FRO­NIUS Pull User manual

Operating
instructions
TPS/i Robotics welding system
Pull
PushPull CMT
42,0426,0219,EN 021-15032022
EN Operating instructions

Contents
Safety rules 8
Explanation of safety notices 8
General 8
Intended use 9
Environmental conditions 9
Obligations of the operator 9
Obligations of personnel 9
Mains connection 9
Protecting yourself and others 10
Danger from toxic gases and vapours 10
Danger from flying sparks 11
Risks from mains current and welding current 11
Meandering welding currents 13
EMC Device Classifications 13
EMC measures 13
EMF measures 14
Specific hazards 14
Requirement for the shielding gas 15
Danger from shielding gas cylinders 15
Danger from escaping shielding gas 16
Safety measures at the installation location and during transport 16
Safety measures in normal operation 17
Commissioning, maintenance and repair 17
Safety inspection 18
Disposal 18
Safety symbols 18
Data protection 18
Copyright 18
Description of the warning notices on the device 19
System configurations 21
System configurations - conventional robot 23
PowerDrive with wire drum 23
PowerDrive with wire drum and external wirefeeding hose 24
PushPull with 4-roller unreeling wirefeeder and wire drum 25
PushPull with 4-roller unreeling wirefeeder and wirespool 26
PushPull with SB 60i, 4-roller unreeling wirefeeder and wirespool 27
PushPull with 2-roller unreeling wirefeeder, wire drum and external wirefeeding hose 28
CMT with SB 60i, 4-roller unreeling wirefeeder and wire drum 29
CMT with SB 500i, 4-roller unreeling wirefeeder, wire drum and external wirefeeding hose 30
CMT with SB 60i, 4-roller unreeling wirefeeder and wirespool 31
System configurations - PAP 32
PowerDrive with wire drum 32
PushPull with 4-roller unreeling wirefeeder and wire drum 33
PushPull with 4-roller unreeling wirefeeder and wirespool 34
PushPull with 2-roller unreeling wirefeeder and wire drum 35
PushPull with wire buffer, 4-roller unreeling wirefeeder and wire drum 36
PushPull with wire buffer, 4-roller unreeling wirefeeder and wirespool 37
CMT with SB 60i, 4-roller unreeling wirefeeder and wire drum 38
CMT with SB 500i, 4-roller unreeling wirefeeder and wire drum 39
CMT with SB 500i, 4-roller unreeling wirefeeder and wirespool 40
System components 41
SplitBox SB 500i R 43
Device concept 43
Proper use 43
Safety 43
Warning notices on the device 44
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SplitBox SB 60i R 46
Device concept 46
Proper use 46
Safety 46
Warning notices on the device 47
TPSi wire buffer 49
General 49
CrashBox /i 50
General 50
Also required for installation 51
Device concept 52
Areas of utilisation 52
Information on repairing CrashBoxes 52
Scope of supply 52
WF Robacta Drive 53
General 53
Warning notices on the device 53
PushPull hosepack 54
General 54
Scope of supply 54
Robot welding torch 55
Safety 55
General 55
WF 25i REEL R /4R, WF 30i REEL R /2R 57
Safety 57
Device concept 57
Application area 57
Proper use 57
Warning notices on the device 58
Interconnecting hosepack 60
General 60
General 60
PowerLiner 61
General 61
WireSense 62
General 62
Requirements 62
How it works 62
WireSense - edge detection 63
WireSense - contour detection 64
Technical details 65
OPT/i camera mount 66
General 66
Drilling template 66
Controls, connections and mechanical components 67
General 69
Safety 69
General 69
SplitBox SB 500i R / SB 500i R PAP 70
SB 500i R control elements, connections and mechanical components 70
SB 500i R PAP control elements, connections and mechanical components 71
Gas test/wire threading control panel (optional) 72
SplitBox SB 60i R 75
SB 60i R:control elements, connections and mechanical components 75
SB 60i R /L:control elements, connections and mechanical components 76
WF 25i Robacta Drive / WF 60i Robacta Drive CMT 77
WF 25i Robacta Drive / WF 60i Robacta Drive CMT control panel 77
Status indicators 79
WF 25i REEL R /4R, WF 30i REEL R /2R 81
Controls, connections and mechanical components 81
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Control panel 82
Assembling system components - conventional robot 85
General 87
Safety 87
Assembly sequence, conventional robot 87
Fitting the SplitBox SB 500i R 88
Fitting the wirefeeder holder 88
Fitting the SB 500i R 88
Fitting the SB 500i R (left variant) 88
Fitting the CrashBox /i to the robot 89
Fitting the CrashBox /i to the robot 89
Installing the CrashBox/i Dummy on the robot 90
Fitting the WF Robacta Drive to a conventional robot 92
Fitting the hosepack to the WF Robacta Drive (conventional) 92
Fitting the WF Robacta Drive to the robot (conventional) 93
Fitting the WF Robacta Drive to the robot 94
Optimum hosepack arrangement 95
Fitting the interconnecting hosepack 96
Fitting the Standard interconnecting hosepack to the robot 96
Connecting the MHP W hosepack 97
Connecting the MHP W hosepack 97
Connecting the SplitBox SB 500i R to the system components 100
Safety 100
General 100
Connecting the SplitBox SB 500i R to the system components 100
Assembling system components - PAP robot 103
General 105
Safety 105
Assembly sequence, PAP robot 105
Maximum axis rotation 106
Fitting the SplitBox SB 500i R PAP 107
Fitting the SB 500i R PAP 107
Installing the CrashBox Drive /i PAP on the robot 108
Installing the CrashBox Drive /i PAP on the robot 108
Installing the CrashBox Drive /i PAP Dummy on the robot 109
Fitting the WF Robacta Drive to a PAP robot 111
Fitting the hosepack to the WF Robacta Drive (PAP) 111
Fitting the WF Robacta Drive to the robot (PAP) 112
Fitting the interconnecting hosepack 115
Fitting the PAP interconnecting hosepack to the robot 115
Connecting the SplitBox SB 500i R PAP to the system components 116
Safety 116
General 116
Connecting the SplitBox SB 500i R PAP to the system components 116
Assembling further system components 119
Fitting the SplitBox SB 60i R 121
Fitting the SB 60i R to the robot 121
Fitting the SB 60i R to the balancer 121
Mounting the SB 60i R on the wall 122
Connecting the torch hosepack to the SplitBox SB 60i R 123
Fitting the TPSi wire buffer 124
Fitting the TPSi wire buffer 124
Connecting the control line to the wire buffer 125
Fitting the unreeling wirefeeder 126
Fitting the unreeling wirefeeder 126
Connecting the extension hosepack 127
Connecting the extension hosepack 127
Fitting the torch body to the WF Robacta Drive 129
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Fitting the gas-saver nozzle 129
Fitting the inner liner inside the torch body 130
Fitting the torch body to the WF Robacta Drive 132
Fitting the OPT/i camera mount 133
Load-bearing capacity of the OPT/i camera mount 133
Safety 133
Fitting the OPT/i camera mount 134
Fitting the inner liner 135
Fitting the inner liner (unreeling wirefeeder - SplitBox SB 500i R) 135
Fitting the inner liner (unreeling wirefeeder- WF Robacta Drive with external wirefeeding
hose)
135
Fitting the PowerLiner (unreeling wirefeeder - WF Robacta Drive with external wirefeed-
ing hose)
136
Fitting the inner liner (unreeling wirefeeder - wire buffer) 137
Fitting the inner liner (SplitBox - WF 25i with internal inner liner) 138
Fitting the inner liner (wire buffer - WF Robacta Drive with internal wirefeeding hose) 139
Fitting the inner liner (wire buffer - WF Robacta Drive with external wirefeeding hose) 140
Fitting the inner liner inside the torch hosepack 141
Start-up 143
Inserting/replacing feed rollers 145
General 145
WF 25i Reel 4R: inserting/replacing feed rollers for the 4-roller drive 145
WF 30i Reel 2R: inserting/replacing feed rollers for the 2-roller drive 146
Inserting/replacing the WF 25i Robacta Drive feed rollers 147
Inserting/replacing the WF 60i Robacta Drive CMT feed rollers 149
Feeding in the wire electrode 152
Insulated routing of wire electrode to wirefeeder 152
Feeding in the wire electrode 152
Setting the contact pressure for the WF 25i Robacta Drive 153
Setting the contact pressure for the WF 60i Robacta Drive CMT 154
Start-up 155
Requirements 155
General 155
Troubleshooting, maintenance and disposal 157
Troubleshooting 159
Safety 159
Fault diagnosis 159
Care, maintenance and disposal 163
General 163
Safety 163
Every start-up 163
Special care of O-rings 163
Whenever the welding torch or torch hosepack is changed 164
Changing the torch hosepack, changing the interconnecting hosepack 164
Every 6 months 164
Recognising faulty wearing parts 165
Replacing the WF 25i Robacta Drive clamping lever 165
Replacing the WF 60i Robacta Drive CMT clamping lever 166
Replacing the WF Robacta Drive gas-saver nozzle 166
Replacing the SB 60i R inner liner 167
Replacing the TPSi wire buffer wire guide 169
Changing the direction of operation of the TPSi wire buffer 170
Replacing the TPSi wire buffer lever 171
Fitting wearing parts to the torch body 172
Fitting wearing parts to the torch body - MTW 700 i 172
Removing the CrashBox PAP from the robot 173
Disposal 174
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Technical data 175
SB 500i R, R left variant, PAP 177
SB 500i R, R left variant, PAP 177
SB 60i R 178
SB 60i R 178
CrashBox /i 179
CrashBox /i 179
PushPull hosepack 183
Gas-cooled PushPull hosepacks 183
Water-cooled PushPull hosepacks 184
WF 25i Robacta Drive 186
WF 25i Robacta Drive /G 186
WF 25i Robacta Drive /W 186
WF 60i Robacta Drive CMT 187
WF 60i Robacta Drive CMT /G 187
WF 60i Robacta Drive /W CMT 187
WF 25i REEL R /4R/G/W 189
WF 30i REEL R /2R/G/W 190
Robot welding torch 191
Gas-cooled robot welding torches 191
Water-cooled robot welding torches 192
Interconnecting hosepacks 194
HP 70i 194
HP 95i 194
HP 120i 194
HP 70i, HP PC Cable HD 70 194
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Safety rules
Explanation of
safety notices DANGER!
Indicates immediate danger.
▶If not avoided, death or serious injury will result.
WARNING!
Indicates a potentially hazardous situation.
▶If not avoided, death or serious injury may result.
CAUTION!
Indicates a situation where damage or injury could occur.
▶If not avoided, minor injury and/or damage to property may result.
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
General The device is manufactured using state-of-the-art technology and according to
recognised safety standards. If used incorrectly or misused, however, it can
cause:
-injury or death to the operator or a third party,
-damage to the device and other material assets belonging to the operating
company,
-inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing the
device must:
-be suitably qualified,
-have sufficient knowledge of automated welding, and
-read and carefully follow these operating instructions as well as the operat-
ing instructions for all system components.
The operating instructions must always be at hand wherever the device is being
used. In addition to the operating instructions, attention must also be paid to any
generally applicable and local regulations regarding accident prevention and en-
vironmental protection.
All safety and danger notices on the device
-must be in a legible state,
-must not be damaged,
-must not be removed,
-must not be covered, pasted or painted over.
For the location of the safety and danger notices on the device, refer to the sec-
tion headed "General" in the operating instructions for the device.
Before commissioning the device, rectify any faults that could compromise
safety.
This is for your personal safety!
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Intended use The devices and components described in these Operating Instructions are in-
tended exclusively for automated MIG/MAG applications in conjunction with
Fronius components.
Any use above and beyond this purpose is deemed improper. The manufacturer
shall not be held liable for any damage arising from such usage.
Proper use also includes:
-Carefully reading and following all the instructions given in the Operating In-
structions
-Studying and obeying all safety instructions and danger notices carefully
-Performing all stipulated inspection and servicing work
The manufacturer likewise accepts no liability for inadequate or incorrect results.
Environmental
conditions
Operation or storage of the device outside the stipulated area will be deemed as
not in accordance with the intended purpose. The manufacturer shall not be held
liable for any damage arising from such usage.
Ambient temperature range:
-during operation: -10 °C to + 40 °C (14 °F to 104 °F)
-during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
Relative humidity:
-up to 50% at 40 °C (104 °F)
-up to 90% at 20 °C (68 °F)
The surrounding air must be free from dust, acids, corrosive gases or substances,
etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)
Obligations of
the operator
The operator must only allow persons to work with the device who:
-are familiar with the fundamental instructions regarding safety at work and
accident prevention and have been instructed in how to use the device
-have read and understood these operating instructions, especially the sec-
tion "safety rules", and have confirmed as much with their signatures
-are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are
working in a safety-conscious manner.
Obligations of
personnel
Before using the device, all persons instructed to do so undertake:
-to observe the basic instructions regarding safety at work and accident pre-
vention
-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.
Mains connec-
tion
Devices with a higher rating may affect the energy quality of the mains due to
their current consumption.
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This may affect a number device types in terms of:
-Connection restrictions
-Criteria with regard to the maximum permissible mains impedance *)
-Criteria with regard to the minimum short-circuit power requirement *)
*) at the interface with the public grid
see "Technical data"
In this case, the plant operator or the person using the device should check
whether the device may be connected, where appropriate by discussing the mat-
ter with the power supply company.
IMPORTANT! Ensure that the mains connection is earthed properly
Protecting your-
self and others
Anyone working with the device exposes themselves to numerous risks, e.g.
-flying sparks and hot pieces of metal
-Arc radiation, which can damage eyes and skin
-Hazardous electromagnetic fields, which can endanger the lives of those us-
ing cardiac pacemakers
-Risk of electrocution from mains current and welding current
-Greater noise pollution
-Harmful welding fumes and gases
Suitable protective clothing must be worn when working with the device. The
protective clothing must have the following properties:
-Flame-resistant
-Insulating and dry
-Covers the whole body, is undamaged and in good condition
-Safety helmet
-Trousers with no turn-ups
Protective clothing refers to a variety of different items. Operators should:
-Protect eyes and face from UV rays, heat and sparks using a protective visor
and regulation filter
-Wear regulation protective goggles with side protection behind the protect-
ive visor
-Wear stout footwear that provides insulation even in wet conditions
-Protect the hands with suitable gloves (electrically insulated and providing
protection against heat)
-Wear ear protection to reduce the harmful effects of noise and to prevent in-
jury
Keep all persons, especially children, out of the working area while any devices
are in operation or welding is in progress. If, however, there are people in the vi-
cinity:
-Make them aware of all the dangers (risk of dazzling by the arc, injury from
flying sparks, harmful welding fumes, noise, possible risks from mains cur-
rent and welding current, etc.)
-Provide suitable protective equipment
-Alternatively, erect suitable safety screens/curtains.
Danger from tox-
ic gases and va-
pours
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that cause cancer, as stated in Monograph
118 of the International Agency for Research on Cancer.
Use at-source extraction and a room extraction system.
If necessary, use a welding torch with an integrated extraction device.
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