TPS/i Robotics Push/Pull, CMT

Warnings are intended to warn people of possible injury and to prevent personal injury and damage to the product. They relate to individual actions performed with and on the product.

Safety instructions are intended to ensure safe use of the product. They are preventive and help to inform users about basic risks when using the product. They do not refer specifically to individual actions performed with and on the product.

Warnings are intended to warn people of possible injury and to prevent personal injury and damage to the product. They relate to individual actions performed with and on the product.

Safety instructions are intended to ensure safe use of the product. They are preventive and help to inform users about basic risks when using the product. They do not refer specifically to individual actions performed with and on the product.

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.

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 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 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.)

Checks must be carried out at regular intervals to ensure that operators are working in a safety-conscious manner.

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.

^*) 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

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.

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 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.

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.

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.

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

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.

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.

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.

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.

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.

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.

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.

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.

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 Fronius 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 Fronius.

Do not mix Fronius original coolant with other coolants.

Only connect Fronius system components to the cooling circuit.

Cooling Liquid FCL 10/20 is not flammable. The ethanol-based coolant can ignite under certain. 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 the 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.

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 machines be calibrated at the same 12-monthly interval.

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

Further details on the safety inspection and calibration can be obtained from a Fronius branch or Fronius Service Partner.

Used equipment and batteries must be returned to the distributor or an authorised local collection system. Do not dispose of batteries in domestic waste. Protect batteries from high temperatures, direct sunlight, moisture and corrosive environments.

Arrange for the safe collection and proper disposal of damaged, leaking or decommissioned batteries by a battery recycling company or the Fronius Service Partner.

It should also be noted that batteries contain substances that, if disposed of improperly, can have a significant negative impact on the environment as well as on human health and the safety of persons, in particular due to the leakage of hazardous substances, such as heavy metals or electrolytes, which can contaminate the soil, water and air.

The full text of the EU Declaration of Conformity can be found at
https://www.fronius.com .

Devices with the CSA mark satisfy the requirements of the relevant standards in Canada and the USA.

Copyright of this document remains with Fronius International GmbH.

Text, illustrations and other media correspond to the technical state of the art at the time of publication. Fronius reserves the right to make changes. If you have any suggestions for improvement, or can point out any inconsistencies in this document, we will be most grateful for your comments.

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

The arrangement of the symbols may vary.

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.

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.

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.

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.

Minimum length between unreeling wirefeeder and drive unit:
4 m

Possible wire diameters:
0.8 - 2.0 mm

Welding process:
Standard, Puls, LSC, PMC

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

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

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!

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

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

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

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.

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.

Minimum length between wirefeeder and drive unit:
4 m

Possible wire diameters:
0.8 - 2.0 mm

Welding process:
Standard, Puls, LSC, PMC

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

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.

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

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

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

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

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

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

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:

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:

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:

The device is intended exclusively for combining the welding media during automated MIG/MAG welding in combination with Fronius system components. Any other use shall be deemed to be not in accordance with the intended use.

Intended use also means:

Das Gerät ist mit Sicherheitssymbolen und einem Leistungsschild ausgestattet. Die Sicherheitssymbole und das Leistungsschild dürfen weder entfernt noch übermalt werden. Die Sicherheitssymbole warnen vor Fehlbedienung, woraus schwerwiegende Personen- und Sachschäden resultieren können.

	Schweißen ist gefährlich. Für das ordnungsgemäße Arbeiten mit dem Gerät müssen folgende Grundvoraussetzungen erfüllt sein: Ausreichende Qualifikation für das Schweißen Geeignete Schutzausrüstung Fernhalten unbeteiligter Personen von dem Drahtvorschub und dem Schweißprozess
	Ausgediente Geräte nicht in den Hausmüll geben, sondern entsprechend den Sicherheitsvorschriften entsorgen.
	Beschriebene Funktionen erst anwenden, wenn folgende Dokumente vollständig gelesen und verstanden wurden: diese Bedienungsanleitung sämtliche Bedienungsanleitungen der Systemkomponenten, insbesondere Sicherheitsvorschriften
	Hände, Haare, Kleidungsstücke und Werkzeuge von beweglichen Teilen fernhalten, wie z. B.: Zahnräder Vorschubrollen Drahtspulen und Schweißdrähten Nicht in rotierende Antriebsteile greifen. Abdeckungen und Seitenteile dürfen nur für die Dauer von Wartungs- und Reparaturarbeiten geöffnet / entfernt werden. Während des Betriebes Sicherstellen, dass alle Abdeckungen geschlossen und sämtliche Seitenteile ordnungsgemäß montiert sind. Alle Abdeckungen und Seitenteile geschlossen halten.

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 intended exclusively for combining the welding media during automated MIG/MAG welding in combination with Fronius system components. Any other use shall be deemed to be not in accordance with the intended use.

Intended use also means:

Das Gerät ist mit Sicherheitssymbolen und einem Leistungsschild ausgestattet. Die Sicherheitssymbole und das Leistungsschild dürfen weder entfernt noch übermalt werden. Die Sicherheitssymbole warnen vor Fehlbedienung, woraus schwerwiegende Personen- und Sachschäden resultieren können.

	Schweißen ist gefährlich. Für das ordnungsgemäße Arbeiten mit dem Gerät müssen folgende Grundvoraussetzungen erfüllt sein: Ausreichende Qualifikation für das Schweißen Geeignete Schutzausrüstung Fernhalten unbeteiligter Personen von dem Drahtvorschub und dem Schweißprozess
	Beschriebene Funktionen erst anwenden, wenn folgende Dokumente vollständig gelesen und verstanden wurden: diese Bedienungsanleitung sämtliche Bedienungsanleitungen der Systemkomponenten, insbesondere Sicherheitsvorschriften
	Ausgediente Geräte nicht in den Hausmüll geben, sondern entsprechend den Sicherheitsvorschriften entsorgen.

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.

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

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.

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

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

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

CrashBox Drive /i PAP scope of supply

Conventional CrashBox /i scope of supply

Do not fit the CrashBox Drive /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.

Das Gerät ist mit Sicherheitssymbolen und einem Leistungsschild ausgestattet. Die Sicherheitssymbole und das Leistungsschild dürfen weder entfernt noch übermalt werden. Die Sicherheitssymbole warnen vor Fehlbedienung, woraus schwerwiegende Personen- und Sachschäden resultieren können.

Leistungsschild WF 25i Robacta Drive

Leistungsschild WF 60i Robacta Drive CMT

	Schweißen ist gefährlich. Für das ordnungsgemäße Arbeiten mit dem Gerät müssen folgende Grundvoraussetzungen erfüllt sein: Ausreichende Qualifikation für das automatisierte Schweißen Geeignete Schutzausrüstung Fernhalten unbeteiligter Personen von dem Drahtvorschub und dem Schweißprozess
	Beschriebene Funktionen erst anwenden, wenn folgende Dokumente vollständig gelesen und verstanden wurden: diese Bedienungsanleitung sämtliche Bedienungsanleitungen der Systemkomponenten, insbesondere Sicherheitsvorschriften

The Robacta MHPi RD hosepack is designed for gas-cooled and water-cooled robot applications. It connects the SplitBox to the wirefeeder.
The length of the hosepack depends on the robot.

The Robacta MHPi RD hosepack is designed for gas-cooled and water-cooled robot applications. It connects the SplitBox to the wirefeeder.
The length of the hosepack depends on the robot.

*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 recording option

*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 recording option

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.

All indoor and automated MIG/MAG applications.

The device has been manufactured in line with the state of the art and according to recognised safety standards.

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.

Utilisation in accordance with the intended purpose also comprises:

Das Gerät ist mit Sicherheitssymbolen und einem Leistungsschild ausgestattet. Die Sicherheitssymbole und das Leistungsschild dürfen weder entfernt noch übermalt werden. Die Sicherheitssymbole warnen vor Fehlbedienung, woraus schwerwiegende Personen- und Sachschäden resultieren können.

Bsp.: WF 30i REEL R /2R/G/W

	Ausgediente Geräte nicht in den Hausmüll geben, sondern entsprechend den Sicherheitsvorschriften entsorgen.
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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.

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.

The interconnecting hosepack connects the welding machine to the SplitBox SB 60i R.
The interconnecting hosepack is fixed in position on the SplitBox SB 60i R and is available in the following preconfigured lengths:

The PowerLiner is a wirefeeder system for all standard wire types. Wire diameters of 0.6 mm to 1.6 mm may be used.
The PowerLiner does not need an inner liner. The wire electrode is guided by rollers set at an angle of 90 degrees. Seventy-six rollers are used for each metre of wirefeeding hose. As a result, rolling friction rather than slip friction occurs during wirefeeding.

The PowerLiner can be made up to any length. For Robacta Drive applications, lengths of up to 10 m can be realised. For CMT applications, lengths of up to 6 m can be realised between the unreeling wirefeeder and wire buffer and 4 m between the wire buffer and drive unit.
A connection can be established to large spool systems, wire drums, welding torches or wirefeeders using QuickConnect.

Pay attention to the wirefeeding direction when fitting the PowerLiner.

The PowerLiner is a wirefeeder system for all standard wire types. Wire diameters of 0.6 mm to 1.6 mm may be used.
The PowerLiner does not need an inner liner. The wire electrode is guided by rollers set at an angle of 90 degrees. Seventy-six rollers are used for each metre of wirefeeding hose. As a result, rolling friction rather than slip friction occurs during wirefeeding.

The PowerLiner can be made up to any length. For Robacta Drive applications, lengths of up to 10 m can be realised. For CMT applications, lengths of up to 6 m can be realised between the unreeling wirefeeder and wire buffer and 4 m between the wire buffer and drive unit.
A connection can be established to large spool systems, wire drums, welding torches or wirefeeders using QuickConnect.

Pay attention to the wirefeeding direction when fitting the PowerLiner.

If OPT/i WireSense software activation is available on the welding machine, the surface, edges and weld seams of a workpiece can be measured with the wire electrode.
The wire electrode functions as a sensor that can precisely scan a component by means of high-frequency reversing wire movement.
Component geometries are recorded and the position of the individual sheets in relation to one another is precisely determined.

If OPT/i WireSense software activation is available on the welding machine, the surface, edges and weld seams of a workpiece can be measured with the wire electrode.
The wire electrode functions as a sensor that can precisely scan a component by means of high-frequency reversing wire movement.
Component geometries are recorded and the position of the individual sheets in relation to one another is precisely determined.

The CMT Welding Package is not required for the WireSense function.

A sensor voltage with limited current is applied to the wire electrode. If the wire electrode touches the component, a short circuit is created without welding. The short circuit is broken again by lifting the wire electrode.
The change in position of the wire electrode up to the short circuit is analysed by the welding machine and sent as a height measurement signal to the robot control.

The height measurement signal is compared with the current robot controller position data.
If there are differences, the robot can correct the Tool Center Point (TCP) or the respective coordinate system and compensate for component position changes accordingly.

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).

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).

The following statuses may be indicated on the display of the WF 25i Robacta Drive / WF 60i Robacta Drive CMT:

	Normal operation
	Error in Stop / Robot not ready
	Gas testing is active
	No connection to the control Update
	Teach mode active
	Wire threading active
	Wire retract active
	In applications with a double-head wirefeeder, when process line 1 is selected. 2 and 3 light up on the other process lines but are smaller in size
	In applications with a double-head wirefeeder, when process line 2 is selected. 1 and 3 light up on the other process lines but are smaller in size
	In applications with a double-head wirefeeder, when process line 3 is selected. 1 and 2 light up on the other process lines but are smaller in size
	For applications with WireSwitch, when process line 1 is active
	For applications with WireSwitch, when process line 2 is active

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:

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

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:

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

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:

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

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:

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