FRO­NIUS LaserHybrid Ultracompact Twin User manual

/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0255,EN 003-16082017
LaserHybrid Ultracompact Twin Operating Instructions
LaserHybrid
EN

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EN
Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.

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Contents
Safety rules ................................................................................................................................................ 9
Explanation of safety symbols .............................................................................................................. 9
General ................................................................................................................................................. 9
Proper use ............................................................................................................................................ 10
Environmental conditions...................................................................................................................... 10
Obligations of the operator.................................................................................................................... 10
Obligations of personnel ....................................................................................................................... 11
Personal protective equipment ............................................................................................................. 11
Danger from toxic gases and vapours .................................................................................................. 11
Danger from escaping shielding gas..................................................................................................... 12
Danger from flying sparks ..................................................................................................................... 12
Hazards from welding current ............................................................................................................... 12
Vagrant welding currents ...................................................................................................................... 13
EMC measures ..................................................................................................................................... 13
Specific hazards.................................................................................................................................... 14
Informal safety measures...................................................................................................................... 15
Safety measures at the installation location.......................................................................................... 15
Safety measures in normal operation ................................................................................................... 16
Safety inspection................................................................................................................................... 16
Alterations ............................................................................................................................................. 16
Replacement and wearing parts ........................................................................................................... 17
Calibration of power sources ................................................................................................................ 17
CE marking ........................................................................................................................................... 17
Copyright............................................................................................................................................... 17
General information 19
General ...................................................................................................................................................... 21
General ................................................................................................................................................. 21
Proper use/intended purpose................................................................................................................ 21
Advantages ........................................................................................................................................... 21
Application areas .................................................................................................................................. 22
System overview................................................................................................................................... 22
Laser welding head scope of supply..................................................................................................... 23
Optional components ............................................................................................................................ 23
Requirements............................................................................................................................................. 24
System requirements and minimum equipment required for the laser-twin welding process ............... 24
Power source synchronisation .............................................................................................................. 24
Software activation................................................................................................................................ 24
Mechanical requirements...................................................................................................................... 25
Dimensioning of the robot ..................................................................................................................... 25
Functional principle .................................................................................................................................... 26
Functional principle ............................................................................................................................... 26
Lead power source and trail power source ........................................................................................... 26
Welding technology aspects ...................................................................................................................... 27
Welding technology aspects ................................................................................................................. 27
Earth connection ................................................................................................................................... 27
Welding circuit inductivity L, welding circuit resistance r....................................................................... 27
Tilt angle of the welding torch ............................................................................................................... 28
Possible arc combinations .................................................................................................................... 28
Pulse/Pulse ........................................................................................................................................... 28
Connecting to the robot control.................................................................................................................. 30
Robot interfaces for the laser-twin welding process ............................................................................. 30
Standard robot interfaces...................................................................................................................... 31
Twin fieldbus systems .......................................................................................................................... 32
Standard fieldbus systems.................................................................................................................... 33
Control elements and connections 35
Description of the device............................................................................................................................ 37

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Description of the device....................................................................................................................... 37
Connection specifications .......................................................................................................................... 39
Connection specifications ..................................................................................................................... 39
Compressed air diagram....................................................................................................................... 40
Start-up 41
General ...................................................................................................................................................... 43
Safety.................................................................................................................................................... 43
Setup regulations .................................................................................................................................. 43
Mains connection .................................................................................................................................. 43
Assembling a laser-twin system............................................................................................................ 43
Commissioning (overview).................................................................................................................... 45
Fitting the laser welding head to the robot ................................................................................................. 46
Requirements for the robot ................................................................................................................... 46
Fitting the laser welding head to the robot ............................................................................................ 46
Connecting the LaserHybrid Ultracompact Twin hosepack to the laser welding head .............................. 47
Preparatory work................................................................................................................................... 47
Connecting the LaserHybrid Ultracompact Twin hosepack to the laser welding head ......................... 48
Connect/replace the external wirefeeding hoses on the laser welding head ........................................ 52
And finally... .......................................................................................................................................... 53
Connecting the laser optics system, Crossjet and additional extractor...................................................... 54
Connecting the laser optics system ...................................................................................................... 54
Connecting the Crossjet and additional extractor ................................................................................. 56
Laying the hosepack on the robot.............................................................................................................. 57
Laying the hosepack on the robot......................................................................................................... 57
Threading the wire electrode ..................................................................................................................... 58
Preparatory work................................................................................................................................... 58
Removing the welding torch wearing parts ........................................................................................... 58
Threading the wire electrode ................................................................................................................ 59
Fitting the welding torch wearing parts ................................................................................................. 62
Setting the radial air flow............................................................................................................................ 64
Requirements........................................................................................................................................ 64
Setting the radial air flow....................................................................................................................... 64
Adjusting the laser welding head ............................................................................................................... 67
Stick out ................................................................................................................................................ 67
Adjustable axes..................................................................................................................................... 67
Adjusting device on the laser welding head.......................................................................................... 68
Adjusting the x-axis............................................................................................................................... 68
Adjusting the y-axis............................................................................................................................... 69
Creating a reference program.................................................................................................................... 70
Safety.................................................................................................................................................... 70
General ................................................................................................................................................. 70
Creating a reference program............................................................................................................... 70
Signal sequence for LaserHybrid welding.................................................................................................. 72
Safety.................................................................................................................................................... 72
Signal sequence for LaserHybrid welding............................................................................................. 72
Measures to be taken before the start of welding ...................................................................................... 74
Measures to be taken before the start of welding ................................................................................. 74
Parameter settings on the power source .............................................................................................. 74
Recommendations for operating a laser-twin welding system................................................................... 75
Recommendations for operating a laser-twin welding system.............................................................. 75
Maintenance 77
Changing the wire electrode ...................................................................................................................... 79
Preparatory work................................................................................................................................... 79
Unthreading the wire electrode ............................................................................................................. 80
Changing the wire electrode ................................................................................................................. 82
Replacing wearing parts ............................................................................................................................ 83
Preparatory work................................................................................................................................... 83
Removing the feed rollers ..................................................................................................................... 83
Replacing the inlet nozzles ................................................................................................................... 86
Replacing and installing the feed rollers ............................................................................................... 86

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Replacing the welding torch and welding torch inner liners ....................................................................... 88
Safety.................................................................................................................................................... 88
Preparatory work................................................................................................................................... 88
Replace the welding torch..................................................................................................................... 89
Replacing the welding torch inner liners ............................................................................................... 90
Replacing welding torch wearing parts ...................................................................................................... 91
Safety.................................................................................................................................................... 91
Welding torch spare parts ..................................................................................................................... 91
Removing the welding torch wearing parts ........................................................................................... 91
Fitting the welding torch wearing parts ................................................................................................. 93
Replacing the spatter guard sheet ............................................................................................................. 95
Removing the spatter guard plate......................................................................................................... 95
Fitting the spatter guard plate ............................................................................................................... 95
Replacing the laser optics system ............................................................................................................. 97
Safety.................................................................................................................................................... 97
Preparatory work................................................................................................................................... 97
Removing the laser optics system ........................................................................................................ 98
Mounting positions for installing the laser optics system ...................................................................... 101
Installing the laser optics system .......................................................................................................... 102
Fitting the spatter guard plate ............................................................................................................... 105
And finally... .......................................................................................................................................... 105
Creating a reference program and setting the position of the wire electrode in relation to the focus point
of the laser ................................................................................................................................................. 106
Safety.................................................................................................................................................... 106
General ................................................................................................................................................. 106
Checking the position of the wire electrode in relation to the focal spot of the laser ............................ 106
Example: Using the reference program after changing the welding torch ............................................ 107
Measures to reduce optics contamination ................................................................................................. 108
Measures to reduce optics contamination ............................................................................................ 108
Appendix 111
Technical data............................................................................................................................................ 113
LaserHybrid Ultracompact Twin(laser welding head) ........................................................................... 113
LaserHybrid Ultracompact Twin hosepack ........................................................................................... 113
Spare parts list: LaserHybrid Ultracompact Twin....................................................................................... 114

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Safety rules
Explanation of
safety symbols
If you see any of the symbols depicted in the "Safety rules" chapter, special care is re-
quired.
General
DANGER! Indicates immediate and real danger. If it is not avoided, death or se-
rious injury will result.
WARNING! Indicates a potentially dangerous situation. Death or serious injury
may result if appropriate precautions are not taken.
CAUTION! Indicates a situation where damage or injury could occur. If it is not
avoided, minor injury and/or damage to property may result.
NOTE! Indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT! Indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.
The LaserHybrid head is manufactured using state-of-the-art technology and
according to recognised safety standards. If used incorrectly or misused, how-
ever, it can cause:
- injury or death to the operator or a third party,
- damage to the LaserHybrid head and other material assets belonging to
the operator,
- inefficient operation of the LaserHybrid head.
All persons involved in commissioning, operating, maintaining and servicing
the LaserHybrid head must:
- be suitably qualified,
- have sufficient knowledge of welding and
- carefully observe these operating instructions as well as the operating in-
structions for the following system components:
the laser
the laser optics system
the power source and its wirefeeder
the robot and its control system
The operating instructions must always be at hand wherever the LaserHybrid
head is being used. In addition to the operating instructions, attention must
also be paid to any generally applicable and local regulations regarding acci-
dent prevention and environmental protection.
All safety and danger notices on the LaserHybrid head
- 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 LaserHybrid head, re-
fer to the "General" section in the operating instructions for your LaserHybrid
head.
Before switching on the device, rectify any faults that could compromise safe-
ty.
This is for your personal safety!

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Proper use
Environmental
conditions
Obligations of the
operator
The LaserHybrid head is to be used exclusively for its intended purpose.
The LaserHybrid head is intended solely for use in LaserHybrid welding of al-
uminium, CrNi and steel materials.
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 and danger notices carefully
- performing all stipulated inspection and servicing work.
Never attempt to use the LaserHybrid head or the power source being used
for thawing frozen pipes.
The LaserHybrid head is designed for use in industry and the workshop. The
manufacturer accepts no responsibility for any damage caused through use in
a domestic setting.
The manufacturer likewise accepts no liability for inadequate or incorrect work
results.
Operation or storage of the LaserHybrid head 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 air temperature range:
- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- during transport and storage: -25 °C to + 55 °C (-13 °F to 131 °F)
Relative humidity:
- up to 50% at 40 °C (104 °F)
- up to 90% at 20 °C (68 °F)
The ambient air must be free from dust, acids, corrosive gases or substances,
etc.
Can be used at altitudes up to 2000 m (6561 ft. 8.16 in.)
The operator must only allow persons to work with the LaserHybrid head who:
- are familiar with the fundamental instructions regarding safety at work and
accident prevention and have been instructed in how to use the LaserHy-
brid head
- have read and understood these operating instructions, especially the
"Safety rules" section, 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.

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Obligations of
personnel
Personal protec-
tive equipment
Danger from toxic
gases and va-
pours
Before starting work, all persons using the LaserHybrid head 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.
For your personal safety, take the following precautions:
Persons in the closed cell for the LaserHybrid process must:
wear solid footwear that provides insulation even in wet conditions
protect their hands by wearing suitable gloves (electrically insulated and heat-
proof)
protect their eyes from laser beams by wearing regulation-compliant laser
safety goggles. In addition, they must protect their faces and eyes from UV
rays using a protective visor and regulation filter element for laser protection
class 4 worn in front of the laser safety goggles and the face. Even when using
this regulation filter element for laser protection class 4, they should not look
into the laser beam.
only wear suitable (i.e. flame-retardant) clothing
use ear protectors to protect them from the cross-jet noise (120 dbA)
If other persons are in the closed cell for the LaserHybrid process, you must:
- make them aware of all the dangers that may occur during operation (e.g.
risk of a build-up of gases that are detrimental to health, possible risk of
suffocation due to lack of oxygen in the air, danger from laser light, etc.)
- provide them with protective equipment
- erect safety screens or curtains
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that may, under certain circumstances,
cause birth defects or cancer.
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.

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Danger from es-
caping shielding
gas
Danger from fly-
ing sparks
Hazards from
welding current
Otherwise, a protective mask with an air supply must be worn.
Close the shielding gas cylinder valve or main gas supply if no welding is tak-
ing place.
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 de-
gree of toxicity of welding fumes:
- Metals used for the workpiece
- Electrodes
- Coatings
- Cleaners, degreasers, etc.
The relevant material safety data sheets and manufacturer's specifications for
the listed components should therefore be studied carefully.
Flammable vapours (e.g. solvent fumes) should be kept away from the radia-
tion area of the laser and the arc.
Risk of suffocation from the uncontrolled escape of shielding gas
Shielding gas is colourless and odourless and, in the event of a leak, can dis-
place 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 cylin-
der 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.
Flying sparks may cause fires or explosions.
Never weld close to flammable materials.
Flammable materials must be at least 11 m (35 ft.) away from the LaserHybrid
welding process, 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 in-
jury 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 ac-
cordance 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 can be fatal. Every electric shock is hazardous to life.
All welding cables must be firmly attached, undamaged and properly insulat-
ed. Replace any loose connections and scorched cables immediately.

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EN
Vagrant welding
currents
EMC measures
If the following instructions are ignored, vagrant welding currents may occur.
These can destroy earthed conductor terminals, the power source being
used, the LaserHybrid welding head and other electrical equipment.
Ensure the workpiece clamp is connected tightly to the workpiece.
On electrically conductive floors, the power source must be set up in such a
way as to be insulated from the floor, wherever possible.
Warning, electromagnetic field. Electromagnetic fields may cause as yet
unknown damage to health.
It is the operator's responsibility to ensure that no electromagnetic interference
occurs in electrical and electronic devices.
If electromagnetic interference is found to be occurring, the owner/operator is
obliged to take all necessary measures to prevent this interference.
Check for possible problems, and check and evaluate neighbouring devices'
resistance to interference according to national and international require-
ments:
- Safety devices
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
- The health of persons in the vicinity, e.g. users of pacemakers and hear-
ing aids
Individuals with pacemakers must seek advice from their doctor before ap-
proaching the welding work area.
Supporting measures for avoidance of EMC problems:
a) Mains supply
- If electromagnetic interference arises despite the correct mains con-
nection, additional measures are necessary (e.g. use of a suitable
line filter)
b) Welding power-leads
- must be kept as short as possible
- must be laid close together (also to avoid EMC problems)
- must be laid apart from other leads
c) Equipotential bonding
d) Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
e) Shielding, if necessary
- Shield off other nearby devices
- Shield off entire welding installation

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Specific hazards Risk of injury to the eyes from the laser beam. In addition to the protective visor
with regulation UV filter element, ensure that all persons wear regulation laser
safety goggles to protect their eyes from laser beams. You should still ensure
that nobody can accidentally look into the laser beam.
With highly shiny, reflective workpiece surfaces, there is a further danger
caused by reflected and scattered laser radiation. Suitable precautions must
be taken to ensure that all persons in the area are sufficiently protected from
scattered laser radiation.
Keep hands, hair, clothing and tools away from moving parts. For example:
- Fans
- Cogs
- Rollers
- Shafts
- Wirespools and welding wires
Do not reach into the rotating cogs of the wire drive or into rotating drive com-
ponents.
Covers and side panels may only be opened or removed for as long as main-
tenance 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 away from the body (devices with
wire-feed unit) 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 al-
lowed to cool down before handling.
Special provisions apply in areas at risk of fire or explosion
- observe relevant national and international regulations.
Power sources for work in areas with increased electric risk (e.g. near boilers)
must carry the "Safety" sign. However, the power source must not be located
in such areas.
Risk of scalding from escaping coolant. Switch off cooling unit before discon-
necting coolant flow or return lines.
Observe the information on the coolant safety data sheet when handling cool-
ant. The coolant safety data sheet may be obtained from your service centre
or downloaded from the manufacturer's website.

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EN
Informal safety
measures
Safety measures
at the installation
location
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 load-car-
rying equipment.
- Chains and 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 devic-
es).
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, coun-
terbalanced lift truck or other mechanical hoist.
All lifting accessories (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 Tef-
lon tape.
The operating instructions must always be at hand wherever the LaserHybrid
head is being used.
In addition to the operating instructions, any generally applicable and local
regulations regarding accident prevention and environmental protection must
be provided and followed.
All safety and danger notices on the LaserHybrid head must be kept in a leg-
ible condition.
The cell for the LaserHybrid welding process must meet the following require-
ments:
- be sealed off from adjoining rooms to make it lightproof
- be screened with min. 1 mm thick steel plate and/or approved laser pro-
tective glass to prevent any UV or laser radiation escaping
- both the laser welding process and the arc welding process must stop au-
tomatically as soon as the cell is opened
A device that topples over can easily kill someone. Place the device on a solid,
level surface.
- 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 protec-
tion 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.

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Safety measures
in normal opera-
tion
Safety inspection
Alterations
When transporting the device, observe the relevant national and local guide-
lines and accident prevention regulations. This applies especially to guidelines
regarding the risks arising during transport.
Before transporting the device, allow coolant to drain completely and detach
the following components:
- Wire feed speed
- Wirespool
- Shielding gas cylinder
After transporting the device, the device must be visually inspected for dam-
age before commissioning. Any damage must be repaired by trained service
technicians before commissioning the device.
Only operate the LaserHybrid head if all protection and 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 starting up the LaserHybrid head, ensure that no one is likely to be en-
dangered.
Check the LaserHybrid head at least once a week for obvious damage and
proper functioning of the safety devices.
The operator is obliged to have the LaserHybrid head checked by a qualified
electrician to ensure it is safe for use after any modifications, alterations, re-
pairs, care and maintenance, and in any case at least every twelve months.
Regulation Title
IEC (EN) 60 974-1 Arc welding equipment - Part 1: Power sources
BGV A2, §5 Electrical plant and equipment
BGV D1, §33 / §49 Welding, cutting and associated processes
VDE 0701-1 Repair, modification and inspection of electrical ap-
pliances;
general requirements
VDE 0702-1 Repeat tests on electrical equipment
1
2
3
4
5
6
7
8
9
1
0
1
1
1
2
Do not carry out any modifications, alterations, etc. to the LaserHybrid head
without the manufacturer's consent.
Components that are not in perfect condition must be replaced immediately.

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EN
Replacement and
wearing parts
Calibration of
power sources
CE marking
Copyright
Use only original spare and wearing parts (also applies to standard parts).
It is impossible to guarantee that parts sourced from third parties are designed
and manufactured to meet the demands made of them, or that they satisfy
safety requirements.
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.
In view of international standards, regular calibration of power sources is nec-
essary. Fronius recommends a 12-month calibration interval. For more infor-
mation, please contact your service centre.
The LaserHybrid head fulfils the fundamental requirements of the Low Voltage
Directive and the Electromagnetic Compatibility Directive and is thus CE-
marked.
Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We
reserve the right to make changes. The contents of the operating instructions
shall not provide the basis for any claims whatsoever on the part of the pur-
chaser. If you have any suggestions for improvement, or can point out any
mistakes that you have found in the instructions, we will be most grateful for
your comments.

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General information