeder WF REEL

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

    Supply voltage

    24 V DC / 60 V DC

    Nominal current

    0.5 A / 1.2 A

    Wire speed

    1 - 25 m/min
    39.37 - 984.25 ipm.

    Wire drive

    4-roller drive

    Wire diameter

    0.8 - 2.4 mm
    0.03 - 0.09 in.

    Degree of protection

    IP 21

    Mark of conformity

    CE, CSA

    Dimensions l x w x h

    250 x 210 x 190 mm
    9.8 x 8.3 x 7.5 in.

    Weight

    4.8 kg
    10.58 Ib.

    1. Technical data
    2. Unreeling wirefeeder WF REEL

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

    Supply voltage

    24 V DC / 60 V DC

    Nominal current

    0.5 A / 1.2 A

    Wire speed

    1 - 25 m/min
    39.37 - 984.25 ipm.

    Wire drive

    4-roller drive

    Wire diameter

    0.8 - 2.4 mm
    0.03 - 0.09 in.

    Degree of protection

    IP 21

    Mark of conformity

    CE, CSA

    Dimensions l x w x h

    250 x 210 x 190 mm
    9.8 x 8.3 x 7.5 in.

    Weight

    4.8 kg
    10.58 Ib.

    1. Technical data
    2. Unreeling wirefeeder WF REEL

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

    Supply voltage

    24 V DC / 60 V DC

    Nominal current

    0.5 A / 0.9 A

    Wire speed

    1 - 30 m/min
    39.37 - 1181.10 ipm.

    Wire drive

    2-roller drive

    Wire diameter

    0.8 - 1.6 mm
    0.03 - 0.06 in.

    Degree of protection

    IP 21

    Mark of conformity

    CE, CSA

    Dimensions l x w x h

    250 x 210 x 190 mm
    9.8 x 8.3 x 7.5 in.

    Weight

    4.6 kg
    10.14 Ib.

    1. Technical data

    CrashBox /i

    Technical data, triggering torques and weight/distance diagram

    Item numbers

     

    CrashBox /i

    44,0350,3589

    CrashBox /i XL

    44,0350,3760

    CrashBox /i XXL

    44,0350,3380

    CrashBox /i PAP

    44,0350,3663

    CrashBox /i PAP XL

    44,0350,3759

    CrashBox /i PAP XXL

    44,0350,0202

    Reset accuracy (1)

    ± 0.05 mm a)

    Maximum deflection in x/y direction

     

    CrashBox /i

    ~ 45°

    CrashBox /i XL

    ~ 45°

    CrashBox /i XXL

    ~ 45°

    CrashBox /i PAP

    ~ 30°

    CrashBox /i PAP XL

    ~ 30°

    CrashBox /i PAP XXL

    ~ 30°

    Triggering torques in x/y direction
    (+/- 10%)

     

    CrashBox /i

    21 Nm / 15.49 lb-ft

    CrashBox /i XL

    42 Nm / 30.98 lb-ft

    CrashBox /i XXL

    63.1 Nm / 46.54 lb-ft

    CrashBox /i PAP

    21 Nm / 15.49 lb-ft

    CrashBox /i PAP XL

    31.5 Nm / 23.23 lb-ft

    CrashBox /i PAP XXL

    41 Nm / 30.24 lb-ft

    Weight

     

    CrashBox /i

    1200 g

    CrashBox /i XL

    1200 g

    CrashBox /i XXL

    1250 g

    CrashBox /i PAP

    700 g

    CrashBox /i PAP XL

    700 g

    CrashBox /i PAP XXL

    750 g

    Dimensions

     

    CrashBox /i

    Ø90 mm x 60 mm b)

    CrashBox /i XL

    Ø90 mm x 60 mm b)

    CrashBox /i XXL

    Ø90 mm x 60 mm

    CrashBox /i PAP

    Ø90 mm x 40 mm b)

    CrashBox /i PAP XL

    Ø90 mm x 40 mm b)

    CrashBox /i PAP XXL

    Ø90 mm x 40 mm

    a) At a distance of 300 mm from the robot flange
    b) With bellows: Ø110 mm

    Triggering torques and weight/distance diagram

    Max. possible deflection

    z direction [mm]

    ~ 30

    ~ 30

    ~ 30

    ~ 30

    ~ 30

     

     

    The specified values only apply in a static state!

    x/y - direction [°]

    ~ 45

    ~ 45

    ~ 45

    ~ 30

    ~ 30

    ~ 30

     

    Deflection at a distance of 300 mm

    max [°]

    1.5275

    1.5275

    1.5275

    1.5275

    1.5275

     

     

    max [mm]

    8

    8

    8

    8

    8

     

     

    min [°]

    0.684

    0.684

    0.664

    0.6302

    0.6302

     

     

    min [mm]

    3.5

    3.5

    3.5

    3.3

    3.3

     

     

    Weight (distance [mm]) [kg]

    400

    5.25

    10.5

    15.78

    5.25

    7.88

     

     

    300

    7.00

    14.0

    21.03

    7.00

    10.5

     

     

    200

    10.5

    21.0

    31.55

    10.5

    15.75

     

     

    100

    21.0

    42.0

    63.1

    21.0

    31.5

     

     

    50

    42.0

    84.0

    126.2

    42.0

    63.0

     

     

    Triggering
    torque
    (+/- 10%)

    21 Nm

    42 Nm

    63.1 Nm

    21 Nm

    31.5 Nm

    41.0 Nm

     

    CrashBox /i

    CrashBox /i XL

    CrashBox /i XXL

    CrashBox /i PAP

    CrashBox /i PAP XL

    CrashBox /i PAP XXL

     

    1. Technical data
    2. CrashBox /i

    Technical data, triggering torques and weight/distance diagram

    Item numbers

     

    CrashBox /i

    44,0350,3589

    CrashBox /i XL

    44,0350,3760

    CrashBox /i XXL

    44,0350,3380

    CrashBox /i PAP

    44,0350,3663

    CrashBox /i PAP XL

    44,0350,3759

    CrashBox /i PAP XXL

    44,0350,0202

    Reset accuracy (1)

    ± 0.05 mm a)

    Maximum deflection in x/y direction

     

    CrashBox /i

    ~ 45°

    CrashBox /i XL

    ~ 45°

    CrashBox /i XXL

    ~ 45°

    CrashBox /i PAP

    ~ 30°

    CrashBox /i PAP XL

    ~ 30°

    CrashBox /i PAP XXL

    ~ 30°

    Triggering torques in x/y direction
    (+/- 10%)

     

    CrashBox /i

    21 Nm / 15.49 lb-ft

    CrashBox /i XL

    42 Nm / 30.98 lb-ft

    CrashBox /i XXL

    63.1 Nm / 46.54 lb-ft

    CrashBox /i PAP

    21 Nm / 15.49 lb-ft

    CrashBox /i PAP XL

    31.5 Nm / 23.23 lb-ft

    CrashBox /i PAP XXL

    41 Nm / 30.24 lb-ft

    Weight

     

    CrashBox /i

    1200 g

    CrashBox /i XL

    1200 g

    CrashBox /i XXL

    1250 g

    CrashBox /i PAP

    700 g

    CrashBox /i PAP XL

    700 g

    CrashBox /i PAP XXL

    750 g

    Dimensions

     

    CrashBox /i

    Ø90 mm x 60 mm b)

    CrashBox /i XL

    Ø90 mm x 60 mm b)

    CrashBox /i XXL

    Ø90 mm x 60 mm

    CrashBox /i PAP

    Ø90 mm x 40 mm b)

    CrashBox /i PAP XL

    Ø90 mm x 40 mm b)

    CrashBox /i PAP XXL

    Ø90 mm x 40 mm

    a) At a distance of 300 mm from the robot flange
    b) With bellows: Ø110 mm

    Triggering torques and weight/distance diagram

    Max. possible deflection

    z direction [mm]

    ~ 30

    ~ 30

    ~ 30

    ~ 30

    ~ 30

     

     

    The specified values only apply in a static state!

    x/y - direction [°]

    ~ 45

    ~ 45

    ~ 45

    ~ 30

    ~ 30

    ~ 30

     

    Deflection at a distance of 300 mm

    max [°]

    1.5275

    1.5275

    1.5275

    1.5275

    1.5275

     

     

    max [mm]

    8

    8

    8

    8

    8

     

     

    min [°]

    0.684

    0.684

    0.664

    0.6302

    0.6302

     

     

    min [mm]

    3.5

    3.5

    3.5

    3.3

    3.3

     

     

    Weight (distance [mm]) [kg]

    400

    5.25

    10.5

    15.78

    5.25

    7.88

     

     

    300

    7.00

    14.0

    21.03

    7.00

    10.5

     

     

    200

    10.5

    21.0

    31.55

    10.5

    15.75

     

     

    100

    21.0

    42.0

    63.1

    21.0

    31.5

     

     

    50

    42.0

    84.0

    126.2

    42.0

    63.0

     

     

    Triggering
    torque
    (+/- 10%)

    21 Nm

    42 Nm

    63.1 Nm

    21 Nm

    31.5 Nm

    41.0 Nm

     

    CrashBox /i

    CrashBox /i XL

    CrashBox /i XXL

    CrashBox /i PAP

    CrashBox /i PAP XL

    CrashBox /i PAP XXL

     

    1. Technical data

    Torch hosepack

    MHP 400i G / R

    Welding current at 10 min/40°C
    M21 (EN ISO 14175)

    C1 (EN ISO 14175)


    40 % ED* / 400 A
    60 % ED* / 320 A
    100 % ED* / 260 A

    60 % ED* / 400 A
    100 % ED* / 320 A

    Wire diameter

    0.8 - 1.6 mm
    0.031 - 0.063 inch

    Length

    0,95 / 1,10 / 1,25 / 1,45 / 1,75 /
    1,95 / 2,25 / 3,25 / 4,25 m

    3.12 / 3.6 / 4.1 / 4.76 / 5.74 /
    6.4 / 7.38 / 10.66 / 13.94 ft.

     

     

    *
    ED = Duty cycle
    1. Technical data
    2. Torch hosepack

    MHP 400i G / R

    Welding current at 10 min/40°C
    M21 (EN ISO 14175)

    C1 (EN ISO 14175)


    40 % ED* / 400 A
    60 % ED* / 320 A
    100 % ED* / 260 A

    60 % ED* / 400 A
    100 % ED* / 320 A

    Wire diameter

    0.8 - 1.6 mm
    0.031 - 0.063 inch

    Length

    0,95 / 1,10 / 1,25 / 1,45 / 1,75 /
    1,95 / 2,25 / 3,25 / 4,25 m

    3.12 / 3.6 / 4.1 / 4.76 / 5.74 /
    6.4 / 7.38 / 10.66 / 13.94 ft.

     

     

    *
    ED = Duty cycle
    1. Technical data
    2. Torch hosepack

    MHP 400i G / R / PAP

    Welding current at 10 min/40°C
    M21 (EN ISO 14175)



    C1 (EN ISO 14175)


    40 % ED* / 400 A
    60 % ED* / 320 A
    100 % ED* / 260 A

    60 % ED* / 400 A
    100 % ED* / 320 A

    Wire diameter

    0.8 - 1.6 mm
    0.031 - 0.063 inch

    Length

    0,93 / 0,94 / 0,96 / 1,0 / 1,04 / 1,06 / 1,09 / 1,12 / 1,13 / 1,15 / 1,18 / 1,19 / 1,2 / 1,22 / 1,25 / 1,31 / 1,35 / 1,37 / 1,4 / 1,43 / 1,45 / 1,51 / 1,59 / 2,13 / 2,28 m

    3.05 / 3.08 / 3.15 / 3.28 / 3.4 / 3.48 / 3.58 / 3.67 / 3.71 / 3.77 / 3.87 / 3.9 / 3.94 / 4.0 / 4.10 / 4.3 / 4.43 / 4.5 / 4.59 / 4.69 / 4.76 / 4.95 / 5.22 / 6.99 / 7.48 ft.

     

     

    *
    ED = Duty cycle
    1. Technical data
    2. Torch hosepack

    MHP 500 S R / G / PAP

    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

    1. Technical data
    2. Torch hosepack

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

    Welding current at 10 min/40° C
    M21(EN ISO 14175)
    C1 (EN ISO 14175)


    100 % ED* / 700 A
    100 % ED* / 700 A

    Wire diameter

    0.8 - 1.6 mm
    0.031 - 0.063 inch

    Length

    0.95 / 1.10 / 1.25 / 1.45 / 1.75 / 1.95 / 2.25 m

    3.12 / 3.61 / 4.1 / 4.76 / 5.74 / 6.4 / 7.38 ft.

    Lowest cooling capacity Pmin in accordance with standard IEC 60974-2, depending on the length of the hosepack

     

    0,95 m / 3.12 ft
    1,10 m / 3.61 ft
    1,25 m / 4.1 ft
    1,45 m / 4.76 ft
    1,55 m / 5.08 ft
    1,65 m / 5.41 ft
    1,75 m / 5.74 ft
    1,95 m / 6.4 ft
    2,25 m / 7.38 ft

    1200 W
    1300 W
    1300 W
    1400 W
    1450 W
    1550 W
    1600 W
    1800 W
    2000 W

    Minimum coolant flow Qmin

    1 l/min
    0.26 gal (US) / min

    Minimum coolant pressure pmin

    3 bar
    43.5 psi

    Maximum coolant pressure pmax

    5 bar
    72.5 psi

     

     

    *
    ED = Duty cycle
    1. Technical data
    2. Torch hosepack

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

    Welding current at 10 min/40°C
    M21 (EN ISO 14175)


    C1 (EN ISO 14175)


    60 % ED* / 700 A
    100 % ED* / 580 A

    60 % ED* / 700 A
    100 % ED* / 580 A

    Wire diameter

    0.8 - 1.6 mm
    0.031 - 0.063 inch

    Length

    3.25 / 4.25 m
    10.66 / 13.12 ft.

    Lowest cooling capacity in accordance with standard IEC 60974-2, depending on the length of the hosepack

     

    3.25 m / 10.66 ft
    4.25 m / 13.12 ft

    1400 W
    1600 W

    Minimum coolant flow Qmin

    1 l/min
    0.26 gal (US) / min

    Minimum coolant pressure pmin

    3 bar
    43.5 psi

    Maximum coolant pressure pmax

    5 bar
    72.5 psi

     

     

    *
    ED = Duty cycle
    1. Technical data
    2. Torch hosepack

    MHP 700i W / R / PAP

    Welding current at 10 min/40° C
    M21(EN ISO 14175)
    C1 (EN ISO 14175)


    100 % ED* / 700 A
    100 % ED* / 700 A

    Wire diameter

    0.8 - 1.6 mm
    0.031 - 0.063 inch

    Length

    0.93 / 0.96 / 1.04 / 1.06 / 1.09 / 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 / 2.28 m

    3.05 / 3.15 / 3.41 / 3.48 / 3.58 / 3.67 / 3.71 / 3.77 / 3.87 / 3.9 / 3.94 / 4 / 4.3 / 4.43 / 4.5 / 4.59 / 4.69 / 4.95 / 7.48 ft.

    Lowest cooling capacity in accordance with standard IEC 60974-2, depending on the length of the hosepack

    0.93 / 0.94 / 0.96 m
    3.05 / 3.08 / 3.15 ft

    1.04 / 1.06 / 1.09 m
    3.41 / 3.48 / 3.58 ft

    1.12 / 1.13 / 1.15 / 1.18 / 1.19 / 1.2 / 1.22 m
    3.67 / 3.71 / 3.77 / 3.87 / 3.9 / 3.94 / 4 ft

    1.31 m
    4.3 ft

    1.35 / 1.37 / 1.4 / 1.43 / 1.45 / 1.51 / 1.59 m
    4.43 / 4.5 / 4.59 / 4.69 / 4.76 / 4.95 / 5.22 ft

    2013 / 2.28 m
    6.99 / 7.48 ft

    1200 W


    1250 W


    1300 W


    1350 W


    1400 W


    2000 W

    Minimum coolant flow Qmin

    1 l/min
    0.26 gal (US) / min

    Minimum coolant pressure pmin

    3 bar
    43.5 psi

    Maximum coolant pressure pmax

    5 bar
    72.5 psi

     

     

    *
    ED = Duty cycle
    1. Technical data

    Robot welding torch

    Gas-cooled robot welding torches

    MTB 250i G/R (TX, TXM)

    Welding current at 10 min/40° C
    M21 (EN ISO 14175)



    C1 (EN ISO 14175)


    40 % ED* / 250 A
    60 % ED* / 200 A
    100 % ED* / 170 A

    -
    60 % ED* / 250 A
    100 % ED* / 200 A

    Wire diameter

    0.8 - 1.2 mm
    0.030 - 0.045 inch

     

    MTB 320i G/R (TX, TXM)

    Welding current at 10 min/40° C
    M21 (EN ISO 14175)



    C1 (EN ISO 14175)


    40 % ED* / 320 A
    60 % ED* / 260 A
    100 % ED* / 210 A

    -
    60 % ED* / 320 A
    100 % ED* / 260 A

    Wire diameter

    0.8 - 1.6 mm
    0.030 - 0.062 inch

     

    MTB 330i G/R (TX, TXM)

    Welding current at 10 min/40° C
    M21 (EN ISO 14175)



    C1 (EN ISO 14175)


    40 % ED* / 330 A
    60 % ED* / 270 A
    100 % ED* / 220 A

    -
    60 % ED* / 330 A
    100 % ED* / 270 A

    Wire diameter

    0.8 - 1.6 mm
    0.030 - 0.062 inch

     

    MTB 350i G/R (TX, TXM)

    Welding current at 10 min/40° C)
    M21 (EN ISO 14175)



    C1 (EN ISO 14175)


    40 % ED* / 350 A
    60 % ED* / 300 A
    100 % ED* / 250 A

    -
    60 % ED* / 350 A
    100 % ED* / 300 A

    Wire diameter

    0.8 - 1.6 mm
    0.030 - 0.062 inch

     

    MTB 400i G/R (TX, TXM)

    Welding current at 10 min/40° C)
    M21 (EN ISO 14175)



    C1 (EN ISO 14175)


    40 % ED* / 400 A
    60 % ED* / 320 A
    100 % ED* / 260 A

    -
    60 % ED* / 400 A
    100 % ED* / 320 A

    Wire diameter

    0.8 - 1.6 mm
    0.030 - 0.062 inch

     

     

    *
    ED = Duty cycle
    1. Technical data
    2. Robot welding torch

    Gas-cooled robot welding torches

    MTB 250i G/R (TX, TXM)

    Welding current at 10 min/40° C
    M21 (EN ISO 14175)



    C1 (EN ISO 14175)


    40 % ED* / 250 A
    60 % ED* / 200 A
    100 % ED* / 170 A

    -
    60 % ED* / 250 A
    100 % ED* / 200 A

    Wire diameter

    0.8 - 1.2 mm
    0.030 - 0.045 inch

     

    MTB 320i G/R (TX, TXM)

    Welding current at 10 min/40° C
    M21 (EN ISO 14175)



    C1 (EN ISO 14175)


    40 % ED* / 320 A
    60 % ED* / 260 A
    100 % ED* / 210 A

    -
    60 % ED* / 320 A
    100 % ED* / 260 A

    Wire diameter

    0.8 - 1.6 mm
    0.030 - 0.062 inch

     

    MTB 330i G/R (TX, TXM)

    Welding current at 10 min/40° C
    M21 (EN ISO 14175)



    C1 (EN ISO 14175)


    40 % ED* / 330 A
    60 % ED* / 270 A
    100 % ED* / 220 A

    -
    60 % ED* / 330 A
    100 % ED* / 270 A

    Wire diameter

    0.8 - 1.6 mm
    0.030 - 0.062 inch

     

    MTB 350i G/R (TX, TXM)

    Welding current at 10 min/40° C)
    M21 (EN ISO 14175)



    C1 (EN ISO 14175)


    40 % ED* / 350 A
    60 % ED* / 300 A
    100 % ED* / 250 A

    -
    60 % ED* / 350 A
    100 % ED* / 300 A

    Wire diameter

    0.8 - 1.6 mm
    0.030 - 0.062 inch

     

    MTB 400i G/R (TX, TXM)

    Welding current at 10 min/40° C)
    M21 (EN ISO 14175)



    C1 (EN ISO 14175)


    40 % ED* / 400 A
    60 % ED* / 320 A
    100 % ED* / 260 A

    -
    60 % ED* / 400 A
    100 % ED* / 320 A

    Wire diameter

    0.8 - 1.6 mm
    0.030 - 0.062 inch

     

     

    *
    ED = Duty cycle
    1. Technical data
    2. Robot welding torch

    MTB 500S G R, MTB 500S G R TD

    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

    1. Technical data
    2. Robot welding torch

    Water-cooled robot welding torches

    MTB 250i W/R

    Welding current at 10 min/40° C
    M21 (EN ISO 14175)
    C1 (EN ISO 14175)


    100 % ED* / 250 A
    100 % ED* / 250 A

    Wire diameter

    0.8 - 1.2 mm / 0.032 - 0.047 inch

     

    MTB 330i W/R (TX, TXM)

    Welding current at 10 min/40° C
    M21 (EN ISO 14175)
    C1 (EN ISO 14175)


    100 % ED* / 330 A
    100 % ED* / 330 A

    Wire diameter

    0.8 - 1.6 mm / 0.032 - 0.063 inch

     

    MTB 400i W/R (TX, TXM)

    Welding current at 10 min/40° C
    M21 (EN ISO 14175)
    C1 (EN ISO 14175)


    100 % ED* / 400 A
    100 % ED* / 400 A

    Wire diameter

    0.8 - 1.6 mm / 0.032 - 0.063 inch

    MTB 500i W/R (TX, TXM)

    Welding current at 10 min/40° C
    M21 (EN ISO 14175)
    C1 (EN ISO 14175)


    100 % ED* / 500 A
    100 % ED* / 500 A

    Wire diameter

    1.0 - 1.6 mm / 0.039 - 0.063 inch

     

    MTB 700i W/R (TX, TXM)

    Welding current at 10 min/40° C
    M21 (EN ISO 14175)
    C1 (EN ISO 14175)


    100 % ED* / 700 A
    100 % ED* / 500 A

    Wire diameter

    1.0 - 1.6 mm / 0.039 - 0.063 inch

     

     

    *
    ED = Duty cycle
    1. Technical data
    2. Robot welding torch

    MTB 350i W R

    Water-cooled robot welding torches

    Welding current at 10 min/40° C

    M21 (EN ISO 14175)

    C1 (EN ISO 14175)

     

    100 % ED* / 350 A

    100 % ED* / 350 A

    Wire diameter

    0.8 - 1.2 mm / 0.032 - 0.047 inch

    *
    ED = Duty cycle
    1. Technical data

    Interconnecting hosepacks

    HP 70i

    Welding current at 10 min / 40 °C
    (104 °F)

    40% ED* / 400 A
    60% ED* / 365 A
    100% ED* / 320 A

     

     

    *
    ED = Duty cycle
    1. Technical data
    2. Interconnecting hosepacks

    HP 70i

    Welding current at 10 min / 40 °C
    (104 °F)

    40% ED* / 400 A
    60% ED* / 365 A
    100% ED* / 320 A

     

     

    *
    ED = Duty cycle
    1. Technical data
    2. Interconnecting hosepacks

    HP 95i

    Welding current at 10 min / 40 °C
    (104 °F)

    40% ED* / 500 A
    60% ED* / 450 A
    100% ED* / 360 A

     

     

    *
    ED = Duty cycle
    1. Technical data
    2. Interconnecting hosepacks

    HP 120i

    Welding current at 10 min / 40 °C
    (104 °F)

    40% ED* / 600 A
    60% ED* / 530 A
    100% ED* / 430 A

     

     

    *
    ED = Duty cycle
    1. Technical data
    2. Interconnecting hosepacks

    HP 70i, HP PC Cable HD 70

    Welding current at 10 min / 40 °C
    (104 °F)

    60% ED* / 600 A
    100% ED* / 500 A

     

     

    *
    ED = Duty cycle