FRO­NIUS LaserHybrid Series User manual

/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0291,EA 001-08062018
WF 25i LaserHybrid 6 kW UC
WF 25i LaserHybrid 4 kW UC
SB 360i LaserHybrid
Operating Instructions
LaserHybrid
EN-US

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EN-US
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 familiarize yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features your Fronius product has to offer. This will allow you to make full use of its advan-
tages.
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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EN-US
Contents
Safety Instructions ..................................................................................................................................... 9
Explanation of Safety Instructions......................................................................................................... 9
General ................................................................................................................................................. 9
Intended Use......................................................................................................................................... 10
Environmental Conditions ..................................................................................................................... 10
Obligations of the Operating Company................................................................................................. 10
Obligations of Personnel....................................................................................................................... 10
Personal Protective Equipment............................................................................................................. 11
Danger from Toxic Gases and Vapors.................................................................................................. 11
Danger Posed by Shielding Gas Leak .................................................................................................. 12
Danger from Flying Sparks ................................................................................................................... 12
Hazards from welding current ............................................................................................................... 12
Vagrant welding currents ...................................................................................................................... 13
EMC Measures ..................................................................................................................................... 13
Particular Hazard Areas........................................................................................................................ 14
Informal Safety Measures ..................................................................................................................... 15
Safety Measures at the Installation Location ........................................................................................ 15
Safety Measures in Normal Operation.................................................................................................. 16
Safety Inspection .................................................................................................................................. 16
Modifications ......................................................................................................................................... 16
Spare and Wearing Parts...................................................................................................................... 17
Calibrating Power Sources ................................................................................................................... 17
The CE label ......................................................................................................................................... 17
Copyright............................................................................................................................................... 17
General Information 19
General ...................................................................................................................................................... 21
General ................................................................................................................................................. 21
Intended Use......................................................................................................................................... 21
Applications........................................................................................................................................... 21
Scope of Supply.................................................................................................................................... 22
Optional Components ........................................................................................................................... 22
Requirements............................................................................................................................................. 23
Mechanical Requirements .................................................................................................................... 23
Robot Requirements ............................................................................................................................. 23
Ground Connection............................................................................................................................... 23
Alignment .............................................................................................................................................. 24
System Overview ....................................................................................................................................... 25
System Overview .................................................................................................................................. 25
Other LaserHybrid Systems.................................................................................................................. 26
Design Variants..................................................................................................................................... 27
Operating controls and connections 31
Product description .................................................................................................................................... 33
Product description ............................................................................................................................... 33
Device Description, SB 360i LaserHybrid ............................................................................................. 34
Pressure Monitoring in the SplitBox SB 360i LaserHybrid.................................................................... 35
Connection Specifications.......................................................................................................................... 36
Connection Specifications..................................................................................................................... 36
Compressed Air Diagram...................................................................................................................... 37
Commissioning 39
General ...................................................................................................................................................... 41
Safety.................................................................................................................................................... 41
Setup Regulations................................................................................................................................. 41
Grid Connection .................................................................................................................................... 41
Setting Up LaserHybrid Welding System.............................................................................................. 42

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Installing the Laser Welding Head on the Robot........................................................................................ 43
Mount Laser Welding Head on the Robot............................................................................................. 43
Installing and Connecting SplitBox SB 360i LaserHybrid .......................................................................... 44
Installing SplitBox SB 360i LaserHybrid on Robot ................................................................................ 44
Connecting the SplitBox SB 360i LaserHybrid...................................................................................... 46
Connecting the CrossJet and Additional Extraction................................................................................... 49
Connecting the CrossJet and Additional Extraction..............................................................................49
Connecting/Changing the Wirefeeding Hose on the Laser Welding Head ................................................ 50
Connecting/Changing the Wirefeeding Hose on the Laser Welding Head ........................................... 50
Installing/Changing Wirefeed Rollers......................................................................................................... 51
Preparation ........................................................................................................................................... 51
Installing/Replacing the Wirefeed Rollers ............................................................................................. 51
Final Tasks............................................................................................................................................ 52
Connecting the Laser Optics...................................................................................................................... 53
Connecting the Laser Optics................................................................................................................. 53
Preparing Welding Torch ........................................................................................................................... 56
Equip Welding Torch............................................................................................................................. 56
Place LaserHybrid hosepack on the robot ................................................................................................. 58
Installing Hosepack on Robot ............................................................................................................... 58
Threading the Wire Electrode .................................................................................................................... 59
Threading the Wire Electrode ............................................................................................................... 59
Setting up Laser Welding Head ................................................................................................................. 61
Stick Out ............................................................................................................................................... 61
Adjustable Axes .................................................................................................................................... 61
Adjustment Device on the Laser Welding Head ................................................................................... 62
Adjusting the X Axis .............................................................................................................................. 62
Adjusting the Y Axis .............................................................................................................................. 63
Set the radial airflow .................................................................................................................................. 64
Requirements........................................................................................................................................ 64
Set the Radial Airflow............................................................................................................................ 64
Creating Reference Program ..................................................................................................................... 67
Safety.................................................................................................................................................... 67
General ................................................................................................................................................. 67
Create a Reference Program................................................................................................................ 67
Signal Sequence for LaserHybrid Welding ................................................................................................ 69
Safety.................................................................................................................................................... 69
Signal Sequence for LaserHybrid Welding ........................................................................................... 69
Measures before Starting Welding............................................................................................................. 71
Measures before Starting Welding........................................................................................................ 71
Operation Recommendations for LaserHybrid Welding System................................................................ 72
Operation Recommendations for LaserHybrid Welding System........................................................... 72
Maintenance 73
Replacing the Welding Torch and Welding Torch Wearing Parts.............................................................. 75
Safety.................................................................................................................................................... 75
Welding Torch Spare Parts................................................................................................................... 75
Replacing the Welding Torch................................................................................................................ 75
Replacing Welding Torch Wearing Parts .............................................................................................. 76
Replace the spatter guard plate................................................................................................................. 78
Removing the Spatter Guard Plate ....................................................................................................... 78
Mounting the Spatter Guard Plate ........................................................................................................ 78
Replace the LaserHybrid UC hosepack..................................................................................................... 79
Removing the LaserHybrid UC Hosepack ............................................................................................ 79
Connect the LaserHybrid UC Hosepack ............................................................................................... 81
Replacing the Laser Optics........................................................................................................................ 84
Safety.................................................................................................................................................... 84
Disconnecting the Fiber Optic Cable from the Laser Optics ................................................................. 84
Removing the Laser Optics................................................................................................................... 85
Assembly Positions for Installing the Laser Optics ............................................................................... 88
Installing the Laser Optics..................................................................................................................... 88
Checking Position of the Wire Electrode in relation to the Laser Focus .................................................... 92
Safety.................................................................................................................................................... 92
General ................................................................................................................................................. 92

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EN-US
Checking Position of the Wire Electrode in relation to the Laser Focus ............................................... 92
Example: Use of the Reference Program after Welding Torch Replacement....................................... 93
Measures to Reduce Contamination of the Optics .................................................................................... 94
Measures to Reduce Contamination of the Optics ............................................................................... 94
Appendix 97
Technical Data ........................................................................................................................................... 99
Laser Welding Head WF25iLaserHybridUC ......................................................................................... 99
LaserHybrid Hosepack MHP 360i LH-UC............................................................................................. 99
Spare parts list: WF 25i LaserHybrid 4/6 kW UC....................................................................................... 100

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EN-US
Safety Instructions
Explanation of
Safety Instruc-
tions
If you see any of the symbols depicted in the "Safety Rules," special care is required.
General
DANGER! Indicates an immediate danger. Death or serious injury may result if
appropriate precautions are not taken.
WARNING! Indicates a possibly dangerous situation. Death or serious injury may
result if appropriate precautions are not taken.
CAUTION! Indicates a situation where damage or injury could occur. Minor injury
or damage to property may result if appropriate precautions are not taken.
NOTE! Indicates the possibility of flawed results and 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 has been manufactured using state-of-the-art technol-
ogy and according to recognized safety standards. If used incorrectly or mis-
used, however, 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 operating company,
- inefficient operation of the LaserHybrid head.
All persons involved in the commissioning, operation, maintenance, and ser-
vicing of the LaserHybrid head must
- be suitably qualified,
- have knowledge of welding and
- have read and implemented carefully these Operating Instructions and
the OI for the following system components:
Laser
Laser optics
Power source and associated wirefeeder
Robot and its controller
The Operating Instructions must always be at hand wherever the LaserHybrid
head is being used. In addition to the Operating Instructions, all applicable lo-
cal rules and regulations regarding accident prevention and environmental
protection must also be followed.
All safety instructions and warning signs on the LaserHybrid head itself must:
- be kept in a legible state
- not be damaged/marked
- not be removed
- not be covered, pasted, or painted over.
For the location of the safety and danger notices on the LaserHybrid head, re-
fer to the section headed "General" in the Operating Instructions for the Lase-
rHybrid head.
Before switching it on, resolve any faults that could compromise safety.
Your personal safety is at stake!

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Intended Use
Environmental
Conditions
Obligations of the
Operating Com-
pany
Obligations of
Personnel
The LaserHybrid head is to be used exclusively for its intended purpose.
The LaserHybrid head is intended exclusively for LaserHybrid welding of alu-
minum, CrNi and steel materials.
Any other use does not constitute proper use.
The manufacturer is not responsible for any damage resulting from improper
use.
Proper use also means:
- Completely reading and obeying all instructions in the Operating Instruc-
tions
- Completely reading and obeying all safety instructions and danger notic-
es
- Carrying out all the specified inspection and servicing work.
Never use the LaserHybrid head or the power source to thaw pipes.
The LaserHybrid head is designed for operation in industry and business. The
manufacturer shall not be liable for any damage resulting from use in a living
area.
The manufacturer shall not be liable for faulty or incorrect work results either.
Operation or storage of the LaserHybrid head outside the stipulated area will
be deemed as not in accordance with the intended purpose. The manufacturer
is not responsible for any damage resulting from improper use.
Temperature range of the ambient air:
- 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)
Ambient air: free of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)
The operating company must only allow persons to work with the LaserHybrid
head if they
- are familiar with the basic occupational safety and accident prevention
regulations and are trained in handling the LaserHybrid head
- have read and understood these Operating Instructions, especially the
section "Safety Rules," and have confirmed this with their signature
- are trained according to the requirements for the work results.
The safety-conscious work of the personnel must be checked regularly.
All persons who are assigned to work with the LaserHybrid head must do the
following before beginning work:
- Follow the basic regulations for occupational safety and accident preven-
tion
- Read these Operating Instructions, especially the section "Safety Rules,"
and confirm that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property dam-
age can occur in one's absence.

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EN-US
Personal Protec-
tive Equipment
Danger from Tox-
ic Gases and Va-
pors
Please take the following precautions for your own personal safety:
Persons present in the sealed cell for the LaserHybrid process must
wear rigid, wet-insulating footwear
protect hands with appropriate gloves (featuring electrical insulation and ther-
mal protection)
protect their eyes from laser beams by wearing regulation-compliant safety
glasses for lasers. To protect their face and eyes against UV beams, further
protection in the form of a protective shield with regulation-compliant filter in-
sert for laser protection class 4 must also be used in front of the safety glasses
for lasers and the person's face. Do not look into the laser beam, even with a
regulation-compliant filter insert for laser protection class 4.
Only wear suitable (flame-resistant) clothing
Wear hearing protection designed for crossjet noise (120 dbA)
If there are persons present in the sealed cell for the LaserHybrid process,
- inform them of all the dangers that may be posed during operation (e.g.
potential accumulation of gases hazardous to health, risk of asphyxiation
due to lack of oxygen in the breathable air, hazards posed by laser light,
etc.)
- provide protective equipment
- construct protective walls or install protective curtains.
The fumes produced during welding contain toxic gases and vapors.
Welding fumes contain substances that may cause birth defects and cancer in
some circumstances.
Keep your head out of the welding fumes and gases.
Take the following precautionary measures for fumes and harmful gases:
- Do not breathe them in.
- Extract them from the work area using appropriate equipment.
Ensure that there is sufficient fresh air.
Use breathing apparatus with air supply if there is insufficient ventilation.
When no welding is taking place, close the valve of the shielding gas cylinder
or the main gas supply.
If there is uncertainty as to whether the extraction capacity is sufficient, com-
pare the measured toxic emission values against the permissible limit values.

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Danger Posed by
Shielding Gas
Leak
Danger from Fly-
ing Sparks
Hazards from
welding current
The following components are factors that determine how toxic the welding
fumes are:
- The metals used for the workpiece
- Electrodes
- Coatings
- Cleaning agents, degreasers, and the like
Consult the corresponding material safety data sheets and manufacturer's in-
structions for the components listed above.
Keep flammable vapors (such as solvent vapors) out of the laser and arc ra-
diation range.
Risk of asphyxiation due to uncontrolled shielding gas leak
Shielding gas is colorless and odorless and may suppress the oxygen in the
ambient air in the event of leakage.
- Ensure there is a sufficient supply of fresh air with a ventilation flow rate
of at least 20 m³ per hour.
- Please observe the safety and maintenance information for the shielding
gas cylinder or the main gas supply.
- When no welding is taking place, close the valve of the shielding gas cyl-
inder or the main gas supply.
- Always check the shielding gas cylinder or main gas supply for uncon-
trolled gas leakage before each start-up.
Flying sparks can cause fires and explosions.
Never undertake welding near flammable materials.
Flammable materials must be kept at least 11 meters (35 ft.) from the Laser-
Hybrid welding process or protected with a certified cover.
Keep suitable, tested fire extinguishers on hand.
Sparks and pieces of hot metal may also get into surrounding areas through
small cracks and openings. Take appropriate measures to ensure that there
is no risk of injury or fire.
Do not undertake welding in areas at risk of fire and explosion, or on sealed
tanks, drums, or pipes if these have not been prepared in accordance with cor-
responding national and international standards.
Do not undertake welding on containers in which gases, fuels, mineral oils,
and the like are/were stored. Residues pose a risk of explosion.
An electric shock can be fatal. Every electric shock is hazardous to life.
All welding cables must be firmly attached, undamaged and properly insu-
lated. Replace any loose connections and scorched cables immediately.

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EN-US
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 elec-
trically 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 health
problems that are not yet known.
The operator is responsible for ensuring that there is no electromagnetic inter-
ference with electrical and electronic equipment.
If electromagnetic interference is discovered, the operator is obliged to take
action to rectify the situation.
Check and evaluate possible problems and the interference immunity of
equipment in the vicinity according to national and international regulations:
- Safety devices
- Grid power lines, signal lines, and data transfer lines
- EMC and telecommunications equipment
- Devices for measuring and calibrating
- The health of persons close by, e.g., those with pacemakers and hearing
aids
Persons with pacemakers must seek advice from their doctor before staying
in the immediate vicinity of where the welding work is taking place.
Supporting measures to avoid EMC problems:
a) Grid power supply
- If electromagnetic interference occurs despite a grid connection that
complies with regulations, take additional measures (e.g., use a suit-
able grid filter).
b) Welding power-leads
- Keep them as short as possible
- Route them close together (also to avoid EMC problems)
- Route them far from other lines
c) Equipotential bonding
d) Workpiece grounding
- If necessary, establish grounding using suitable capacitors
e) Shield, if necessary
- Shield other devices in the vicinity
- Shield the entire welding installation

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Particular Hazard
Areas Laser beam poses a risk of injury to the eyes. In addition to using the protec-
tive shield with a regulation-compliant UV filter insert, eyes should be protect-
ed from laser beams using regulation-compliant safety glasses for lasers. It
must still be ensured, however, that no one can accidentally look into the laser
beam.
If the workpiece surface is especially bright or highly reflective, reflected laser-
scattering radiation poses a further risk. Take suitable precautions so that per-
sons present have adequate protection from laser-scattering radiation also.
Keep hands, hair, loose clothing, and tools away from moving parts, such as:
- Ventilators
- Gear wheels
- Rollers
- Shafts
- Wirespools and welding wires
Do not insert body parts into rotating gear wheels on the wire drive or into ro-
tating drive parts.
Covers and side parts must only be opened/removed during maintenance and
repair work.
During operation:
- Ensure that all covers are closed and all side parts have been mounted
properly.
- Keep all covers and side parts closed.
Welding wire from the welding torch poses a high risk of injury (cuts to the
hand, injuries to the face and eyes, etc.).
For this reason, always hold the welding torch away from your body (devices
with wirefeeder) and wear suitable protective goggles.
Do not touch workpieces during or after welding – risk of burns.
Slag may fly off from workpieces that are cooling down. For this reason, be
sure to wear regulation-compliant protective equipment and ensure that other
people are sufficiently protected even when reworking workpieces.
Leave the welding torch and other parts with a high operating temperature to
cool before working on them.
Special regulations apply in areas where there is a risk of fire or explosion
– observe relevant national and international regulations.
Power sources for work in spaces where electrical hazards pose a greater risk
(e.g. the boiler room) must be marked with a (Safety) sign. The power source
should not be located in these types of spaces, however.
Risk of scalding due to coolant leakage. Before disconnecting connections for
the coolant supply hose or return connection, switch off the cooling unit.
When handling coolants, observe the specifications on the safety data sheet.
The coolant safety data sheet is available from your service center or from the
manufacturer's homepage.

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EN-US
Informal Safety
Measures
Safety Measures
at the Installation
Location
Only use suitable load-carrying equipment from the manufacturer for trans-
porting devices by crane.
- Attach chains or ropes to all designated suspension points on suitable
load-carrying equipment.
- Chains or ropes must be as close to perpendicular as possible.
- Remove the gas cylinder and wirefeeder (MIG/MAG and TIG devices).
Always use a suitable wirefeeder hoisting attachment with insulation on the
crane for hoisting the wirefeeder (MIG/MAG and TIG devices).
If the device is fitted with a carrier belt or handle, this should be used exclu-
sively for transportation by hand. The carrier belt is not suitable for transporta-
tion by crane, counterbalanced lift truck or other mechanical chain hoists.
All lifting equipment (belts, straps, chains, etc.) used in connection with the de-
vice or its components must be checked regularly (e.g., for mechanical dam-
age, corrosion, or changes due to other environmental influences).
The test interval and scope must, as a minimum, comply with the respective
valid national standards and guidelines.
There is a risk of colorless, odorless shielding gas escaping without notice if
an adapter is used for the shielding gas connection. Use suitable Teflon tape
to seal the thread of the shielding gas connection adapter on the device side
before installation.
The Operating Instructions must always be at hand wherever the LaserHybrid
head is being used.
In addition to the Operating Instructions, all applicable local rules and regula-
tions regarding accident prevention and environmental protection must also
be made available and be followed.
All safety and danger notices on the LaserHybrid head must be kept in a leg-
ible state.
The cell for the LaserHybrid welding process must meet the following require-
ments:
- be light-proof in relation to surrounding rooms
- is shielded with at least 1 mm steel plate and/or approved laser protective
glass to protect against UV and laser beams
- The laser welding process and the arc welding process must be stopped
automatically and immediately as soon as the cell is opened.
A toppling device can be deadly! Set up the device securely on an even, solid
surface
- A tilt angle of no more than 10° is permitted
Special regulations apply in areas at risk of fire or explosion
- Follow the appropriate national and international regulations.
Use instructions and checks within the company to ensure that the vicinity of
the workplace is always clean and organized.
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 an all-round clearance of 0.5 m (1 ft. 7.69
in.) so that the cooling air can enter and leave unhindered.

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Safety Measures
in Normal Opera-
tion
Safety Inspection
Modifications
Take care to ensure that the applicable national and regional guidelines and
accident prevention regulations are observed when transporting the device,
especially guidelines concerning hazards during transport and shipment.
Before transporting the device, always completely drain the coolant and dis-
mantle the following components:
- Wirefeeder
- Wirespool
- Shielding gas cylinder
It is essential to conduct a visual inspection of the device to check for damage
after it has been transported but before it is commissioned. Have any damage
repaired by trained service technicians before commissioning the device.
Only operate the LaserHybrid head if all protective 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 operat-
ing company,
- inefficient operation of the device.
Safety devices that are not fully functional must be repaired before the device
is switched on.
Never bypass or disable safety devices.
Before conditioning the LaserHybrid head, ensure that no one can be put in
danger.
The LaserHybrid head must be examined at least once a week for externally
detectable damage and functionality of the safety devices.
The operator is required to have the LaserHybrid head tested by an electrician
after every alteration, installation or modification, and all repairs and mainte-
nance, and at least every 12 months, to ensure that it is in its correct state.
Regulation Title
IEC (EN) 60 974-1 Equipment for Arc Welding, Part 1: Welding Current
Sources
BGV A2, Section 5 Electrical Plants and Equipment
BGV D1, Sections 33 /
49
Welding, Cutting and Related Work Methods
VDE 0701-1 Repairing, Modifying and Testing Electrical Devic-
es;
General Requirements
VDE 0702-1 Repeating Tests on Electrical Devices
1
2
3
4
5
6
7
8
9
1
0
1
1
1
2
Do not carry out any alterations, installations, or modifications to the LaserHy-
brid head without first obtaining the manufacturer’s permission.
Parts that are not in perfect condition must be replaced immediately.

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EN-US
Spare and Wear-
ing Parts
Calibrating Power
Sources
The CE label
Copyright
Use only original spare and wearing parts (also applies to standard parts).
It is impossible to guarantee that externally procured parts are designed and
manufactured to meet the demands made on them, or that they satisfy safety
requirements.
When ordering, specify the exact name and part number according to the
Spare Parts List as well as the serial number of your device.
Regular calibration of power sources is required in accordance with interna-
tional standards. The manufacturer recommends a calibration interval of 12
months. Please contact your service center if you require further details.
The LaserHybrid head meets the basic requirements of the Low Voltage and
Electromagnetic Compatibility Directives and therefore has CE sign.
Copyright of these operating instructions remains with the manufacturer.
Text and illustrations are technically correct at the time of going to print. The
right to make modifications is reserved. The contents of the operating instruc-
tions shall not provide the basis for any claims whatsoever on the part of the
purchaser. If you have any suggestions for improvement, or can point out any
mistakes that you have found in the operating instructions, we will be most
grateful for your comments.

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General Information