Alimentador Fronius WF 25i R PAP

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Operating instructions
TPS/i Robotics welding system
EN
Push MIG/MAG robot welding system
42,0426,0183,EN 019-31032021
Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
Contents
EN
Safety rules 7
Explanation of safety notices 7
General 7
Intended use 8
Environmental conditions 8
Obligations of the operator 8
Obligations of personnel 8
Mains connection 8
Protecting yourself and others 9
Danger from toxic gases and vapours 9
Danger from flying sparks 10
Risks from mains current and welding current 10
Meandering welding currents 11
EMC Device Classifications 12
EMC measures 12
EMF measures 12
Specific hazards 13
Requirement for the shielding gas 14
Danger from shielding gas cylinders 14
Danger from escaping shielding gas 14
Safety measures at the installation location and during transport 15
Safety measures in normal operation 15
Commissioning, maintenance and repair 16
Safety inspection 16
Disposal 16
Safety symbols 17
Data protection 17
Copyright 17
Description of the warning notices on the device 18
System configurations 21
System configurations - conventional robot 23
Push with wire drum 23
Push with wirespool 24
Push with 4-roller unreeling wirefeeder and wire drum 25
System configurations - PAP 26
Push with wire drum 26
Push with wirespool 27
Push with 4-roller unreeling wirefeeder and wire drum 28
System components 29
WF wire-feed unit 31
Device concept 31
Proper use 31
Safety 31
Warning notices on the device 32
WF 25i REEL R /4R, WF 30i REEL R /2R 34
Safety 34
Device concept 34
Application area 34
Proper use 34
Warning notices on the device 34
Interconnecting hosepack 37
General 37
Torch hosepack 38
General remarks 38
Scope of supply 38
Buttons on the Robacta MHP hosepack 38
CrashBox /i 39
3
General remarks 39
Also required for installation 39
Device concept 39
Application areas 40
Information on repairing CrashBoxes 40
Scope of supply 40
Clamp system scope of supply and options 41
Robot welding torch 42
Safety 42
General 42
Controls, connections and mechanical components 43

Control elements and mechanical components 45
Safety 45
Control elements and mechanical components 45
Gas test/wire threading control panel (optional) 45
WF 15i / 25i / 30i R 48
WF 15i R, WF 30i R connections 48
WF 30i R / L connections 48
WF 25i R connections 49
WF 25i R / L connections 50
WF 15i / 25i / 30i R PAP 51
WF 15i R PAP, WF 30i R PAP connections 51
WF 25i R PAP connections 51
WF 25i R / L PAP connections 52
WF 25i REEL R /4R, WF 30i REEL R /2R 53
Safety 53
Controls, connections and mechanical components 53
Control panel 55
Installation - conventional robot 59

Fitting the welding system to a conventional robot 61
Safety 61
Fitting the TPS/i welding system to a conventional robot 61
Fitting the wire-feed unit 62
Fitting the wirefeeder holder 62
Fitting the wirefeeder 62
Fitting the CrashBox /i to the robot 64
Fitting the CrashBox /i to the robot 64
Installing the CrashBox/i Dummy on the robot 65
Fitting the clamp system 67
Special tilt angle for the welding torch 67
Fitting the clamp system 68
Fitting the clamp system with extension 68
Fitting the MHP G / W hosepack 69
Fitting the MHP G / W conventional hosepack - Standard 69
Optimum hosepack arrangement 69
Fitting the TPS/i torch neck 70
Safety 70
Fitting the TPS/i torch body - Standard 70
“OPT / i MHP WireBrake” option 70
Fitting the inner liner inside the torch hosepack 71
Fitting the interconnecting hosepack 73
Fitting the Standard interconnecting hosepack to the robot 73
Connecting the extension hosepack 73
Connecting the MHP W hosepack 75
Connecting the MHP W hosepack 75
Connecting wire-feed unit to system components 78
Safety 78
General 78
Connecting the wirefeeder to the system components 78
4
Fitting the OPT / i MHP WireBrake and torch body 81
Safety 81
EN
Prerequisites for operation 81
Compressed air supply specifications 81
Remedying the clamping marks on the wire electrode 81
Technical data 82
Fitting the OPT/i MHP WireBrake 82
Removing the OPT / i MHP WireBrake and torch body 84
Safety 84
Removing the OPT / i MHP WireBrake and torch body 84
Fitting the unreeling wirefeeder 85
Fitting the unreeling wirefeeder 85
Installation - PAP 87
Fitting the welding system to a PAP robot 89
Safety 89
Fitting the TPS/i welding system to a PAP robot 89
Maximum axis rotation 89
Fitting the wire-feed unit 91
Fitting the WF 15i/25i/30i R PAP 91
Installing the CrashBox /i PAP on the robot 92
Installing the CrashBox /i PAP on the robot 92
Installing the CrashBox/i Dummy on the robot 93
Fitting the MHPi/MHP S G/W PAP hosepack 95
Fitting the Robacta MHP G/W PAP hosepack 95
Fitting the MHPi/MHP S G/W PAP SM hosepack 99
Fitting the Robacta MHP G/W PAP SM hosepack 99
Fitting the interconnecting hosepack 103
Fitting the PAP interconnecting hosepack to the robot 103
Connecting the extension hosepack 104
Connecting the interconnecting hosepack 105
Connecting wire-feed unit to system components 106
Safety 106
General 106
Connecting the WF 15i/25i/30i R PAP to the system components 106
Start-up 109
Inserting/replacing feed rollers 111
General 111
WF 25i Reel 4R: inserting/replacing feed rollers for the 4-roller drive 111
WF 30i Reel 2R: inserting/replacing feed rollers for the 2-roller drive 112
Inserting/replacing feed rollers 113
Feeding in the wire electrode 115
Insulated routing of wire electrode to wirefeeder 115
Feeding in the wire electrode 115
Setting the contact pressure 117
Start-up 118
Requirements 118
General 118
Troubleshooting, maintenance and disposal 119

Troubleshooting 121
Safety 121
Fault diagnosis 121
Care, maintenance and disposal 124
General 124
Safety 124
5
Every start-up 124
Special care of O-rings 125
Whenever the welding torch or torch hosepack is changed 125
Every 6 months 125
Preparing the WF 15i/25i/30i R PAP for replacement of the welding torch inner liner 125
Recognising faulty wearing parts 126
MTG d, MTW d - Fitting wearing parts to the torch body 127
Fitting wearing parts to the torch body - MTW 700 i 128
Removing the CrashBox PAP from the robot (without mounting key) 128
Removing the CrashBox PAP from the robot (with mounting key) 130
Changing the torch hosepack, changing the interconnecting hosepack 132
Cleaning the welding torch 133
Disposal 133
Technical data 135

WF wire-feed unit 137
WF 15i R, WF 15i R PAP 137
WF 25i R, WF 25i R PAP, WF 25i R / L 137
WF 30i R, WF 30i R PAP, WF 30i R / L 138
Unreeling wirefeeder WF REEL 139
WF 25i REEL R /4R/G/W 139
WF 30i REEL R /2R/G/W 139
CrashBox /i 140
Technical data, triggering torques and weight/distance diagram 140
Torch hosepack 143
MHP 400i G / R 143
MHP 400i G / R / PAP 143
MHP 700i W / R (0.95 - 2.25 m / 3.12 - 7.38 ft.) 144
MHP 700i W / R (3.25 - 4.25 m / 10.66 - 13.12 ft.) 145
MHP 700i W / R / PAP 146
Robot welding torch 147
Gas-cooled robot welding torches 147
Water-cooled robot welding torches 148
Interconnecting hosepacks 150
HP 70i 150
HP 95i 150
HP 120i 150
HP 70i, HP PC Cable HD 70 150
6
Safety rules
EN
Explanation of
DANGER!
safety notices
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 recog-
nised 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 com-
pany,
- 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 operating
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 applic-
able and local regulations regarding accident prevention and environmental 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 section
headed "General" in the operating instructions for the device.
Before commissioning the device, rectify any faults that could compromise safety.
This is for your personal safety!
7
Intended use The devices and components described in these Operating Instructions are intended
exclusively for automated MIG/MAG applications in conjunction with Fronius compon-
ents.
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 instructions and danger notices carefully
- Performing all stipulated inspection and servicing work
The manufacturer likewise accepts no liability for inadequate or incorrect results.
Environmental Operation or storage of the device outside the stipulated area will be deemed as not in
conditions 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 The operator must only allow persons to work with the device who:
operator - 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 section
"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 Before using the device, all persons instructed to do so undertake:

personnel - 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.
Mains connection Devices with a higher rating may affect the energy quality of the mains due to their cur-
rent consumption.
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 *)
8
*) at
the interface with the public grid
see "Technical data"
EN
In this case, the plant operator or the person using the device should check whether the
device may be connected, where appropriate by discussing the matter with the power
supply company.
IMPORTANT! Ensure that the mains connection is earthed properly
Protecting your- Anyone working with the device exposes themselves to numerous risks, e.g.
self and others - 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 using car-
diac 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 protective 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 injury
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 vicinity:
- 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 current and welding
current, etc.)
- Provide suitable protective equipment
- Alternatively, erect suitable safety screens/curtains.
Danger from The fumes produced during welding contain harmful gases and vapours.
toxic gases and
vapours Welding fumes contain substances that cause cancer, as stated in Monograph 118 of the
International Agency for Research on Cancer.
Use at-source extraction and a room extraction system.

If necessary, use a welding torch with an integrated extraction device.
Keep your face away from welding fumes and gases.
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. Ensure that there is a ventilation rate of at least
20 m³ per hour at all times.
9
Otherwise, a welding helmet with an air supply must be worn.
If there is any doubt about whether the extraction capacity is sufficient, the measured
toxic emission values should be compared with the permissible limit values.
The following components are responsible, amongst other things, for the degree of tox-
icity of welding fumes:
- Metals used for the workpiece
- Electrodes
- Coatings
- Cleaners, degreasers, etc.
- Welding process used
The relevant material safety data sheets and manufacturer's specifications for the listed
components should therefore be studied carefully.
Recommendations for trade fair scenarios, risk management measures and for identify-
ing working conditions can be found on the European Welding Association website under
Health & Safety (https://european-welding.org).
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation
area.
Close the shielding gas cylinder valve or main gas supply if no welding is taking place.
Danger from fly- Flying sparks may cause fires or explosions.

ing sparks
Never weld close to flammable materials.
Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the arc, or
alternatively covered with an approved cover.
A suitable, tested fire extinguisher must be available and ready for use.
Sparks and pieces of hot metal may also get into adjacent areas through small gaps or
openings. Take appropriate precautions to prevent any danger of injury or fire.
Welding must not be performed in areas that are subject to fire or explosion or near
sealed tanks, vessels or pipes unless these have been prepared in accordance with the
relevant national and international standards.
Do not carry out welding on containers that are being or have been used to store gases,
propellants, mineral oils or similar products. Residues pose an explosive hazard.
Risks from mains An electric shock is potentially life threatening and can be fatal.
current and weld-
ing current Do not touch live parts either inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed
rollers and all pieces of metal that are in contact with the welding wire are live.
Always set the wirefeeder up on a sufficiently insulated surface or use a suitable, insu-
lated wirefeeder holder.
Make sure that you and others are protected with an adequately insulated, dry base or
cover for the earth or ground potential. This base or cover must extend over the entire
area between the body and the earth or ground potential.
All cables and leads must be secured, undamaged, insulated and adequately dimen-
sioned. Replace loose connections and scorched, damaged, or inadequately dimen-
sioned cables and leads immediately.
10
Use the handle to ensure the power connections are tight before every use.
In the case of power cables with a bayonet connector, rotate the power cable around the
EN
longitudinal axis by at least 180° and pretension.
Do not wrap cables or leads around the body or parts of the body.
The electrode (rod electrode, tungsten electrode, welding wire, etc.) must
- never be immersed in liquid for cooling
- Never touch the electrode when the power source is switched on.
Double the open circuit voltage of a power source can occur between the welding elec-
trodes of two power sources. Touching the potentials of both electrodes at the same time
may be fatal under certain circumstances.
Arrange for the mains cable to be checked regularly by a qualified electrician to ensure
the ground conductor is functioning properly.
Protection class I devices require a mains supply with ground conductor and a connector
system with ground conductor contact for proper operation.
Operation of the device on a mains supply without ground conductor and on a socket
without ground conductor contact is only permitted if all national regulations for protective
separation are observed.
Otherwise, this is considered gross negligence. The manufacturer shall not be held liable
for any damage arising from such usage.
If necessary, provide adequate earthing for the workpiece.
Switch off unused devices.
Wear a safety harness if working at height.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to prevent
anyone from plugging the mains plug back in and switching it on again.
After opening the device:

- Discharge all live components
- Ensure that all components in the device are de-energised.
If work on live parts is required, appoint a second person to switch off the main switch at
the right moment.
Meandering weld- If the following instructions are ignored, meandering welding currents can develop with
ing currents the following consequences:
- Fire hazard
- Overheating of parts connected to the workpiece
- Irreparable damage to ground conductors
- Damage to device and other electrical equipment
Ensure that the workpiece is held securely by the workpiece clamp.
Attach the workpiece clamp as close as possible to the area that is to be welded.
Position the device with sufficient insulation against electrically conductive environments,
e.g. Insulation against conductive floor or insulation to conductive racks.
If distribution boards, twin-head mounts, etc., are being used, note the following: The
electrode of the welding torch / electrode holder that is not used is also live. Make sure
that the welding torch / electrode holder that is not used is kept sufficiently insulated.
11
In the case of automated MIG/MAG applications, ensure that only an insulated wire elec-
trode is routed from the welding wire drum, large wirefeeder spool or wirespool to the
wirefeeder.
EMC Device Clas- Devices in emission class A:

sifications - Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:

- Satisfy the emissions criteria for residential and industrial areas. This is also true for
residential areas in which the energy is supplied from the public low-voltage mains.
EMC device classification as per the rating plate or technical data.
EMC measures In certain cases, even though a device complies with the standard limit values for emis-
sions, it may affect the application area for which it was designed (e.g. when there is
sensitive equipment at the same location, or if the site where the device is installed is
close to either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rectify the
situation.
Check and evaluate the immunity to interference of nearby devices according to national
and international regulations. Examples of equipment that may be susceptible to interfer-
ence from the device include:
- Safety devices
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
Supporting measures for avoidance of EMC problems:

1. Mains supply
- If electromagnetic interference arises despite correct mains connection, addi-
tional measures are necessary (e.g. use a suitable line filter).
2. Welding power leads
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
5. Shielding, if necessary
- Shield off other nearby devices
- Shield off entire welding installation
EMF measures Electromagnetic fields may pose as yet unknown risks to health:
- effects on the health of others in the vicinity, e.g. wearers of pacemakers and hear-
ing aids
- wearers of pacemakers must seek advice from their doctor before approaching the
device or any welding that is in progress
- for safety reasons, keep distances between the welding cables and the welder's
head/torso as large as possible
- do not carry welding cables and hosepacks over the shoulders or wind them around
any part of the body
12
Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example:
EN
- Fans
- Cogs
- Rollers
- Shafts
- Wirespools and welding wires
Do not reach into the rotating cogs of the wire drive or into rotating drive components.
Covers and side panels may only be opened/removed while maintenance or repair work
is being carried out.
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 allowed 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 disconnecting
coolant flow or return lines.
Observe the information on the coolant safety data sheet when handling coolant. The
coolant safety data sheet may be obtained from your service centre or downloaded from
the manufacturer's website.
Use only suitable load-carrying equipment supplied by the manufacturer when transport-
ing devices by crane.
- Hook chains and/or ropes onto all suspension points provided on the load-carrying
equipment.
- Chains and ropes must be at the smallest angle possible to the vertical.
- Remove gas cylinder and wire-feed unit (MIG/MAG and TIG devices).
If the wire-feed unit is attached to a crane holder during welding, always use a suitable,
insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).
If the device has a carrying strap or handle, this is intended solely for carrying by hand.
The carrying strap is not to be used if transporting with a crane, counterbalanced lift truck
or other mechanical hoist.
All lifting 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.
13
Odourless and colourless shielding gas may escape unnoticed if an adapter is used for
the shielding gas connection. Prior to assembly, seal the device-side thread of the
adapter for the shielding gas connection using suitable Teflon tape.
Requirement for Especially with ring lines, contaminated shielding gas can cause damage to equipment
the shielding gas and reduce welding quality.
Meet the following requirements regarding shielding gas quality:
- Solid particle size < 40 µm
- Pressure condensation point < -20 °C
- Max. oil content < 25 mg/m³
Use filters if necessary.
Danger from Shielding gas cylinders contain gas under pressure and can explode if damaged. As the
shielding gas cyl- shielding gas cylinders are part of the welding equipment, they must be handled with the
inders greatest of care.
Protect shielding gas cylinders containing compressed gas from excessive heat, mech-
anical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instructions to pre-
vent them falling over.
Keep the shielding gas cylinders well away from any welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.
Only use shielding gas cylinders suitable for the application in hand, along with the cor-
rect and appropriate accessories (regulator, hoses and fittings). Only use shielding gas
cylinders and accessories that are in good condition.
Turn your face to one side when opening the valve of a shielding gas cylinder.
Close the shielding gas cylinder valve if no welding is taking place.
If the shielding gas cylinder is not connected, leave the valve cap in place on the cylin-
der.
The manufacturer's instructions must be observed as well as applicable national and

international regulations for shielding gas cylinders and accessories.
Danger from Risk of suffocation from the uncontrolled escape of shielding gas
escaping shield-
ing gas Shielding gas is colourless and odourless and, in the event of a leak, can displace 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 cylinder 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.
14
Safety measures A device toppling over could easily kill someone. Place the device on a solid, level sur-
EN
at the installation face such that it remains stable
location and dur- - The maximum permissible tilt angle is 10°.
ing transport
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 protection shown
on the rating plate.
When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft. 7.69
in.) to ensure that cooling air can flow in and out freely.
When transporting the device, observe the relevant national and local guidelines and
accident prevention regulations. This applies especially to guidelines regarding the risks
arising during transport.
Do not lift or transport operational devices. Switch off devices before transport or lifting.
Before transporting the device, allow coolant to drain completely and detach the follow-
ing components:
- Wirefeeder
- Wirespool
- Shielding gas cylinder
After transporting the device, the device must be visually inspected for damage before
commissioning. Any damage must be repaired by trained service technicians before
commissioning the device.
Safety measures Only operate the device when all safety devices are fully functional. If the safety devices
in normal opera- are not fully functional, there is a risk of
tion - 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 switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper functioning of
safety devices.
Always fasten the shielding gas cylinder securely and remove it beforehand if the device
is to be transported by crane.
Only the manufacturer's original coolant is suitable for use with our devices due to its
properties (electrical conductibility, anti-freeze agent, material compatibility, flammability,
etc.).
Only use suitable original coolant from the manufacturer.
Do not mix the manufacturer's original coolant with other coolants.
Only connect the manufacturer's system components to the cooling circuit.
15
The manufacturer accepts no liability for damage resulting from use of other system
components or a different coolant. In addition, all warranty claims will be forfeited.
Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under
certain conditions. Transport the coolant only in its original, sealed containers and keep
well away from any sources of ignition.
Used coolant must be disposed of properly in accordance with the relevant national and
international regulations. The coolant safety data sheet may be obtained from your ser-
vice centre or downloaded from the manufacturer's website.
Check the coolant level before starting to weld, while the system is still cool.
Commissioning, It is impossible to guarantee that bought-in parts are designed and manufactured to meet
maintenance and the demands made of them, or that they satisfy safety requirements.
repair - Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without the manu-
facturer's consent.
- Components that are not in perfect condition must be replaced immediately.
- 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.
The housing screws provide the ground conductor connection for earthing the housing
parts.
Only use original housing screws in the correct number and tightened to the specified
torque.
Safety inspection The manufacturer recommends that a safety inspection of the device is performed at
least once every 12 months.
The manufacturer recommends that the power source be calibrated during the same 12-
month period.
A safety inspection should be carried out by a qualified electrician

- after any changes are made
- after any additional parts are installed, or after any conversions
- after repair, care and maintenance has been carried out
- at least every twelve months.
For safety inspections, follow the appropriate national and international standards and
directives.
Further details on safety inspection and calibration can be obtained from your service
centre. They will provide you on request with any documents you may require.
Disposal Do not dispose of this device with normal domestic waste! To comply with the European
Directive on Waste Electrical and Electronic Equipment and its implementation as
national law, electrical equipment that has reached the end of its life must be collected
separately and returned to an approved recycling facility. Any device that you no longer
require must either be returned to your dealer or given to one of the approved collection
and recycling facilities in your area. Ignoring this European Directive may have poten-
tially adverse affects on the environment and your health!
16
Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage and elec-
EN
tromagnetic compatibility directives (e.g. relevant product standards of the EN 60 974
series).
Fronius International GmbH hereby declares that the device is compliant with Directive
2014/53/EU. The full text on the EU Declaration of Conformity can be found at the follow-
ing address: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant stand-
ards for Canada and the USA.
Data protection The user is responsible for the safekeeping of any changes made to the factory settings.
The manufacturer accepts no liability for any deleted personal settings.
Copyright 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 purchaser. If you have any sugges-
tions for improvement, or can point out any mistakes that you have found in the instruc-
tions, we will be most grateful for your comments.
17
Description of the For certain device versions, warning notices are affixed to the device.
warning notices
on the device The arrangement of the symbols may vary.
A B
! Warning! Attention!
The symbols represent possible dangers.
A Drive rollers can injure fingers.
B The welding wire and drive parts are live during operation.
Keep hands and metal objects away!
1. An electric shock can be fatal.
1.1 Wear dry, insulating gloves. Do not touch the wire electrode with bare hands. Do
not wear wet or damaged gloves.
1.2 Use a base that is insulated from the floor and work area to protect against elec-
tric shock.
1.3 Before working on the device, switch off the device and pull out the mains plug or
disconnect it from the power supply.
2. Inhalation of welding fumes can be harmful to health.
2.1 Keep your face away from any welding fumes.
2.2 Use forced-air ventilation or a local extraction system to remove welding fumes.
2.3 Remove welding fumes with a fan.
18
EN
3 Welding sparks can cause an explosion or fire.
3.1 Keep flammable materials away from the welding process. Never weld close to
flammable materials.
3.2 Welding sparks can cause a fire. Have fire extinguishers to hand. If necessary,
have a supervisor ready who can operate the fire extinguisher.
3.3 Do not weld on drums or closed containers.
4. Arc rays can burn the eyes and injure the skin.
4.1 Wear headgear and protective goggles. Use ear protection and a shirt collar with
button. Use a welding helmet with the correct tinting. Wear suitable protective
clothing over the entire body.
xx,xxxx,xxxx *
5. Before working on the system or welding:

undertake training on the device and read the instructions!
6. Do not remove or paint over the warning sticker.
* Manufacturer order number of the sticker
19
20
System configurations
21
22
System configurations - conventional robot
EN
Push with wire (6)
drum (7) **
(1) * (8
(8)
(2)
(3)
(4)
(5)
(1) Wirefeeding hose with inner liner
(2) TPSi power source
(3) CU cooling unit
(4) Upright console
(5) HP interconnecting hosepack
(6) Wirefeeder WF 15i R / WF 25i R / WF 30i R
(7) MHP /i R torch hosepack
(8) MTB /i R robot welding torch
Maximum wirefeed length:

max. 8 m between wire drum and wirefeeder
(max. 10 m with PowerLiner)
Possible wire diameters:

0.8 - 2.0 mm
Welding process:
Standard, Pulse, LSC, PMC
* Use the largest inner liner (incl. basic kit)

** Use the inner liner corresponding to the wire diameter (incl. basic kit)
23
Push with
(6)
wirespool (7) **
((8)
(5) *
(1)
(2)
(3)
(4)
(2) CU cooling unit
(3) Upright console

max. 2 m between wirefeeder and wirespool

0.8 - 2.0 mm
Welding process:

24
Push with 4-roller
EN
(3) (8)
unreeling (1) * (9) **
wirefeeder and
wire drum
(10)
(
(1) * (2)
(4)
(5)
(6)
(7)
(2) SpeedNet cable COM
(3) Unreeling wirefeeder WV 25i Reel 4R
(5) CU cooling unit
(6) Upright console

- max. 20 m between wirefeeder and unreeling wirefeeder
- max. 8 m between wire drum and unreeling wirefeeder

0.8 - 2.0 mm
Welding process:

25
System configurations - PAP
Push with wire

(6) (7) **
drum
(1) * (8
(8)
(2)
(3)
(4)
(5)
(3) CU cooling unit
(4) Upright console

max. 8 m between wire drum and wirefeeder

0.8 - 2.0 mm
Welding process:

26
Push with
EN
(6) (7) **
wirespool
(8
(8)
(5) *
(1)
(2)
(3)
(4)
(2) CU cooling unit
(3) Upright console

max. 2 m between wirefeeder and wirespool

0.8 - 2.0 mm
Welding process:

27
Push with 4-roller
(3) (8) (9) **
unreeling (1) *
wirefeeder and
wire drum
(1) * (2) (10)
(4)
(5)
(6)
(7)
(2) SpeedNet cable COM
(3) Unreeling wirefeeder WV 25i Reel 4R
(5) CU cooling unit
(6) Upright console

- max. 20 m between wirefeeder and unreeling wirefeeder
- max. 8 m between wire drum and unreeling wirefeeder

0.8 - 2.0 mm
Welding process:

28
System components
29
30
WF wire-feed unit
EN
Device concept The robot wirefeeders of the WF 15i/25i/30i R and R PAP series have been specifically
designed for robot mounting.
The wirefeeders are available in several different versions:
WF 15i/25i/30i R:
For applications in which the hosepack is externally mounted on the robot.
WF 15i/25i/30i R PAP:
For applications in which the hosepack is mounted in the robot arm.
WF 25i R / L and 30i R / L:

For applications in which the torch hosepack is connected to the wirefeeder from the left.
Proper use The device is designed exclusively for wirefeeding in automated MIG/MAG welding
applications in conjunction with Fronius system components. Any use above and beyond
this purpose is deemed improper. The manufacturer shall not be held liable for any dam-
age arising from such usage.
Utilisation in accordance with the intended purpose also comprises:

- carefully reading these operating instructions
- following all the instructions and safety rules in these operating instructions
- performing all stipulated inspection and maintenance work
Safety
WARNING!
Danger due to incorrect operation and incorrectly performed work.

This can result in severe personal injury and damage to property.
▶ All the functions described may only be used by trained and qualified personnel.
▶ Fully read and understand this document.
▶ Fully read and understand all the Operating Instructions for the system components,
especially the safety rules.
31
Warning notices The device is fitted with safety symbols and a rating plate. The safety symbols and rating
on the device plate must not be removed or painted over. The safety symbols warn against operating
the equipment incorrectly, as this may result in serious injury and damage.
WF 25i R /4R/G/W/FSC
Part No.: 4,049,035

www.fronius.com
Ser.No.: 24020072
IEC 60 974-5/-10 Cl.A IP 43
U11 60 V I11 1.2 A
U12 24 V I12 0.5 A
1 - 25 m/min 40 - 984 ipm

I2 360A/100% 450A/60% 500A/40%
Caution: Parts may be at welding

voltage
Attention: Les pièces peuvent être
à la tension de soudage
40,0006,3035
Do not use the functions described here until you have fully read and understood the fol-
lowing documents:
- These Operating Instructions
- All the Operating Instructions for the system components, especially the safety rules
Welding is dangerous. The following basic requirements must be met to ensure the
equipment is used properly:
- Anyone performing automated welding must be sufficiently qualified
- Suitable protective equipment must be used
- All persons not involved must be kept at a safe distance from the wirefeeder and the
welding process
Do not dispose of used devices with domestic waste. Dispose of them according to the
safety rules.
32
EN
Keep hands, hair, clothing and tools away from moving parts. For example:
- Cogs
- Feed rollers
- Wirespools and wire electrodes
Covers and side panels may only be opened/removed while maintenance 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.
33
WF 25i REEL R /4R, WF 30i REEL R /2R
Safety
WARNING!
Incorrect operation or shoddy workmanship can cause serious injury and damage.
▶ The following documents must be completely read and understood before commis-
sioning the unreeling wirefeeder:
these Operating Instructions
the Operating Instructions of the power source in use
the Operating Instructions of all other system components
the safety rules and safety instructions in the above-mentioned documents.
CAUTION!
Risk of injury from rotating drive parts if covers are open.

▶ When performing maintenance or set-up work, make sure that the drive components
of the unreeling wirefeeder cannot be started by the power source, by a wirefeeder
or by any other system add-ons.
Device concept The unreeling wirefeeder is an extra drive unit for ensuring constant and precision
wirefeeding over large wirefeeding distances between the welding wire drum and the
robot wirefeeder.
While in operation, the unreeling wirefeeder is synchronised with the power source.
It is supplied with power and controlled by the power source in the welding system.
The unreeling wirefeeder is available in two versions:

- WF 25i REEL R /4R
Integrated version with 4-roller drive
- WF 30i REEL R /2R
Integrated version with 2-roller drive - not permitted in conjunction with a basket-type
spool
Application area All indoor and automated MIG/MAG applications.
Proper use The device is designed exclusively for wirefeeding in automated MIG/MAG welding
applications in conjunction with Fronius system components. Any use above and beyond
this purpose is deemed improper. The manufacturer shall not be held liable for any dam-
age arising from such usage.
Utilisation in accordance with the intended purpose also comprises:

- carefully reading these operating instructions
- following all the instructions and safety rules in these operating instructions
- performing all stipulated inspection and maintenance work
Warning notices The device is fitted with safety symbols and a rating plate. The safety symbols and rating
on the device plate must not be removed or painted over. The safety symbols warn against operating
the equipment incorrectly, as this may result in serious injury and damage.
34
EN
40,0006,3035
Example: WF 30i REEL R /2R/G/W
Do not dispose of used devices with domestic waste. Dispose of them according to the
safety rules.
Welding is dangerous. The following basic requirements must be met to ensure the
equipment is used properly:
- Anyone performing automated welding must be sufficiently qualified
- Suitable protective equipment must be used
- All persons not involved must be kept at a safe distance from the wirefeeder and the
welding process
Do not use the functions described here until you have fully read and understood the fol-
lowing documents:
- These Operating Instructions
- All the Operating Instructions for the system components, especially the safety rules
Keep hands, hair, clothing and tools away from moving parts. For example:
- Cogs
- Feed rollers
- Wirespools and welding wires
35
Covers and side panels may only be opened / removed while maintenance or repair
work is being carried out.
Wear eye protection
36
Interconnecting hosepack
EN
General
The interconnecting hosepack connects the power source to the wirefeeder. With the
TPS/i welding system the interconnecting hosepack is available in two versions - one
split and one standard variant.
- 3 / 5 / 10 / 15 m (extension - split variant)
- CON hosepacks 4 / 5.5 / 8 / 10 / 15 / 16 m (continuous variant)
37
Torch hosepack
General remarks The Robacta MHP hosepack is designed for gas-cooled and water-cooled robot applica-
tions. It connects the TPS/i robot wirefeeders to the Robacta MTB robot welding torches.
Scope of supply
Robacta MHP PAP hosepack

Robacta MHP conventional hosepack
(1) Robacta MHP hosepack
Not supplied:
- Inner liners
- Inlet nozzles
Buttons on the "Wire threading" and "wire retract" buttons

Robacta MHP are located on the Robacta MHP hosep-
hosepack ack
Buttons on the Robacta MHP hosepack
38
CrashBox /i
EN
General remarks
CrashBox /i PAP fitted to robot arm CrashBox /i fitted to robot arm with clamp system
The CrashBox /i is a protection device for the torch body, the drive unit, the wire brake
and the torch body coupling. In the event of a collision, the CrashBox sends a signal to
the robot control, which stops the robot immediately. The torch holder on the CrashBox
protects the welding torch and the system components fitted from damage should a colli-
sion occur.
The clamp system is used for holding gas-cooled and water-cooled robot welding
torches. With torch body curvatures of 22°, 36° and 45°, the clamp system positions the
welding torch in such a way that the TCP is in the 6th axis or at a 45° angle to the 6th
axis, depending on the torque angle gauge.
A robot-specific, isolated robot flange is required for fitting the CrashBox /i.
Also required for Depending on the particular robot:

installation - 1 x robot flange with screws
Robot flange as per price list
Observe torques:
Max. tightening torque for screws of

strength class 8.8
M4 3.3 Nm / 2.43 lb-ft
M5 5.0 Nm / 3.69 lb-ft
M6 6.0 Nm / 4.43 lb-ft
M8 27.3 Nm / 20.14 lb-ft
M10 54 Nm / 39.83 lb-ft
M12 93 Nm / 68.60 lb-ft
Device concept The CrashBox /i is designed specifically for fitting to the robot arm and for holding gas-
cooled and water-cooled robot hosepacks and robot drive units. For PAP systems, the
torch hosepack runs through the CrashBox and then through the robot arm. In conven-
39
tional robot systems the torch hosepack runs along the robot arm and is attached to the
clamp. In the event of a crash, the magnetic coupling smoothly deflects the forces along
a large deflection path.
Application areas The clamp system can be used for the following push robot hosepacks:
- MHP i G / MHP i W TPS /i hosepacks
- MTG/MTW TransSteel hosepacks
Information on NOTE!
repairing Crash-
Boxes Only send complete CrashBoxes for repair!
Incomplete CrashBoxes (e.g. without a magnetic ring) cannot be checked in the course
of a repair.
Scope of supply
(1) (2) (3) (4) (3) (2) (5) (6) (1) (2)(3) (4) (3) (2) (5)(6)
CrashBox /i PAP scope of supply CrashBox /i Standard scope of supply
(1) CrashBox /i holder

(2) 1-ear clamp *
(3) Locking ring, 2-part *
(4) Bellows
(5) Cheese-head screws, M4 x 16 mm
(6) Magnetic ring
* Delivered fitted to bellows (4)
Do not fit the CrashBox /i holder (1) and magnetic ring (4) together before fitting to the
robot. The components become even more difficult to release due to the strong magnet-
ism.
40
Clamp system (1) M8 hexagon nut
EN
scope of supply (2) M8 washer
and options (3) Clamp
(4) Torque angle gauge
(5) M8 x 40 mm Allen screw
Optional (material for extension):

(6) M8 x 40 mm screw
(7) M8 washer
(8) Extension
(9) Torque angle gauge
(10) M8 hexagon nut
41
Robot welding torch
Safety
CAUTION!
Risk of burns from hot torch body, hot torch body coupling and other hot welding
torch components.
Before starting work on the torch body, the torch body coupling and all other welding
torch components:
▶ Allow the torch body, torch body coupling and all other welding torch components to
cool down to room temperature (+25 °C, +77 °F)
▶ Wear electrically insulated and heat protective gloves
▶ Use a suitable tool
General
The robot welding torch transmits the arc power to the workpiece. The gas or water-
cooled TPS/i welding torch is designed for use with the CrashBox /i.
The torch body has an integrated lead for gas nozzle touch sensing.
Standard:
With wearing parts, without contact tip
OVT:
Without wearing parts
TXi:
Automatic torch body changeover
TXM:
Manual torch body changeover
42
Controls, connections and mechan-
ical components
43
44
Control elements and mechanical components
EN
Safety
WARNING!
Danger from incorrect operation.

Control elements No. Function

and mechanical
components (1) Cover
(1) (2) Clamping lever

for setting the contact pressure of
the feed rollers
(2) (3) 4-roller drive
(3) (4) Protective cover for the 4-roller

drive
(4)
(5) Gas test / wire threading control
(5) panel
Gas test/wire No. Function

threading control
panel (optional) (1) Operating status LED
Shows steady green when the
device is ready for use
(1) (2) (3) (4)
No. Function
(2) Gas-test button

For setting the required gas flow rate on the pressure regulator
- Gas will flow out for 30 seconds after the gas-test button is pressed. Press
the button again to stop the gas flow prematurely
(3) Wire retract button

For retracting the wire electrode with no accompanying flow of gas or current
- While the button is being pressed, the wirefeeder runs at the preset wire
retract speed
The wire electrode can be retracted using one of two methods:
45
Method 1
Retracting the wire electrode using the preset wire retract speed:
- Press and hold the wire retract button
After pressing the wire retract button, the wire electrode is retracted by 1 mm
(0.039 in.).
After a short pause, the wirefeeder continues to retract the wire electrode - if
the wire retract button remains pressed, the speed increases every second
by 10 m/min (393.70 ipm) up to the preset wire retract speed.
Method 2
Retracting the wire electrode in 1 mm increments (0.039 in. increments) – always
press the wire retract button for less than one second (tap)
IMPORTANT! Do not allow long lengths of wire electrode to be retracted, as the

wire electrode is not wound onto the wirespool when retracted.
IMPORTANT! If there was a ground earth connection with the contact tip before
the wire retract button was pressed, the wire electrode will be retracted when the
button is pressed until it is short-circuit-free - it retracts by no more than 10 mm
(0.39 in.) with each press of the button.
If the wire electrode is to be retracted further, the wire retract button must be
pressed again.
(4) Wire threading button

For threading the wire electrode into the torch hosepack with no accompanying
flow of gas or current
- While the button is pressed, the wirefeeder runs at the preset feeder inching
speed
Wire threading can be performed using one of two methods:
Method 1
Threading the wire electrode using the preset feeder inching speed:
- Press and hold the wire threading button
After pressing the wire threading button, the wire electrode is thread in by 1
mm (0.039 in.).
After a short pause, the wirefeeder continues to feed in the wire electrode - if
the wire threading button remains pressed, the speed increases every
second by 10 m/min (393.70 ipm) up to the preset feeder inching speed.
If the wire electrode comes into contact with a ground earth connection, the
wirefeeding will be stopped and the wire electrode will be retracted again by
1 mm (0.039 in.).
Method 2
Threading the wire electrode in 1 mm increments (0.039 in. increments) - always
press (tap) the wire threading button for less than 1 second
46
wirefeeding will be stopped and the wire electrode will be retracted again by 1
mm (0.039 in.).
EN
NOTE!
If there is a ground earth connection with the contact tip before the wire threading
button is pressed, the wire electrode will be retracted when the button is pressed
until it is short-circuit-free – it retracts by no more than 10 mm (0.39 in.) with each
press of the button.
If there is still a ground earth connection with the contact tip after 10 mm (0.39 in.) of wire
retraction, pressing the wire threading button again will cause the wire electrode to be
retracted again by a maximum of 10 mm (0.39 in.). The process will be repeated until
there is no longer a ground earth connection with the contact tip.
47
WF 15i / 25i / 30i R
WF 15i R,
(1) (4) (5) (6) (7)
WF 30i R connec-
tions
(2)
(3)
No. Function
(1) Welding torch connection
(2) Coolant connection

For connecting the coolant connection socket from the interconnecting hosepack
(3) Coolant connection socket

For connecting to the torch hosepack
(4) SpeedNet connection

For connecting the SpeedNet cable from the interconnecting hosepack
(5) Shielding gas connection
(6) (+) current socket

For connecting the power cable from the interconnecting hosepack
(7) Wire infeed
WF 30i R / L con- (1) (2) (3) (4) (7)

nections
(5)
(6)
48
No. Function
EN
(1) Wire infeed




WF 25i R connec- (1) (2) (3) (4) (5)

tions
No. Function


(5) Wire infeed
49
WF 25i R / L con-
(1) (2) (3) (4) (5)
nections
No. Function
(1) Wire infeed


50
WF 15i / 25i / 30i R PAP
EN
WF 15i R PAP,
(1) (2) (3) (4) (7)
WF 30i R PAP
connections
(5)
(6)
No. Function




(7) Wire infeed
WF 25i R PAP
(1) (2) (3) (4) (5)
connections
51
No. Function


(5) Wire infeed
WF 25i R / L PAP
(1) (2) (3) (4) (5)
connections
No. Function


(5) Wire infeed
52
WF 25i REEL R /4R, WF 30i REEL R /2R
EN
Safety
WARNING!
Danger from incorrect operation.

Controls, connec-
tions and mech-
anical compon-
ents
(3) (2) (1) (5) (4) (1)
Front of WF 25i REEL R /4R/G/W Front of WF 30i REEL R /2R/G/W
(11) (10) (9) (8)

(7) (6)
Left side Rear
53
100 mm
3.9 in.
50 mm
2.0 in.
4 x M5
(13)(12)
Top/underside
No. Function
(1) Cover
(2) Protective cover for the 4-roller drive
(3) 4-roller drive
(4) Protective cover for the 2-roller drive
(5) 2-roller drive
(6) Opening for optional sash lock
(7) Control panel
(9) Blanking cover for optional component
(12) M20 thread

for connecting QuickConnect option
(13) Wire infeed/outfeed tube

Wire infeed (underside)
Wire outfeed (top)
54
Control panel
EN
No. Function
(1) Operating status LED

Shows steady green when the
device is ready for use
(2) Gas-test button

For setting the required gas flow
rate on the pressure regulator
Gas will flow out for 30 seconds

after the gas-test button is
(1) (2) (3) (4)
pressed. Press the button again to
stop the gas flow prematurely.
Gas test / wire threading control panel
55
No. Function
(3) Wire retract button

For retracting the wire electrode with no accompanying flow of gas or current
The wire electrode can be retracted using one of two methods:
Method 1
Retracting the wire electrode using the preset wire retract speed:
Press and hold "Wire retract" button
- The wire electrode will be retracted 1 mm (0.039 in.) after the wire retract
button is pressed
- After a short pause, the wirefeeder continues to retract the wire electrode. If
the wire retract button remains pressed, the speed will increase every
second at a rate of 10 m/min (393.70 ipm) until the preset wire retract speed
is reached
Method 2
Retracting the wire electrode in 1 mm increments (0.039 in. increments) – always

press the wire retract button for less than one second (tap)
NOTE!
Do not allow long lengths of wire electrode to be retracted, as the wire electrode is
not wound onto the wirespool or the welding wire drum when retracted.
NOTE!
If there was a ground earth connection with the contact tip before the wire retract
button was pressed, the wire electrode will be retracted when the button is
pressed until it is short-circuit-free - it retracts by no more 10 mm (0.39 in.) with
each press of the button.
If the wire electrode still needs to be retracted, press the wire retract button again.
(4) Wire threading button

For threading the wire electrode into the torch hosepack with no accompanying
flow of gas or current
Wire threading can be performed using one of two methods:
Method 1
Retracting the wire electrode using the preset feeder inching speed:
Press and hold "Wire threading" button
56
- The wire electrode will be threaded 1 mm (0.039 in.) after the wire threading
button is pressed
EN
- After a short pause, the wirefeeder continues to thread the wire electrode. If
the wire threading button remains pressed, the speed will increase every
second at a rate of 10 m/min (393.70 ipm) until the preset feeder inching
speed is reached
- If the wire electrode comes into contact with a ground earth connection, the
1 mm (0.039 in.)
Method 2
Threading the wire electrode in 1 mm increments (0.039 in. increments) – always

press the wire threading button for less than one second (tap)
1 mm (0.039 in.).
NOTE!
If there is a ground earth connection with the contact tip before the wire threading
button is pressed, the wire electrode will be retracted when the button is pressed
until it is short-circuit-free – it retracts by no more than 10 mm (0.39 in.) with each
press of the button.
If there is still a ground earth connection with the contact tip after 10 mm (0.39 in.) of wire
retraction, pressing the wire threading button again will cause the wire electrode to be
retracted again by a maximum of 10 mm (0.39 in.). The process will be repeated until
there is no longer a ground earth connection with the contact tip.
57
58
Installation - conventional robot
59
60
Fitting the welding system to a conventional robot
EN
Safety
WARNING!
Work that is carried out incorrectly can cause serious injury or damage.
▶ The following activities may only be carried out by trained and qualified personnel.
▶ The Operating Instructions for system components, particularly the chapter entitled
"Safety rules", must be observed.
WARNING!
An electric shock can be fatal.

Before starting the work described below:
▶ Turn the power source mains switch to the "O" position
▶ Disconnect the power source from the mains
▶ Ensure that the power source remains disconnected from the mains until all work
has been completed.
WARNING!
Risk of serious injury and damage from articles being dropped.

For all of the screw connections referred to below:
▶ Check after fitting to ensure they are tight
▶ Check following an unusual operating situation (e.g. crash) to ensure they are tight
▶ Check regularly to ensure they are tight
Fitting the TPS/i Individual components must be fitted to the robot in the following order:
welding system 1. Wire-feed unit - the wirefeeder holder and the side arm holder must be fitted first
to a conventional 2. CrashBox /i
robot 3. Clamp system
4. Torch hosepack
5. Robot welding torch
6. Interconnecting hosepack
61
Fitting the wire-feed unit
Fitting the NOTE!

wirefeeder holder
Depending on the robot, please also note the instructions and information on
installing the wirefeeder in the User Information.
Fitting the 1
wirefeeder WF 15i / 25i / 30i R WF 25i / 30i R / L
2x M8 x 20 mm
2x M8 x 20 mm
6x M6x16
7x 6FSt
1x 6FSt
1x M6x16
62
NOTE!
EN
The coolant line must be routed under
the wirefeeder.
To do so, the wirefeeder must be removed
from the holder and re-fitted after the line
has been routed.
Example: WF 25i R
63
Fitting the CrashBox /i to the robot
Fitting the Crash- 1 Observe the torques when fitting the robot
Box /i to the flange:
robot
strength class 8.8
M4 3.3 Nm / 2.43 lb-ft
M5 5.0 Nm / 3.69 lb-ft
M6 6.0 Nm / 4.43 lb-ft
M8 27.3 Nm / 20.14 lb-ft
M10 54 Nm / 39.83 lb-ft
M12 93 Nm / 68.60 lb-ft
2 3
3,3 Nm / 2.43 lb-ft
4 5
64
6 7
EN
8
Installing the 1 Observe the torques when fitting the robot

CrashBox/i flange:
Dummy on the
robot Max. tightening torque for screws of
strength class 8.8
M4 3.3 Nm / 2.43 lb-ft
M5 5.0 Nm / 3.69 lb-ft
M6 6.0 Nm / 4.43 lb-ft
M8 27.3 Nm / 20.14 lb-ft
M10 54 Nm / 39.83 lb-ft
M12 93 Nm / 68.60 lb-ft
65
2 3
6 Nm / 4.43 lb-ft
3,3 Nm / 2.43 lb-ft
66
Fitting the clamp system
EN
Special tilt angle The positioning of the welding torch in relation to the workpiece is divided into fixed
for the welding angles by the torque angle gauge. Special angles are available on request.
torch
12,5° 12,5°
34,5° 38 48,5°
69
31
- CrashBox /i - CrashBox /i
- Indexdisk 22° 259 - Indexdisk 22° 235
- Clamp TPS/i 61 320 - Clamp TPS/i 61 296
- MHP 700i W R/FSC/0,95m - MHP 400i R /G/FSC/1,45m
- MTB 500i W R/22°/L241/H50 - MTB 400i G R /36°/L224/H86
4,95° 4
12,5° 26,95°
34
57,5°
87
- CrashBox /i 49 - CrashBox /i 61 262

- Indexdisk 36°
- Indexdisk 22° 216 323
- Clamp TPS/i 61 - Clamp TPS/i
277
- MHP 700i W R/FSC/1,45m - MHP 700i W R/FSC/1,25m
- MTB 500i W R/45°/L209/H107 - MTB 500i W R/22°/L241/H50
4,95° 4,95°
40,95° 49,95°
38
58
20
- CrashBox /i - CrashBox /i
242 - Indexdisk 36° 226
- Indexdisk 36°
61 303 - Clamp TPS/i 61 286
- Clamp TPS/i
- MHP 700i W R/FSC/1,25m - MHP 700i W R/FSC/0,95m
- MTB 500i W R/36°/L224/H86 - MTB 500i W R/45°/L209/H107
0° 22° 19 0°
58 36° 17
21
- CrashBox /i 261 - CrashBox /i 244

- Indexdisk 45° 61 322 - Indexdisk 45° 61 305
- Clamp TPS/i - Clamp TPS/i
- MHP 400i R /G/FSC/0,95m - MHP 400i R /G/FSC/1,25m
- MTB 400i G R /22°/L241/H50 - MTB 400i G R /36°/L224/H86
0°
45°
38
- CrashBox /i
61 230
- Indexdisk 45°
- Clamp TPS/i 291
- MHP 700i W R/FSC/1,45m
- MTB 500i W R /45°/L209/H107
67
Fitting the clamp 1 2
system 42 Nm
30.98 lb-ft
Fitting the clamp 1 2

system with 42 Nm
extension 30.98 lb-ft
42 Nm
30.98 lb-ft
68
Fitting the MHP G / W hosepack
EN
Fitting the MHP 1 2
G / W conven-
tional hosepack -
Standard
3 4
6,5 Nm
4.79 lb-ft
Optimum hosep-
ack arrangement
R
R < 200 mm R ≥ 200 mm
69
Fitting the TPS/i torch neck
Safety
CAUTION!
torch components.
torch components:
Fitting the TPS/i

torch body -
Standard
45,0200,1404
Special tool required
IMPORTANT! Whenever the welding torch is fitted or removed, ensure that the coupling
point is clean and dry. Remove any coolant that has escaped from the coupling point.
1 2
18 ± 2 Nm
13.28 ± 1.48 lb-ft
“OPT / i MHP If you would like to fit the “OPT / i MHP WireBrake” option, read the “Fitting the OPT / i
WireBrake” MHP WireBrake and torch body” chapter.
option
70
Fitting the inner
EN
NOTE!
liner inside the
torch hosepack Ensure that the hosepack is straight when fitting the inner liner, otherwise the liner
might not be inserted correctly.
1 2
3 4
**
5
* Steel inner liner
** Plastic inner liner
71
6
*** Screw the clamping nipple onto the
inner liner as far as it will go. The
inner liner must be visible through
the hole in the lock.
***
72
Fitting the interconnecting hosepack
EN
Fitting the Stand- 1 2
ard interconnect-
ing hosepack to
the robot 3 Nm
2.21 lb-ft
Connecting the
CAUTION!
extension hosep-
ack Danger from electric current due to inadequate connections.
This can result in serious injury and damage to property.
▶ All cables, leads and hosepacks must be properly connected, undamaged, correctly
insulated and adequately dimensioned.
1
* Only on water-cooled hosepack
CON = Interconnecting hosepack
EXT = Extension hosepack
73
2
74
Connecting the MHP W hosepack
EN
Connecting the IMPORTANT! Whenever the torch hosepack is fitted or removed, ensure that the coup-
MHP W hosepack ling point is clean and dry. Remove any coolant that has escaped from the coupling
point.
1 2
* Push in hosepack as far as it will go
75
5 6
IMPORTANT! Always route coolant hoses below the hosepack and then guide them to
the connection socket:
WFi R / SB 500i SB 60i
76
(1) Coolant return (red)
(2) Coolant flow (blue)
EN
IMPORTANT! Connect the coolant hoses
to the cooling unit correctly!
Disconnecting the coolant hoses
1 2
PUSH
77
Connecting wire-feed unit to system components
Safety
WARNING!

has been completed
CAUTION!
Risk of injury and damage from loose connections.

▶ All cables, leads and hosepacks must be properly secured, undamaged, insulated
and adequately dimensioned.
General NOTE!
Also follow the instructions and information in the documents 42,0410,1946 and
42,0410,2010 when connecting the wirefeeder to the system components.
Connecting the IMPORTANT! The coolant line must be routed under the wirefeeder.
wirefeeder to the To do so, the wirefeeder must be removed from the holder and re-fitted after the line has
system compon- been routed.
ents
IMPORTANT! Whenever the torch hosepack is fitted or removed, ensure that the coup-
ling point is clean and dry. Remove any coolant that has escaped from the coupling
point.
WF 15i / 25i / 30i R:
78
2 2
EN
WF 15i / 30i R WF 25i R
WF 25i / 30i R/L:
2 2
WF 30i R / L WF 25i R / L
79
3 4
IMPORTANT! After disconnecting the coolant connection from the hosepack, close the
coolant connections on the hosepack using the hosepack's seal cap.
80
Fitting the OPT / i MHP WireBrake and torch body
EN
Safety
CAUTION!
torch components.
torch components:
Prerequisites for NOTE!

operation
OPT/i MHP WireBrake only secures a wire electrode if a torch body is correctly fit-
ted to the OPT/i MHP WireBrake.
System requirements: The wirefeeder of the WF 15i/25i/30i R (PAP) series with the
"16 bar gas purging" option.
NOTE!
To ensure that the WireBrake option functions correctly, wait for 4 seconds after
deactivating the "WireBrake on" signal before activating another signal.
Compressed air The compressed air supply of the OPT/i MHP WireBrake is provided through the hosep-
supply specifica- ack.
tions
Observe the following specifications:
- Compressed air supply of at least 5 bar (72 psi)
- Compressed air supply for aluminium max. 7 bar (102 psi), for all other materials
max. 16 bar (232 psi)
- Compressed air is free of oil
- Compressed air is free of dust – no dirt particles larger than 5 mm
- Compressed air is free of water
Recommendation: use a filter unit with a pressure regulator.
Remedying the NOTE!

clamping marks
on the wire elec- When securing the wire electrode in the OPT/i MHP WireBrake, small clamping
trode marks can occur on the wire electrode.
▶ To remedy the clamping marks, cut off the wire electrode after securing.
Calculation of the cut-off point = torch body length + 50 mm (1.97 in.)
81
Technical data TCP offset 47 mm
1.85 in.
Wire diameter 0.8 - 1.6 mm
0.03 - 0.06 in.
Weight 450 g
0.99 Ib.
Fitting the OPT/i 1 2

MHP WireBrake
3 x 0,1 Nm
3 x 0.07 lb-ft
3 4
ONLY
when p > 5,5 bar / 79.74 psi
NOTE!
The front O-ring must only be removed at a system pressure of > 5.5 bar / 79.74 psi
(step 3).
At a system pressure of < 5.5 bar / 79.74 psi, the second O-ring remains on the WireB-
rake option.
82
For steel inner liners:
5 6
EN
For plastic inner liners:
5 6
83
Removing the OPT / i MHP WireBrake and torch
body
Safety
CAUTION!
torch components.
torch components:
Removing the 1 2
OPT / i MHP
WireBrake and
torch body
84
Fitting the unreeling wirefeeder
EN
Fitting the unreel-
WARNING!
ing wirefeeder
If the power source is connected to the mains supply while the work described below is
being carried out, there is a risk of serious injury and damage.
▶ Only carry out the work described below when the power source mains switch is in
the "O" position and when the power source is disconnected from the mains.
Ensure that the unreeling wirefeeder is fit-

ted in the correct direction. The threading
direction of the wire electrode is marked
with an arrow.
The unreeling wirefeeder is designed exclusively for vertical installation on the following
mounts:
- WF Mounting WALL 4,100,846
- WF Mounting Drum 4,100,845
Operating a 2-roller WF30i REEL R /2R unreeling wirefeeder with a basket-type spool is
not permitted.
1 In accordance with the Installation Instructions, mount the unreeling wirefeeder onto
the wall bracket or the wire drum mount
2 Use the QuickConnect option to connect the wirefeeding hose to the unreeling
wirefeeder
3 Use Fronius SpeedNet to connect the unreeling wirefeeder to the power source in
the welding system
85
86
Installation - PAP
87
88
Fitting the welding system to a PAP robot
EN
Safety
WARNING!
Work that is carried out incorrectly can cause serious injury or damage.
▶ The following activities may only be carried out by trained and qualified personnel.
▶ The Operating Instructions for system components, particularly the chapter entitled
"Safety rules", must be observed.
WARNING!

has been completed.
WARNING!
Risk of serious injury and damage from articles being dropped.

For all of the screw connections referred to below:
▶ Check after fitting to ensure they are tight
▶ Check following an unusual operating situation (e.g. crash) to ensure they are tight
▶ Check regularly to ensure they are tight
Fitting the TPS/i Individual components must be fitted to the robot in the following order:
welding system 1. Wire-feed unit - the wirefeeder holder and the side arm holder must be fitted first
to a PAP robot 2. CrashBox /i
3. Torch hosepack
4. Robot welding torch
5. Interconnecting hosepack
Maximum axis
rotation
(4)
-175°
+90°
(5)
(6) +175°
-200° -90°
+200°
89
(4) Fourth robot axis: +/- 175°
(5) Fifth robot axis: +/- 90°

or
fifth robot axis: +/- 120° - if the fourth robot axis = 0° and the sixth robot axis = 0°
IMPORTANT! The maximum axis rotation of +/- 120° in the fifth robot axis only
applies if there is NO axis rotation present in the fourth and sixth robot axes!
(6) Sixth robot axis: +/- 200°
(4)+(6) Fourth + sixth robot axis: max. +/- 360° total!
NOTE!
Any axis rotation beyond these limits accelerates the wear of the PAP torch hosep-
ack and invalidates any warranty claim.
90
Fitting the wire-feed unit
EN
Fitting the WF 1 2
15i/25i/30i R PAP
3 4
91
Installing the CrashBox /i PAP on the robot

CrashBox /i PAP flange:
on the robot

strength class 8.8
M4 3.3 Nm / 2.43 lb-ft
M5 5.0 Nm / 3.69 lb-ft
M6 6.0 Nm / 4.43 lb-ft
M8 27.3 Nm / 20.14 lb-ft
M10 54 Nm / 39.83 lb-ft
M12 93 Nm / 68.60 lb-ft
2 3
3,3 Nm / 2.43 lb-ft
4 5
92
6 7
EN
8

CrashBox/i flange:
Dummy on the
robot
strength class 8.8
M4 3.3 Nm / 2.43 lb-ft
M5 5.0 Nm / 3.69 lb-ft
M6 6.0 Nm / 4.43 lb-ft
M8 27.3 Nm / 20.14 lb-ft
M10 54 Nm / 39.83 lb-ft
M12 93 Nm / 68.60 lb-ft
93
2 3
3,3 Nm / 2.43 lb-ft 3 Nm / 2.21 lb-ft
94
Fitting the MHPi/MHP S G/W PAP hosepack
EN
Fitting the
Robacta MHP
G/W PAP hosep-
45,0200,1404
ack
1 2
3 4
95
5 6
7 8
14 ± 2 Nm
10.33 ± 1.48 lb-ft
9 10
18 ± 2 Nm
13.28 ± 1.48 lb-ft
option
96
Fitting the inner
EN
NOTE!
liner inside the
1 2
3 4
**
5
* Steel inner liner
97
6
***
98
Fitting the MHPi/MHP S G/W PAP SM hosepack
EN
Fitting the
Robacta MHP
G/W PAP SM
45,0200,1404
hosepack
1 2
3 4
99
5 6
7 8
3 x 2 Nm
3 x 1.48 lb-ft
1 1
18 ± 2 Nm
13.28 ± 1.48 lb-ft
option
100
Fitting the inner
EN
NOTE!
liner inside the
1 2
3 4
**
5
* Steel inner liner
101
6
***
102
Fitting the interconnecting hosepack
EN
Fitting the PAP NOTE!
interconnecting
hosepack to the The mounting of the holder for the interconnecting hosepack depends on the
robot robot manufacturer and robot type.
▶ Mount the holder for the interconnecting hosepack according to the Installation
Instructions for the respective robot.
1 2
3 Lay the interconnecting hosepack in the clamps

4 Close the clamps
103
Connecting the
CAUTION!
extension hosep-
ack Danger from electric current due to inadequate connections.
This can result in serious injury and damage to property.
1
* Only on water-cooled hosepack
CON = Interconnecting hosepack
EXT = Extension hosepack
104
Connecting the
EN
interconnecting
hosepack
105
Connecting wire-feed unit to system components
Safety
WARNING!

has been completed
CAUTION!

▶ All cables, leads and hosepacks must be properly secured, undamaged, insulated
and adequately dimensioned.
General NOTE!
Also follow the instructions and information in the documents 42,0410,1946 and
42,0410,2010 when connecting the wirefeeder to the system components.
Connecting the IMPORTANT! Whenever the torch hosepack is fitted or removed, ensure that the coup-
WF 15i/25i/30i R ling point is clean and dry. Remove any coolant that has escaped from the coupling
PAP to the sys- point.
tem components
1 2
106
3 4
EN
107
108
Start-up
109
110
Inserting/replacing feed rollers
EN
General The feed rollers are not installed in the device when it is first delivered.
In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the
diameter and alloy of the wire being welded.
NOTE!
Risk from inadequate feed rollers.
This can result in poor weld properties.
▶ Only use feed rollers that match the wire electrode.
An overview of the feed rollers available and their possible areas of use can be found in
the Spare Parts Lists.
WF 25i Reel 4R:

CAUTION!
inserting/repla-
cing feed rollers Risk of injury if the feed roller holders fly upwards.
for the 4-roller
drive ▶ When unlocking the clamping lever, keep fingers away from the area to the left and
right of the lever.
1 2
6 45 6
4
7
1 3
2
3
5 1
2
3
CAUTION!
Risk of crushing due to exposed feed rollers.

▶ Always fit the protective cover of the 4-roller drive after changing feed rollers.
111
3 4
2
6
1
5
4 4
3
8
3
1
5
2
2
5
6
7
4
WF 30i Reel 2R: 1 2

inserting/repla-
cing feed rollers
for the 2-roller
drive
CAUTION!
Risk of crushing due to exposed feed rollers.

▶ Always fit the protective cover of the 2-roller drive after changing feed rollers.
3 4
112
5
EN
Inserting/repla-
CAUTION!
cing feed rollers
Danger from feed roller holders flying upwards.
This can result in severe injuries.
▶ When unlocking the clamping lever, keep fingers away from the area to the left and
right of the lever.
1 2
2 4
4
5
4 13
6 2
6
3
7
5
3
CAUTION!
Danger from exposed feed rollers.

This can result in severe injuries.
▶ Always fit the protective cover of the 4-roller drive after inserting or replacing a feed
roller.
113
3 4
3 4
3
4
2
3
9 4
8
5
7 5
6
1
2
1
5 6
2
114
Feeding in the wire electrode
EN
Insulated routing
WARNING!
of wire electrode
to wirefeeder Risk of serious injury and damage or an inferior weld as a result of earth contact
or short-circuit of a non-insulated wire electrode.
▶ In the case of automated applications, ensure that only an insulated wire electrode is
routed from the welding wire drum, large wirefeeder spool or wirespool to the
wirefeeder (e.g. by using a wirefeeding hose).
An earth contact or short-circuit can be caused by:

- a non-insulated, exposed length of wire electrode coming into contact with a con-
ductive object during the welding process
- missing insulation between the wire electrode and the earthed enclosure of a robot
cell
- chafed wirefeeding hoses, exposing the wire electrode
To avoid earth contact or short-circuit:

- Use wirefeeding hoses for insulated routing of wire electrode to wirefeeder
- To prevent chafing, do not route the wirefeeding hoses over sharp edges
- Use hose holders or hose protectors where necessary
- Coupling pieces and hoods for welding wire drums are recommended to ensure safe
transport of the wire electrode
Feeding in the
CAUTION!
wire electrode
Risk of injury and damage from the welding current and accidental ignition of an
arc.
▶ Before starting work, disconnect the ground earth connection between the welding
system and the workpiece.
CAUTION!
Risk of injury and damage from wire electrode emerging.

While working:
▶ Hold the welding torch with the end directed away from the face and body
▶ Wear suitable protective goggles
▶ Do not point the welding torch at people
▶ Make sure that the wire electrode does not touch any conductive or earthed parts
(e.g. housing)
▶ Ensure that all covers are closed, all side panels are in place and that all safety
devices are intact and in their proper place (e.g. protection devices).
CAUTION!
Risk of damage to the welding torch from sharp end of wire electrode.
▶ Deburr the end of the wire electrode well before threading in.
115
CAUTION!
Risk of injury due to springiness of spooled wire electrode.

▶ When inserting the wire electrode into the 4-roller drive, hold the end of the wire
electrode firmly to avoid injuries caused by the wire springing back.
CAUTION!
Risk of injury from moving or rotating parts in the welding system.

▶ Ensure that all covers are closed and that all parts are fitted properly and remain in
place during operation.
1 2
1 3
116
Setting the con-
EN
NOTE!
tact pressure
Set the contact pressure in such a way that the wire electrode is not deformed but
nevertheless ensures proper wirefeeding.
1 The standard contact pressure values can

be found on the sticker on the 4-roller
1
drive
117
Start-up
Requirements When commissioning the welding system, the following requirements must be met:
- All components are installed and connected as described in the "Installation" chapter
- All appropriate welding media is connected
- Feed rollers are inserted in wirefeeders or drive unit
- Wire electrode is threaded in
- Feed roller contact pressure is set
- Motor adjustment completed
- All covers closed, all side panels in place, all safety devices intact and in their proper
place (e.g. protective covers)
General The device is commissioned by means of an active welding start signal.
118
Troubleshooting, maintenance and
disposal
119
120
Troubleshooting
EN
Safety
WARNING!
Danger due to work that has been carried out incorrectly.

▶ All the work described below must only be carried out by trained and qualified per-
sonnel.
WARNING!
Danger from electric current.

▶ Turn the power source mains switch to the "O" position.
▶ Disconnect the power source from the mains.
has been completed.
▶ After opening the device, use a suitable measuring instrument to check that electric-
ally charged components (e.g. capacitors) have been discharged.
CAUTION!
Danger from hot system components.

▶ Before starting work, allow all hot system components to cool down to room temper-
ature (+25 °C, +77 °F). For example:
Examples of hot system components include

- Coolant.
- Water-cooled system components.
- Wirefeeder drive motor.
Fault diagnosis Make a note of the serial number and configuration of the device and contact our After-
Sales Service team with a detailed description of the error, if
- errors occur that are not listed below
- the troubleshooting measures listed are unsuccessful
121
Power source does not function
Mains switch is on, but indicators are not lit up
Cause: There is a break in the mains lead; the mains plug is not plugged in
Remedy: Check the mains lead, ensure that the mains plug is plugged in
Cause: Mains socket or mains plug faulty

Remedy: Replace faulty parts
Cause: Mains fuse protection

Remedy: Change the mains fuse protection
Cause: Short circuit on the 24 V supply of SpeedNet connection socket or external

sensor
Remedy: Unplug connected components
No response after setting a welding start signal

Mains switch is ON and indicators are lit up
Cause: Welding torch or welding torch control line is faulty

Remedy: Replace the welding torch
Cause: Interconnecting hosepack is faulty or not connected properly

Remedy: Check interconnecting hosepack
No welding current
Mains switch is ON and indicators are lit up
Cause: Grounding (earthing) connection is incorrect

Remedy: Check the grounding (earthing) connection for correct polarity
Cause: There is a break in the power cable in the welding torch

Remedy: Replace the welding torch
No protective gas shield

All other functions are OK
Cause: Gas cylinder is empty

Remedy: Change the gas cylinder
Cause: The gas pressure regulator is faulty

Remedy: Replace the gas pressure regulator
Cause: Gas hose is not fitted or is damaged

Remedy: Fit or change the gas hose
Cause: Welding torch is faulty

Remedy: Change the welding torch
Cause: Gas solenoid valve is faulty

Remedy: Contact After-Sales Service
122
Irregular wire feed speed
Cause: Hole in the contact tip is too narrow
EN
Remedy: Use a suitable contact tip
Cause: Faulty inner liner in welding torch

Remedy: Check the inner liner for kinks, dirt, etc.
Cause: The feed rollers are not suitable for the wire electrode being used
Remedy: Use suitable feed rollers
Cause: Feed rollers have the wrong contact pressure

Remedy: Optimise the contact pressure
Wirefeed problems
when using long hosepacks
Cause: Incorrect arrangement of hosepack

Remedy: Arrange the hosepack in as straight a line as possible, avoid tight bends
Welding torch becomes very hot

Cause: The specification of the welding torch is inadequate
Remedy: Observe the duty cycle and loading limits
Cause: Only on water-cooled systems: Inadequate coolant flow

Remedy: Check coolant level, coolant flow, for coolant contamination, etc. For further
information refer to the cooling unit operating instructions.
Poor weld properties

Cause: Incorrect welding parameters
Remedy: Check the settings
Cause: Poor ground earth connection

Remedy: Ensure good contact to workpiece
Cause: Inadequate or no protective gas shield

Remedy: Check the pressure regulator, gas hose, gas solenoid valve, torch gas con-
nection, etc.
Cause: Welding torch is leaking

Remedy: Change the welding torch
Cause: Wrong contact tip, or contact tip is worn out

Remedy: Replace the contact tip
Cause: Wrong wire alloy or wrong wire diameter

Remedy: Check the wire electrode that has been inserted
Cause: Wrong wire alloy or wrong wire diameter

Remedy: Check weldability of the base material
Cause: The shielding gas is not suitable for this wire alloy
Remedy: Use the correct shielding gas
123
Care, maintenance and disposal
General Under normal operating conditions, the device requires only a minimum of care and
maintenance. However, it is vital to observe some important points to ensure the welding
system remains in a usable condition for many years.
Safety
WARNING!
Danger due to work that has been carried out incorrectly.

▶ All the work described below must only be carried out by trained and qualified per-
sonnel.
WARNING!
Danger from electric current.

▶ Turn the power source mains switch to the "O" position.
▶ Disconnect the power source from the mains.
has been completed.
▶ After opening the device, use a suitable measuring instrument to check that electric-
ally charged components (e.g. capacitors) have been discharged.
CAUTION!
Danger from hot system components.

▶ Before starting work, allow all hot system components to cool down to room temper-
ature (+25 °C, +77 °F). For example:
Examples of hot system components include

- Coolant.
- Water-cooled system components.
- Wirefeeder drive motor.
Every start-up - Check all hosepacks and the ground earth connection for damage. Replace any
damaged components.
- Check feed rollers and inner liners for signs of damage. Replace any damaged com-
ponents.
- Check the wirefeeding hoses for damage. Replace any damaged components.
- Check contact pressure of feed rollers and adjust if necessary.
- Check that all screw connections between the robot, wirefeeder holder and wire-
feed unit are secure.
124
Special care of O- IMPORTANT! When replacing O-rings, grease the new O-ring before fitting it.
EN
rings
When repeatedly connecting and disconnecting the coolant hoses on the torch hosep-
ack, grease the O-rings regularly.
Unless a special grease is specified for the O-rings, use the O-ring grease from Fronius
with item number 40,0009,0044.
Whenever the Whenever the welding torch or torch hosepack is changed, ensure that the coupling
welding torch or point is clean and dry. Remove any coolant that has escaped from the coupling point.
torch hosepack is
changed
Every 6 months
CAUTION!
Danger of damage to electronic components.

▶ Do not bring the air nozzle too close to electronic components.
- Open covers, remove device side panels and clean inside of device with dry
reduced compressed air. After cleaning, restore device to its original state.
Preparing the WF 1 2
15i/25i/30i R PAP
for replacement
of the welding
torch inner liner
WARNING!
Toppling or falling devices can cause life-threatening injuries.

Robot movements may not take place until:
▶ The wirefeeder has been retracted and locked
▶ All cables, leads and hosepacks are securely connected to the wirefeeder
125
After replacing the inner liner:
3 4
5 6
CAUTION!

Recognising 1. 2. 3. 4. 5.
faulty wearing
parts
126
1. Insulating parts
- Burned-off outside edges, notches
EN
2. Nozzle fittings
- Heavily covered in welding spatter
3. Spatter guard
4. Contact tips
- Worn-out (oval) wire entry and wire exit holes
- Penetration on the tip of the contact tip
5. Gas nozzles
- Burned-off outside edges
- Notches
MTG d, MTW d - 1 2
Fitting wearing
parts to the torch
body
3
** Screw on and tighten the gas
nozzle as far as it will go
127
Fitting wearing 1 2
parts to the torch
body - MTW 700 i
Removing the 1 2
CrashBox PAP
from the robot
(without mount-
ing key)
3 4
128
5 6
EN
7 8
9 10
129
11
Removing the 1 2
CrashBox PAP
from the robot
(with mounting
key)
3 4
130
5 6
EN
7 8
9 10
131
11
Changing the If a robot wirefeeder or a media splitter is mounted in the third robot axis, take the follow-
torch hosepack, ing into account when changing the torch hosepack or interconnecting hosepack:
changing the
interconnecting
CAUTION!
hosepack
Risk of damage to the robot wirefeeder or media splitter from escaping coolant.
▶ After disconnecting the coolant hoses on the torch hosepack, close the coolant con-
nections with the cover provided immediately.
▶ Position the robot in such a way that escaping coolant cannot flow back into the
robot wirefeeder or the media splitter.
1
1
2
132
Cleaning the
EN
1 2
welding torch
Disposal Dispose of in accordance with the applicable national and local regulations.
133
134
Technical data
135
136
WF wire-feed unit
EN
WF 15i R, Supply voltage 24 V DC / 60 V DC
WF 15i R PAP
Nominal current 0.5 A / 1 A
Welding current at 10 min/40 °C (104 °F) 40% D.C.* 650 A
60% D.C.* 600 A
100% D.C.* 500 A
Maximum shielding gas pressure 7 bar / 101.53 psi
Coolant Original Fronius
Maximum coolant pressure 5 bar / 72.53 psi
Wire speed 0.5 - 15 m/min / 19.68 - 590.55 ipm
Wire drive 4-roller drive
Recommended wire diameter 0.8 - 2.4 mm / 03 - 09 in.
Degree of protection IP 43
Mark of conformity CE, CSA
Dimensions l x w x h 658 x 282 x 362 mm
25.91 x 11.10 x 14.25 in.
Weight 5.8 kg / 12.79 Ib.
*) D.C. = Duty cycle

WF 25i R PAP,
WF 25i R / L Nominal current 0.5 A / 1.2 A
60% D.C.* 450 A
100% D.C.* 360 A
Wire speed 1 - 25 m/min / 39.37 - 984.25 ipm
Recommended wire diameter 0.8 - 1.6 mm / 0.03 - 0.06 in.
25.91 x 11.10 x 14.25 in.
137
WF 30i R PAP,
WF 30i R / L Nominal current 0.5 A / 1.4 A
60% D.C.* 600 A
100% D.C.* 500 A
Wire speed 1 - 30 m/min / 39.37 - 1181.10 ipm
Recommended wire diameter 0.8 - 1.6 mm / 0.03 - 0.06 in.
25.91 x 11.10 x 14.25 in.
138
Unreeling wirefeeder WF REEL
EN
WF 25i REEL Supply voltage 24 V DC / 60 V DC
R /4R/G/W
Nominal current 0.5 A / 1.2 A
Wire speed 1 - 25 m/min
39.37 - 984.25 ipm.
0.03 - 0.09 in.
9.8 x 8.3 x 7.5 in.
Weight 4.8 kg
10.58 Ib.
WF 30i REEL Supply voltage 24 V DC / 60 V DC

R /2R/G/W
Nominal current 0.5 A / 0.9 A
Wire speed 1 - 30 m/min
39.37 - 1181.10 ipm.
0.03 - 0.06 in.
9.8 x 8.3 x 7.5 in.
Weight 4.6 kg
10.14 Ib.
139
CrashBox /i
Technical data,
triggering
torques and
weight/distance
diagram
Item numbers
CrashBox /i 44,0350,3589
CrashBox /i XL 44,0350,3760
CrashBox /i XXL 44,0350,3380
CrashBox /i PAP 44,0350,3663
CrashBox /i PAP XL 44,0350,3759
CrashBox /i PAP XXL 44,0350,0202
Reset accuracy (1) ± 0.05 mm a)
Maximum deflection in x/y direction
CrashBox /i ~ 45°
CrashBox /i XL ~ 45°
CrashBox /i XXL ~ 45°
CrashBox /i PAP ~ 30°
CrashBox /i PAP XL ~ 30°
CrashBox /i PAP XXL ~ 30°
Triggering torques in x/y direction
(+/- 10%)
CrashBox /i 21 Nm / 15.49 lb-ft
CrashBox /i XL 42 Nm / 30.98 lb-ft
CrashBox /i XXL 63.1 Nm / 46.54 lb-ft
CrashBox /i PAP 21 Nm / 15.49 lb-ft
CrashBox /i PAP XL 31.5 Nm / 23.23 lb-ft
CrashBox /i PAP XXL 41 Nm / 30.24 lb-ft
Weight
CrashBox /i 1200 g
CrashBox /i XL 1200 g
CrashBox /i XXL 1250 g
CrashBox /i PAP 700 g
CrashBox /i PAP XL 700 g
140
CrashBox /i PAP XXL 750 g
EN
Dimensions
CrashBox /i Ø90 mm x 60 mm b)
CrashBox /i XL Ø90 mm x 60 mm b)
CrashBox /i XXL Ø90 mm x 60 mm
CrashBox /i PAP Ø90 mm x 40 mm b)
CrashBox /i PAP XL Ø90 mm x 40 mm b)
CrashBox /i PAP XXL Ø90 mm x 40 mm
a) At a distance of 300 mm from the robot flange

b) With bellows: Ø110 mm
141
Triggering Weight (distance [mm]) [kg] Deflection at a distance of 300 mm Max. possible deflection
142
torque
(+/- 10%) 50 100 200 300 400 min [mm] min [°] max [mm] max [°] x/y - direction [°] z direction [mm]
CrashBox /i 21 Nm 42.0 21.0 10.5 7.00 5.25 3.5 0.684 8 1.5275 ~ 45 ~ 30
CrashBox /i XL 42 Nm 84.0 42.0 21.0 14.0 10.5 3.5 0.684 8 1.5275 ~ 45 ~ 30
CrashBox /i XXL 63.1 Nm 126.2 63.1 31.55 21.03 15.78 3.5 0.664 8 1.5275 ~ 45 ~ 30
CrashBox /i PAP 21 Nm 42.0 21.0 10.5 7.00 5.25 3.3 0.6302 8 1.5275 ~ 30 ~ 30
CrashBox /i PAP XL 31.5 Nm 63.0 31.5 15.75 10.5 7.88 3.3 0.6302 8 1.5275 ~ 30 ~ 30
CrashBox /i PAP XXL 41.0 Nm ~ 30
125
CrashBox /i XXL
44,0350,3380
Triggering torques and weight/distance diagram
100
CrashBox /i XL
44,0350,3760
75
CrashBox /i PAP XL
44,0350,3759
50
CrashBox /i
44,0350,3589
weight [kg]
=
The specified values only apply in a static state!

CrashBox /i PAP
44,0350,3663
25
0
30
80
-20
130
180
230
280
330
380
distance to the robots flange [mm]

Torch hosepack
EN
MHP 400i G / R I (ampere) 10 min/40°C 40% D.C.* / 400
M21 (EN 439) 60% D.C.* / 320
100% D.C.* / 260
I (ampere) 10 min/40°C 60% D.C.* / 400
C1 (EN 439) 100% D.C.* / 320
[mm] 0.8 - 1.6
Ø [in.] 0.031 - 0.063
[m] 0.95 / 1.10 / 1.25 / 1.45 / 1.75 / 1.95 /

[ft. + in.] 2.25 / 3.25 / 4.25
3.12 / 3.6 / 4.1 / 4.76 / 5.74 / 6.4 / 7.38 /

10.66 / 13.94
* D.C. = Duty cycle
MHP 400i G / R / I (ampere) 10 min/40°C 40% D.C.* / 400

PAP M21 (EN 439) 60% D.C.* / 320
100% D.C.* / 260
I (ampere) 10 min/40°C 60% D.C.* / 400
C1 (EN 439) 100% D.C.* / 320
[mm] 0.8-1.6
Ø [in.] 0.031 - 0.063
[m] 0.93 / 0.94 / 0.96 / 1.04 / 1.06 / 1.09 /

[ft. + in.] 1.12 / 1.13 / 1.15 / 1.18 / 1.19 / 1.2 / 1.22 /
1.25 / 1.31 / 1.35 / 1.37 / 1.4 / 1.43 / 1.45 /
1.51 / 1.59 / 2.13 / 2.28
3.05 / 3.08 / 3.15 / 3.4 / 3.48 / 3.58 / 3.67 /

3.71 / 3.77 / 3.87 / 3.9 / 3.94 / 4.0 / 4.10 /
4.3 / 4.43 / 4.5 / 4.59 / 4.69 / 4.76 / 4.95 /
5.22 / 6.99 / 7.48
* D.C. = Duty cycle
143
MHP 700i W / R I (ampere) 10 min/40°C 100% D.C.* / 700
(0.95 - 2.25 m / M21 (EN 439)
3.12 - 7.38 ft.)
I (ampere) 10 min/40°C 100% D.C.* / 700
C1 (EN 439)
[mm] 0.8-1.6 (0.031-0.063)
Ø [in.]
[m] 0.95 / 1.10 / 1.25 / 1.45 / 1.75 / 1.95 / 2.25

[ft. + in.]
3.12 / 3.61 / 4.1 / 4.76 / 5.74 / 6.4 / 7.38
Pmin [W] **
0.95 m / 3.12 ft 1200

1.10 m / 3.61 ft 1300
1.25 m / 4.1 ft 1300
1.45 m / 4.76 ft 1400
1.75 m / 5.74 ft 1600
1.95 m / 6.4 ft 1800
2.25 m / 7.38 ft 2000
[l/min] 1
Qmin
[gal./min] 0.26
[bar] 3
pmin
[psi] 43.50
[bar] 5
pmax
[psi] 72.5
* D.C. = Duty cycle

** Lowest cooling capacity in accordance with standard IEC 60974-2, depending on
the length of the hosepack
144
MHP 700i W / R
EN
I (ampere) 10 min/40°C 60% D.C.* 700
(3.25 - 4.25 m / M21 (EN 439) 100% D.C.* 580
10.66 - 13.12 ft.)
I (ampere) 10 min/40°C 60% D.C.* 700
C1 (EN 439) 100% D.C.* 580
[mm] 0.8-1.6 (0.031-0.063)
Ø [in.]
[m] 3.25/4.25
[ft. + in.]
10.66/13.12
Pmin [W] **
3.25 m / 10.66 ft 1400

4.25 m / 13.12 ft 1600
[l/min] 1
Qmin
[gal./min] 0.26
[bar] 3
pmin
[psi] 43.50
[bar] 5
pmax
[psi] 72.5
* D.C. = Duty cycle

145
MHP 700i W / R / I (ampere) 10 min/40°C 100% D.C.* / 700
PAP M21 (EN 439)
I (ampere) 10 min/40°C 100% D.C.* / 700
C1 (EN 439)
[mm] 0.8 - 1.6
Ø [in.] 0.031 - 0.063
[m] 0.93 / 0.96 / 1.04 / 1.06 / 1.09 / 1.12 /

[ft. + in.] 1.13 / 1.15 / 1.18 / 1.19 / 1.2 / 1.22 / 1.31 /
1.35 / 1.37 / 1.4 / 1.43 / 1.51 / 2.28
3.05 / 3.15 / 3.41 / 3.48 / 3.58 / 3.67 /

3.71 / 3.77 / 3.87 / 3.9 / 3.94 / 4 / 4.3 /
4.43 / 4.5 / 4.59 / 4.69 / 4.95 / 7.48
Pmin [W] **
0.93 / 0.94 / 0.96 m 1200

3.05 / 3.08 / 3.15 ft
1.04 / 1.06 / 1.09 m 1250

3.41 / 3.48 / 3.58 ft
1.12 / 1.13 / 1.15 / 1.18 / 1.19 / 1.2 / 1.22 1300

m
3.67 / 3.71 / 3.77 / 3.87 / 3.9 / 3.94 / 4 ft
1350
1.31 m
4.3 ft
1400
1.35 / 1.37 / 1.4 / 1.43 / 1.45 / 1.51 / 1.59
m
4.43 / 4.5 / 4.59 / 4.69 / 4.76 / 4.95 / 5.22 2000
ft
2013 / 2.28 m
6.99 / 7.48 ft
[l/min] 1
Qmin
[gal./min] 0.26
[bar] 3
pmin
[psi] 43.50
[bar] 5
pmax
[psi] 72.5
* D.C. = Duty cycle

146
Robot welding torch
EN
Gas-cooled robot MTB 250i G/R (TX, TXM)
welding torches
X / Imax (10 min/40 °C) 40% D.C.* / 250 A
M21 (EN 439) 60% D.C.* / 200 A
100% D.C.* / 170 A
X / Imax (10 min/40 °C) -
C1 (EN 439) 60% D.C.* / 250 A
100% D.C.* / 200 A
[mm] 0.8-1.2
Ø [in.] 0.030-0.045
MTB 320i G/R (TX, TXM)
X / Imax (10 min/40 °C) 40% D.C.* / 320 A

M21 (EN 439) 60% D.C.* / 260 A
100% D.C.* / 210 A
X / Imax (10 min/40 °C) -
C1 (EN 439) 60% D.C.* / 320 A
100% D.C.* / 260 A
[mm] 0.8-1.6
Ø [in.] 0.030-0.062
X / Imax (10 min/40 °C) 40% D.C.* / 330 A

M21 (EN 439) 60% D.C.* / 270 A
100% D.C.* / 220 A
X / Imax (10 min/40 °C) -
C1 (EN 439) 60% D.C.* / 330 A
100% D.C.* / 270 A
[mm] 0.8-1.6
Ø [in.] 0.030-0.062
X / Imax (10 min/40 °C) 40% D.C.* / 350 A

M21 (EN 439) 60% D.C.* / 300 A
100% D.C.* / 250 A
X / Imax (10 min/40 °C) -
C1 (EN 439) 60% D.C.* / 350 A
100% D.C.* / 300 A
[mm] 0.8-1.6
Ø [in.] 0.030-0.062
147
X / Imax (10 min/40 °C) 40% D.C.* / 400 A

M21 (EN 439) 60% D.C.* / 320 A
100% D.C.* / 260 A
X / Imax (10 min/40 °C) -
C1 (EN 439) 60% D.C.* / 400 A
100% D.C.* / 320 A
[mm] 0.8-1.6
Ø [in.] 0.030-0.062
* D.C. = Duty cycle
Water-cooled MTB 250i W/R

robot welding
torches X / Imax (10 min/40 °C) 100% D.C.* / 250 A
M21 (EN 439)
X / Imax (10 min/40 °C) 100% D.C.* / 250 A
C1 (EN 439)
[mm] 0.8-1.2
Ø [in.] 0.032-0.047
MTB 330i W/R (TX, TXM)
X / Imax (10 min/40 °C) 100% D.C.* / 330 A

M21 (EN 439)
X / Imax (10 min/40 °C) 100% D.C.* / 330 A
C1 (EN 439)
[mm] 0.8-1.6
Ø [in.] 0.032-0.063
X / Imax (10 min/40 °C) 100% D.C.* / 400 A

M21 (EN 439)
X / Imax (10 min/40 °C) 100% D.C.* / 400 A
C1 (EN 439)
[mm] 0.8-1.6
Ø [in.] 0.032-0.063
148
EN
X / Imax (10 min/40 °C) 100% D.C.* / 500 A
M21 (EN 439)
X / Imax (10 min/40 °C) 100% D.C.* / 500 A
C1 (EN 439)
[mm] 1.0-1.6
Ø [in.] 0.039-0.063
X / Imax (10 min/40 °C) 100% D.C.* / 700 A

M21 (EN 439)
X / Imax (10 min/40 °C) 100% D.C.* / 700 A
C1 (EN 439)
[mm] 1.0-1.6
Ø [in.] 0.039-0.063
* D.C. = Duty cycle
149
Interconnecting hosepacks
HP 70i Welding current at 10 min/40 °C (104 °F) 40% D.C.* / 400 A

60% D.C.* / 365 A
100% D.C.* / 320 A
* D.C. = Duty cycle

60% D.C* / 450 A
100% D.C.* / 360 A
* D.C. = Duty cycle

60% D.C.* / 530 A
100% D.C.* / 430 A
* D.C. = Duty cycle
HP 70i, HP PC Welding current at 10 min/40 °C (104 °F) 60% D.C.* / 600 A

Cable HD 70 100% D.C.* / 500 A
* D.C. = Duty cycle
150
EN
151
FRONIUS INTERNATIONAL GMBH
Froniusstraße 1
A-4643 Pettenbach
AUSTRIA
contact@fronius.com
www.fronius.com
Under www.fronius.com/contact you will find the addresses

of all Fronius Sales & Service Partners and locations

Alimentador Fronius WF 25i R PAP

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/ Perfect Charging / Perfect Welding / Solar Energy

Push MIG/MAG robot welding system

Controls, connections and mechanical components 43

Installation - conventional robot 59

Troubleshooting, maintenance and disposal 119

Technical data 135

Indicates a potentially hazardous situation.

Indicates a situation where damage or injury could occur.

All safety and danger notices on the device

This is for your personal safety!

Proper use also includes:

The manufacturer likewise accepts no liability for inadequate or incorrect results.

Ambient temperature range:

Obligations of Before using the device, all persons instructed to do so undertake:

This may affect a number device types in terms of:

IMPORTANT! Ensure that the mains connection is earthed properly

Protective clothing refers to a variety of different items. Operators should:

Use at-source extraction and a room extraction system.

Keep your face away from welding fumes and gases.

Fumes and hazardous gases

Danger from fly- Flying sparks may cause fires or explosions.

If necessary, provide adequate earthing for the workpiece.

Switch off unused devices.

Wear a safety harness if working at height.

After opening the device:

Ensure that the workpiece is held securely by the workpiece clamp.

EMC Device Clas- Devices in emission class A:

Devices in emission class B:

EMC device classification as per the rating plate or technical data.

Supporting measures for avoidance of EMC problems:

Never touch the workpiece during or after welding - risk of burns.

Special provisions apply in areas at risk of fire or explosion - observe relevant

Use filters if necessary.

Never hang a welding torch on a shielding gas cylinder.

Never touch a shielding gas cylinder with an electrode.

Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.

Close the shielding gas cylinder valve if no welding is taking place.

The manufacturer's instructions must be observed as well as applicable national and

Never bypass or disable safety devices.

Before switching on the device, ensure that no one is likely to be endangered.

Only use suitable original coolant from the manufacturer.

Do not mix the manufacturer's original coolant with other coolants.

Only connect the manufacturer's system components to the cooling circuit.

A safety inspection should be carried out by a qualified electrician

Copyright Copyright of these operating instructions remains with the manufacturer.

A Drive rollers can injure fingers.

1. An electric shock can be fatal.

2. Inhalation of welding fumes can be harmful to health.

2.1 Keep your face away from any welding fumes.

2.3 Remove welding fumes with a fan.

3.3 Do not weld on drums or closed containers.

5. Before working on the system or welding:

6. Do not remove or paint over the warning sticker.

* Manufacturer order number of the sticker

(1) Wirefeeding hose with inner liner

(2) TPSi power source

(3) CU cooling unit

(4) Upright console

(5) HP interconnecting hosepack

(6) Wirefeeder WF 15i R / WF 25i R / WF 30i R

(7) MHP /i R torch hosepack

(8) MTB /i R robot welding torch

Maximum wirefeed length: