TPS/i Robotics Push/Pull, CMT Operating Instructions

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!

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.

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.)

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.

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.

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

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.

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.

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.

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.

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.

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.

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:

Mains supply
- If electromagnetic interference arises despite the correct mains connection, additional measures are necessary (e.g. use of a suitable line filter)
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
Equipotential bonding
Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
Shield, if necessary
- Shield other devices nearby
- Shield the entire welding installation

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

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.

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.

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.

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.

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.

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.

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.

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.

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

Devices with the CE mark satisfy the essential requirements of the low-voltage and electromagnetic compatibility directives (e.g. relevant product standards of the EN 60 974 series).

Fronius International GmbH hereby declares that the device is compliant with Directive 2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following address: http://www.fronius.com

Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA.

With regard to data security, the user is responsible for:

backing up any changes made to the factory settings
saving and retaining personal settings

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.

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

(1)	Wirefeeding hose with inner liner
(2)	TPSi welding machine
(3)	CU cooling unit
(4)	Upright console
(5)	HP interconnecting hosepack
(6)	SplitBox SB 500i R
(7)	MHP /i R torch hosepack
(8)	WF 25i Robacta Drive
(9)	MTB /i R robot welding torch

Maximum wirefeed length:
max. 6 m between wire drum and drive unit
(max. 8 m with PowerLiner)

Possible wire diameters:
0.8 - 1.2 mm

Welding process:
Standard, Pulse, LSC, PMC, PMC-MIX-DRIVE

IMPORTANT! Do not use a wire straightening section or guide roller in this configuration.

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

(1)	Wirefeeding hose with inner liner
(2)	TPSi welding machine
(3)	CU cooling unit
(4)	Upright console
(5)	HP interconnecting hosepack
(6)	SplitBox SB 500i R
(7)	MHP /i R torch hosepack
(8)	WF 25i Robacta Drive
(9)	MTB /i R robot welding torch

Maximum wirefeed length:
max. 6 m between wire drum and drive unit
(max. 8 m with PowerLiner)

Possible wire diameters:
0.8 - 1.2 mm

Welding process:
Standard, Pulse, LSC, PMC, PMC-MIX-DRIVE

IMPORTANT! Do not use a wire straightening section or guide roller in this configuration.

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

(1)	Wirefeeding hose with inner liner
(2)	TPSi welding machine
(3)	CU cooling unit
(4)	Upright console
(5)	HP interconnecting hosepack
(6)	SplitBox SB 500i R
(7)	MHP /i R torch hosepack
(8)	WF 25i Robacta Drive
(9)	MTB /i R robot welding torch

Maximum wirefeed length:
max. 6 m between wire drum and drive unit
(max. 8 m with PowerLiner)

Possible wire diameters:
0.8 - 1.2 mm

Welding process:
Standard, Pulse, LSC, PMC, PMC-MIX-DRIVE

IMPORTANT! Do not use a wire straightening section or guide roller in this configuration.

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

(1)	Wirefeeding hose with inner liner
(2)	TPSi welding machine
(3)	CU cooling unit
(4)	Upright console
(5)	HP interconnecting hosepack
(6)	SplitBox SB 500i R
(7)	MHP /i R welding torch hosepack with external wirefeeding hose
(8)	WF 25i Robacta Drive
(9)	MTB /i R robot welding torch

Maximum wirefeed length:
max. 6 m between wire drum and drive unit
(max. 8 m with PowerLiner)

Possible wire diameters:
0.8 - 1.2 mm

Welding process:
Standard, Pulse, LSC, PMC, PMC-MIX-DRIVE

IMPORTANT! Do not use a wire straightening section or guide roller in this configuration.

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

(1)	Wirefeeding hose with inner liner
(2)	SpeedNet cable COM
(3)	Unreeling wirefeeder WF 25i REEL 4R
(4)	TPSi welding machine
(5)	CU cooling unit
(6)	Upright console
(7)	HP interconnecting hosepack
(8)	SplitBox SB 500i R
(9)	MHP /i R torch hosepack
(10)	WF 25i Robacta Drive
(11)	MTB /i R robot welding torch

Maximum wirefeed length:

max. 15 m between drive unit and unreeling wirefeeder
(max. 20 m with PowerLiner)
max. 8 m between unreeling wirefeeder and wire drum
(max. 10 m with PowerLiner)

Minimum length between unreeling wirefeeder and drive unit:
4 m

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)	SpeedNet cable COM
(2)	Unreeling wirefeeder WF 25i REEL 4R + OPT/i WF Reel carriage D300
(3)	TPSi welding machine
(4)	CU cooling unit
(5)	Upright console
(6)	HP interconnecting hosepack
(7)	Wirefeeding hose with inner liner
(8)	SplitBox SB 500i R
(9)	MHP /i R welding torch hosepack with external wirefeeding hose
(10)	WF 25i Robacta Drive
(11)	MTB /i R robot welding torch

Maximum wirefeed length:
max. 15 m between drive unit and unreeling wirefeeder
(max. 20 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)	SpeedNet cable COM
(2)	Unreeling wirefeeder WF 25i REEL 4R + OPT/i WF Reel carriage D300
(3)	TPSi welding machine
(4)	CU cooling unit
(5)	Upright console
(6)	HP interconnecting hosepack SB 60i
(7)	Wirefeeding hose with inner liner
(8)	SplitBox SB 60i R
(9)	MHP /i R torch hosepack
(10)	WF 25i Robacta Drive
(11)	MTB /i R robot welding torch

Maximum wirefeed length:

max. 4 m between drive unit and SB 60i R
max. 6 m between SB 60i R and unreeling wirefeeder

Minimum length between SB 60i R and drive unit:
1 m

Possible wire diameters:
0.8 - 1.6 mm

Welding process:
Standard, Pulse, LSC, PMC, PMC-MIX-DRIVE

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

(1)	Unreeling wirefeeder WF 30i REEL 2R + WF Mounting Drum
(2)	SpeedNet cable COM
(3)	TPSi welding machine
(4)	CU cooling unit
(5)	Upright console
(6)	HP interconnecting hosepack
(7)	Wirefeeding hose with inner liner
(8)	SplitBox SB 500i R
(9)	MHP /i R welding torch hosepack with external wirefeeding hose
(10)	WF 25i Robacta Drive
(11)	MHP /i R robot welding torch

Maximum wirefeed length:
max. 8 m between drive unit and unreeling wirefeeder
(max. 10 m with PowerLiner)

Possible wire diameters:
0.8 - 1.6 mm

Welding process:
Standard, Pulse, LSC, PMC, PMC-MIX-DRIVE

IMPORTANT!

This configuration is only possible with a wire drum. A wirespool cannot be used.
Do not use a wire straightening section or guide roller in this configuration.

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

(1)	Wirefeeding hose with inner liner
(2)	SpeedNet cable COM
(3)	Unreeling wirefeeder WF 25i REEL 4R
(4)	TPSi welding machine
(5)	CU cooling unit
(6)	Upright console
(7)	HP interconnecting hosepack SB 60i
(8)	SplitBox SB 60i R
(9)	MHP /i R torch hosepack
(10)	WF 60i Robacta Drive CMT
(11)	MTB /i R robot welding torch

Maximum wirefeed length:

max. 4 m between drive unit and SB 60i R
max. 6 m between SB 60i R and unreeling wirefeeder
max. 8 m between unreeling wirefeeder and wire drum
(max. 10 m with PowerLiner)

Minimum length between wirefeeder and drive unit:
1 m

Possible wire diameters:
0.8 - 1.6 mm aluminium, 0.8 - 1.4 mm steel

Welding process:
Standard, Pulse, LSC, PMC, PMC-MIX-DRIVE, PMC-RIPPLE-DRIVE, CMT

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

(1)	Wirefeeding hose with inner liner
(2)	SpeedNet cable COM
(3)	Unreeling wirefeeder WF 25i REEL 4R
(4)	TPSi welding machine
(5)	CU cooling unit
(6)	Upright console
(7)	HP interconnecting hosepack
(8)	Wire buffer
(9)	SplitBox SB 500i R
(10)	MHP /i R welding torch hosepack with external wirefeeding hose
(11)	WF 60i Robacta Drive CMT
(12)	MTB /i R robot welding torch

Maximum wirefeed length:

max. 4 m between drive unit and wire buffer
max. 6 m between wire buffer and unreeling wirefeeder
max. 8 m between unreeling wirefeeder and wire drum
(max. 10 m with PowerLiner)

Minimum length between wirefeeder and drive unit:
1 m

Possible wire diameters:
0.8 - 1.6 mm aluminium, 0.8 - 1.4 mm steel

Welding process:
Standard, Pulse, LSC, PMC, CMT

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

(1)	SpeedNet cable COM
(2)	Unreeling wirefeeder WF 25i REEL 4R + OPT/i WF Reel carriage D300
(3)	TPSi welding machine
(4)	CU cooling unit
(5)	Upright console
(6)	HP interconnecting hosepack SB 60i
(7)	Wirefeeding hose with inner liner
(8)	SplitBox SB 60i R
(9)	MHP /i R torch hosepack
(10)	WF 60i Robacta Drive CMT
(11)	MTB /i R robot welding torch

Maximum wirefeed length:

max. 4 m between drive unit and SB 60i R
max. 6 m between SB 60i R and unreeling wirefeeder

Minimum length between wirefeeder and drive unit:
1 m

Possible wire diameters:
0.8 - 1.6 mm aluminium, 0.8 - 1.4 mm steel

Welding process:
Standard, Pulse, LSC, PMC, CMT

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

(1)	Wirefeeding hose with inner liner
(2)	TPSi welding machine
(3)	CU cooling unit
(4)	Upright console
(5)	HP interconnecting hosepack
(6)	SplitBox SB 500i R
(7)	MHP /i R torch hosepack
(8)	WF 25i Robacta Drive
(9)	MTB /i R robot welding torch

Maximum wirefeed length:
max. 6 m between wire drum and drive unit
(max. 8 m with PowerLiner)

Possible wire diameters:
0.8 - 1.2 mm

Welding process:
Standard, Pulse, LSC, PMC, PMC-MIX-DRIVE

IMPORTANT! Do not use a wire straightening section or guide roller in this configuration.

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

(1)	Wirefeeding hose with inner liner
(2)	TPSi welding machine
(3)	CU cooling unit
(4)	Upright console
(5)	HP interconnecting hosepack
(6)	SplitBox SB 500i R
(7)	MHP /i R torch hosepack
(8)	WF 25i Robacta Drive
(9)	MTB /i R robot welding torch

Maximum wirefeed length:
max. 6 m between wire drum and drive unit
(max. 8 m with PowerLiner)

Possible wire diameters:
0.8 - 1.2 mm

Welding process:
Standard, Pulse, LSC, PMC, PMC-MIX-DRIVE

IMPORTANT! Do not use a wire straightening section or guide roller in this configuration.

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

(1)	Wirefeeding hose with inner liner
(2)	SpeedNet cable COM
(3)	Unreeling wirefeeder WF 25i REEL 4R
(4)	TPSi welding machine
(5)	CU cooling unit
(6)	Upright console
(7)	HP interconnecting hosepack
(8)	SplitBox SB 500i R
(9)	MHP /i R torch hosepack
(10)	WF 25i Robacta Drive
(11)	MTB /i R robot welding torch

Maximum wirefeed length:

max. 15 m between drive unit and unreeling wirefeeder
(max. 20 m with PowerLiner)
max. 8 m between unreeling wirefeeder and wire drum
(max. 10 m with PowerLiner)

Minimum length between wirefeeder and drive unit:
4 m

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)	SpeedNet cable COM
(2)	Unreeling wirefeeder WF 25i REEL 4R + OPT/i WF Reel carriage D300
(3)	TPSi welding machine
(4)	CU cooling unit
(5)	Upright console
(6)	HP interconnecting hosepack
(7)	Wirefeeding hose with inner liner
(8)	SplitBox SB 500i R
(9)	MHP /i R torch hosepack
(10)	WF 25i Robacta Drive
(11)	MTB /i R robot welding torch

Maximum wirefeed length:
max. 15 m between drive unit and unreeling wirefeeder
(max. 20 m with PowerLiner)

Minimum length between wirefeeder and drive unit:
4 m

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)	Unreeling wirefeeder WF 30i REEL 2R + WF Mounting Drum
(2)	SpeedNet cable COM
(3)	Wirefeeding hose with inner liner
(4)	TPSi welding machine
(5)	CU cooling unit
(6)	Upright console
(7)	HP interconnecting hosepack
(8)	SplitBox SB 500i R
(9)	MHP /i R torch hosepack
(10)	WF 25i Robacta Drive
(11)	MHP /i R robot welding torch

Maximum wirefeed length:
max. 8 m between drive unit and unreeling wirefeeder
(max. 10 m with PowerLiner)

Minimum length between wirefeeder and drive unit:
4 m

Possible wire diameters:
0.8 - 1.6 mm

Welding process:
Standard, Pulse, LSC, PMC, PMC-MIX-DRIVE

IMPORTANT! This configuration is only possible with a wire drum. A wirespool cannot be used.

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

(1)	Wirefeeding hose with inner liner
(2)	SpeedNet cable COM
(3)	Unreeling wirefeeder WF 25i REEL 4R
(4)	TPSi welding machine
(5)	CU cooling unit
(6)	Upright console
(7)	HP interconnecting hosepack
(8)	SplitBox SB 500i R
(9)	Wire buffer
(10)	MHP /i R torch hosepack
(11)	WF 25i Robacta Drive
(12)	MTB /i R robot welding torch

Maximum wirefeed length:

max. 4 m between drive unit and wire buffer
max. 6 m between wire buffer and unreeling wirefeeder
max. 8 m between unreeling wirefeeder and wire drum
(max. 10 m with PowerLiner)

Possible wire diameters:
0.8 - 2.0 mm aluminium, 0.8 - 1.6 mm steel

Welding process:
Standard, Pulse, LSC, PMC, PMC-MIX-DRIVE

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

(1)	SpeedNet cable COM
(2)	Unreeling wirefeeder WF 25i REEL 4R + OPT/i WF Reel carriage D300
(3)	TPSi welding machine
(4)	CU cooling unit
(5)	Upright console
(6)	HP interconnecting hosepack
(7)	Wirefeeding hose with inner liner
(8)	Wire buffer
(9)	SplitBox SB 500i R
(10)	MHP /i R torch hosepack
(11)	WF 25i Robacta Drive
(12)	MTB /i R robot welding torch

Maximum wirefeed length:

max. 4 m between drive unit and wire buffer
max. 6 m between wire buffer and unreeling wirefeeder

Minimum length between wirefeeder and drive unit:
1 m

Possible wire diameters:
0.8 - 1.6 mm

Welding process:
Standard, Pulse, LSC, PMC, PMC-MIX-DRIVE

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

(1)	Wirefeeding hose with inner liner
(2)	SpeedNet cable COM
(3)	Unreeling wirefeeder WF 25i REEL 4R
(4)	TPSi welding machine
(5)	CU cooling unit
(6)	Upright console
(7)	HP interconnecting hosepack SB 60i
(8)	SplitBox SB 60i R
(9)	MHP /i R torch hosepack
(10)	WF 60i Robacta Drive CMT
(11)	MTB /i R robot welding torch

Maximum wirefeed length:

max. 4 m between drive unit and SB 60i R
max. 6 m between SB 60i R and unreeling wirefeeder
max. 8 m between unreeling wirefeeder and wire drum
(max. 10 m with PowerLiner)

Minimum length between wirefeeder and drive unit:
1 m

Possible wire diameters:
0.8 - 1.6 mm aluminium, 0.8 - 1.4 mm steel

Welding process:
Standard, Pulse, LSC, PMC, CMT

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

(1)	Wirefeeding hose with inner liner
(2)	SpeedNet cable COM
(3)	Unreeling wirefeeder WF 25i REEL 4R
(4)	TPSi welding machine
(5)	CU cooling unit
(6)	Upright console
(7)	HP interconnecting hosepack
(8)	SplitBox SB 500i R
(9)	Wire buffer
(10)	MHP /i R torch hosepack
(11)	WF 60i Robacta Drive CMT
(12)	MTB /i R robot welding torch

Maximum wirefeed length:

max. 4 m between drive unit and wire buffer
max. 6 m between wire buffer and unreeling wirefeeder
max. 8 m between unreeling wirefeeder and wire drum
(max. 10 m with PowerLiner)

Minimum length between wirefeeder and drive unit:
1 m

Possible wire diameters:
0.8 - 1.6 mm aluminium, 0.8 - 1.4 mm steel

Welding process:
Standard, Pulse, LSC, PMC, CMT

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

(1)	SpeedNet cable COM
(2)	Unreeling wirefeeder WF 25i REEL 4R + OPT/i WF Reel carriage D300
(3)	TPSi welding machine
(4)	CU cooling unit
(5)	Upright console
(6)	HP interconnecting hosepack
(7)	Wirefeeding hose with inner liner
(8)	SplitBox SB 500i R
(9)	MHP /i R torch hosepack
(10)	WF 60i Robacta Drive CMT
(11)	MTB /i R robot welding torch

Maximum wirefeed length:

max. 4 m between drive unit and wire buffer
max. 6 m between wire buffer and unreeling wirefeeder

Minimum length between wirefeeder and drive unit:
1 m

Possible wire diameters:
0.8 - 1.6 mm aluminium, 0.8 - 1.4 mm steel

Welding process:
Standard, Pulse, LSC, PMC, CMT

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

The SplitBox (SB) 500i R, SB 500i R / L and SB 500i R PAP devices bring together the welding media for automated MIG/MAG welding and have been specially designed for mounting onto the robot. Two versions of the devices are available:

R = for applications in which the hosepack is externally mounted on the robot
PAP = for applications in which the hosepack is mounted in the robot arm

The SplitBox (SB) 500i R, SB 500i R / L and SB 500i R PAP devices bring together the welding media for automated MIG/MAG welding and have been specially designed for mounting onto the robot. Two versions of the devices are available:

R = for applications in which the hosepack is externally mounted on the robot
PAP = for applications in which the hosepack is mounted in the robot arm

The SplitBox (SB) 500i R, SB 500i R / L and SB 500i R PAP devices bring together the welding media for automated MIG/MAG welding and have been specially designed for mounting onto the robot. Two versions of the devices are available:

R = for applications in which the hosepack is externally mounted on the robot
PAP = for applications in which the hosepack is mounted in the robot arm

The device is designed exclusively for bringing together the welding media 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 the stipulated inspection and maintenance work

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.

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.

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

Welders 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.

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 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 SB 60i R and SB 60i R /L are devices for bringing together the welding media in automated MIG/MAG welding and are specially designed for mounting on robots.

SB 60i R:
Right version of the appliance, for fitting to the right side of the robot

SB 60i R /L:
Left version of the appliance, for fitting to the left side of the robot

The SB 60i R and SB 60i R /L are devices for bringing together the welding media in automated MIG/MAG welding and are specially designed for mounting on robots.

SB 60i R:
Right version of the appliance, for fitting to the right side of the robot

SB 60i R /L:
Left version of the appliance, for fitting to the left side of the robot

The device is designed exclusively for bringing together the welding media 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 the stipulated inspection and maintenance work

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.

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.

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

Welders 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

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

As its name implies, the wire buffer acts as a buffer zone for the rapid reversing movements of the wire electrode needed during the CMT welding process.

The wire buffer can also be used to help coordinate two drive systems that work in different ways. The rear drive system steadily feeds the wire electrode into the wire buffer, while the front highly dynamic drive motor moves it to and fro up to 70 times per second.

The wire electrode is therefore fed to the front drive unit with hardly any force being applied, thus guaranteeing a high-quality welding process.

The wire buffer is suitable for mounting on the side arm or on the balancer.

As its name implies, the wire buffer acts as a buffer zone for the rapid reversing movements of the wire electrode needed during the CMT welding process.

The wire buffer can also be used to help coordinate two drive systems that work in different ways. The rear drive system steadily feeds the wire electrode into the wire buffer, while the front highly dynamic drive motor moves it to and fro up to 70 times per second.

The wire electrode is therefore fed to the front drive unit with hardly any force being applied, thus guaranteeing a high-quality welding process.

The wire buffer is suitable for mounting on the side arm or on the balancer.

A CrashBox Drive /i PAP mounted onto the robot arm with Robacta Drive and MTB

A CrashBox Drive /i mounted onto the robot arm with clamp system, Robacta Drive und MTB

The CrashBox Drive /i is a protection device for the torch body, the drive unit and the welding torch interchangeable coupling. In the event of a collision, the CrashBox sends a signal to the robot control, which stops the robot immediately.

The clamp system is used to hold the drive unit on conventional robots.

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-neck changeover 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 necessary for fitting the CrashBox Drive /i.