FRO­NIUS LaserHybrid WF 25i User manual

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WF 25i LaserHybrid FW
WF 60i LaserHybrid FW CMT
SB 360i LaserHybrid
EN-US
Operating instructions
LaserHybrid
42,0426,0306,EA 007-16032021

Table of contents
Safety Instructions 6
Explanation of Safety Instructions 6
General 6
Intended Use 7
Environmental Conditions 7
Obligations of the Operating Company 7
Obligations of Personnel 7
Personal Protective Equipment 8
Danger from Toxic Gases and Vapors 8
Danger Posed by Shielding Gas Leak 8
Danger from Flying Sparks 9
Danger from Welding Current 9
Stray Welding Currents 9
EMC Measures 9
Particular Hazard Areas 10
Informal Safety Measures 11
Safety Measures at the Installation Location 11
Safety Measures in Normal Operation 12
Safety Inspection 12
Modifications 13
Spare and Wearing Parts 13
Calibrating Power Sources 13
The CE label 13
Copyright 13
General information 15
General 17
General 17
Intended use 17
Applications 17
Laser welding head versions 18
Applications 19
Scope of supply 20
Optional Components 21
Requirements 22
Mechanical Requirements 22
Robot Requirements 22
Ground Connection 22
Alignment 23
System Overview 24
System overview 24
Other LaserHybrid systems 26
Design versions 28
Operating controls and connections 31
Product description 33
Product description 33
Control Panel WF 25i Robacta Drive / WF 60i Robacta Drive CMT 34
Product description SB 360i LaserHybrid 36
Connection Specifications 37
Connection specifications 37
Compressed air diagram 38
Pressure monitoring in the SplitBox SB 360i LaserHybrid 39
Commissioning 41
General 43
Safety 43
Setup Regulations 43
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EN-US

Grid Connection 43
Setting up the LaserHybrid welding system 43
Setting up the CMT LaserHybrid welding system 44
Installing the Laser Welding Head on the Robot 46
Connection options on the robot 46
Mounting the drive unit on the laser welding head 47
Mounting the Laser Welding Head on the Robot 47
Installing and Connecting SplitBox SB 360i LaserHybrid 48
Mounting the SplitBox SB 360i LaserHybrid on the robot 48
Connecting SplitBox SB 360i LaserHybrid 50
Connecting Crossjet 52
Connecting the CrossJet 52
Connecting LaserHybrid Hosepack to Laser Welding Head 54
Mounting the Hosepack on the WF Robacta Drive (Conventional) 54
Connecting/Changing the Wirefeeding Hose on the Laser Welding Head 55
Installing/Changing Wirefeed Rollers 56
Inserting/replacing the WF 25i Robacta drive feed rollers 56
Inserting/replacing the WF 60i Robacta Drive CMT drive feed rollers 58
Connecting Laser Optics and Extra Extraction 60
Connecting the laser optics 60
Connecting the additional extraction system 63
Preparing Welding Torch 66
Fitting the inner liner in the torch body 66
Mounting the welding torch on the WF Robacta Drive (conventional) 67
Installing Hosepack on Robot 69
Placing the hosepack on the robot 69
Adapting the Additional Extraction System 71
Safety 71
Adapting the Additional Extraction System 71
Threading the Wire Electrode 72
Threading the wire electrode 72
Setting the Contact Pressure on the WF 25i Robacta Drive 72
Setting the contact pressure on the WF 60i Robacta Drive CMT 73
Setting up Laser Welding Head 74
Stick Out 74
Adjustable axes 74
Adjustment device on the laser welding head 75
Adjusting the x axis 75
Adjusting the y axis 76
Adjusting the z Axis 76
Creating Reference Program 77
Safety 77
General 77
Creating a Reference Program 77
Signal Sequence for LaserHybrid Welding 79
Safety 79
Signal Sequence for LaserHybrid Welding 79
Measures before Starting Welding 81
Measures before Starting Welding 81
Operation Recommendations for LaserHybrid Welding System 82
Recommendations for the Operation of a LaserHybrid Welding System 82
Specifications for the compressed air supply 82
Maintenance 83
Replacing the Welding Torch and Welding Torch Wearing Parts 85
Safety 85
Mounting Wearing Parts on the Welding Torch 85
Replacing the Spatter Guard Plate and Extra Extraction 86
Replacing the spatter guard plate 86
Replacing the Additional Extraction System 86
Replacing the Laser Optics 87
Safety 87
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Preparation 87
Removing the Laser Optics 89
Installing the laser optics 89
Final Tasks 92
Checking Position of the Wire Electrode in relation to the Laser Focus 93
Safety 93
General 93
Checking Position of the Wire Electrode in relation to the Laser Focus 93
Example: Use of the Reference Program after Welding Torch Replacement 94
Measures to Reduce Contamination of the Optics 95
Measures to Reduce Contamination of the Optics 95
Appendix 97
Technical data 99
WF 25i LaserHybrid 90° 10 kW FW (Laser Welding Head) 99
LaserHybrid hosepack MHP 360i LH 99
SB 360i LH 99
WF 25i Robacta Drive /W 100
WF 60i Robacta Drive /W CMT 100
MTB 700 LH /W 101
MTB 500i LH /W 101
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EN-US

Safety Instructions
Explanation of
Safety Instruc-
tions
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.
General The LaserHybrid head has been manufactured using state-of-the-art technology and
according to recognized safety standards. If used incorrectly or misused, 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 operat-
ing company,
- inefficient operation of the LaserHybrid head.
All persons involved in the commissioning, operation, maintenance, and servicing 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 local rules and regula-
tions 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, refer to the
section headed "General" in the Operating Instructions for the LaserHybrid head.
Before switching it on, resolve any faults that could compromise safety.
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Your personal safety is at stake!
Intended Use The LaserHybrid head is to be used exclusively for its intended purpose.
The LaserHybrid head is intended exclusively for LaserHybrid welding of aluminum, 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 Instructions
- Completely reading and obeying all safety instructions and danger notices
- 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 manufac-
turer 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.
Environmental
Conditions
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.)
Obligations of the
Operating Com-
pany
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.
Obligations of
Personnel
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 prevention
- Read these Operating Instructions, especially the section "Safety Rules," and con-
firm that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property damage can
occur in one's absence.
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EN-US

Personal Protect-
ive Equipment
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 thermal
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 insert 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 oxy-
gen in the breathable air, hazards posed by laser light, etc.)
- provide protective equipment
- construct protective walls or install protective curtains.
Danger from
Toxic Gases and
Vapors
The fumes produced during welding contain toxic gases and vapors.
Welding fumes contain substances that may cause birth defects and cancer in some cir-
cumstances.
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, compare the
measured toxic emission values against the permissible limit values.
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 instructions
for the components listed above.
Keep flammable vapors (such as solvent vapors) out of the laser and arc radiation range.
Danger Posed by
Shielding Gas
Leak
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.
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- 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 cylin-
der or the main gas supply.
- When no welding is taking place, close the valve of the shielding gas cylinder or the
main gas supply.
- Always check the shielding gas cylinder or main gas supply for uncontrolled gas
leakage before each start-up.
Danger from Fly-
ing Sparks
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 LaserHybrid weld-
ing 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 corresponding
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.
Danger from
Welding Current
An electric shock can be fatal. Every electric shock poses a risk of death.
All welding power-leads must be secured, undamaged, and insulated. Replace loose
connections and scorched cables immediately.
Stray Welding
Currents
If the following instructions are not observed, stray welding currents may occur, which
can result in the destruction of ground conductors, the power source used, the LaserHy-
brid head, and other electrical equipment.
Ensure that the workpiece terminal is securely connected to the workpiece. If the floor is
electrically conductive, set up the power source so that it is insulated wherever possible.
EMC Measures 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 interference
with electrical and electronic equipment.
If electromagnetic interference is discovered, the operator is obliged to take action to rec-
tify 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
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EN-US

Persons with pacemakers must seek advice from their doctor before staying in the imme-
diate 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 suitable grid filter).
a) Welding power-leads
- Keep them as short as possible
- Route them close together (also to avoid EMC problems)
- Route them far from other lines
a) Equipotential bonding
b) Workpiece grounding
- If necessary, establish grounding using suitable capacitors
a) Shield, if necessary
- Shield other devices in the vicinity
- Shield the entire welding installation
Particular Hazard
Areas
Laser beam poses a risk of injury to the eyes. In addition to using the protective shield
with a regulation-compliant UV filter insert, eyes should be protected 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 persons 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 rotating 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.
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