42,0426,0219, en

Operating
Instructions
TPS/i Robotics welding system
Pull
PushPull CMT
EN Operating Instructions
42,0426,0219,EN 025-06092023
Contents
EN
Safety rules 8
Explanation of safety notices 8
General 8
Intended use 9
Environmental conditions 9
Obligations of the operator 9
Obligations of personnel 9
Mains connection 9
Protecting yourself and others 10
Danger from toxic gases and vapours 10
Danger from flying sparks 11
Risks from mains current and welding current 11
Meandering welding currents 13
EMC Device Classifications 13
EMC measures 13
EMF measures 14
Specific hazards 14
Requirement for the shielding gas 15
Danger from shielding gas cylinders 15
Danger from escaping shielding gas 16
Safety measures at the installation location and during transport 16
Safety measures in normal operation 17
Commissioning, maintenance and repair 17
Safety inspection 18
Disposal 18
Safety symbols 18
Data protection 18
Copyright 18
Description of the warning notices on the device 20
System configurations 23
System configurations - conventional robot 25
PowerDrive with wire drum 25
PowerDrive with wire drum and external wirefeeding hose 26
PushPull with 4-roller unreeling wirefeeder and wire drum 27
PushPull with 4-roller unreeling wirefeeder and wirespool 28
PushPull with SB 60i, 4-roller unreeling wirefeeder and wirespool 29
PushPull with 2-roller unreeling wirefeeder, wire drum and external wirefeeding hose 30
CMT with SB 60i, 4-roller unreeling wirefeeder and wire drum 31
CMT with SB 500i, 4-roller unreeling wirefeeder, wire drum and external wirefeeding hose 32
CMT with SB 60i, 4-roller unreeling wirefeeder and wirespool 33
System configurations - PAP 34
PowerDrive with wire drum 34
PushPull with 4-roller unreeling wirefeeder and wirespool 36
PushPull with wire buffer, 4-roller unreeling wirefeeder and wire drum 38
PushPull with wire buffer, 4-roller unreeling wirefeeder and wire spool 39
CMT with SB 500i, 4-roller unreeling wirefeeder and wire spool 42
System components 43
SplitBox SB 500i R 45
Device concept 45
Proper use 45
Safety 45
Warning notices on the device 46
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Device concept 48
Proper use 48
Safety 48
TPSi wire buffer 51
General 51
CrashBox /i 52
General 52
Note on the correct operation of CrashBoxes 53
Also required for installation 53
Device concept 54
Areas of utilisation 54
Information on repairing CrashBoxes 54
Scope of supply 54
WF Robacta Drive 55
General 55
PushPull hosepack 56
General 56
Scope of supply 56
Robot welding torch 57
Safety 57
General 57
WF 25i REEL R /4R, WF 30i REEL R /2R 59
Safety 59
Device concept 59
Application area 59
Proper use 59
Interconnecting hosepack 62
General 62
General 62
PowerLiner 63
General 63
WireSense 64
General 64
Requirements 64
How it works 64
WireSense - edge detection 65
WireSense - contour detection 66
Technical details 67
OPT/i camera mount 68
General 68
Drilling template 68
Controls, connections and mechanical components 69

General 71
Safety 71
General 71
SplitBox SB 500i R / SB 500i R PAP 72
Controls, connections, and mechanical components of the SB 500i R 72
Controls, connections, and mechanical components of the SB 500i R PAP 73
SB 60i R:Controls, connections, and mechanical components 75
SB 60i R /L:Controls, connections, and mechanical components 76
WF 25i Robacta Drive / WF 60i Robacta Drive CMT 77
Control panel WF 25i Robacta Drive / WF 60i Robacta Drive CMT 77
Status indicators 77
WF 25i REEL R /4R, WF 30i REEL R /2R 79
Control elements, connections and mechanical components 79
Function of the gas-test, wire retract and wire threading buttons 81
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Function of the gas-test, wire retract and wire threading buttons 81
Assembling system components - conventional robot 83
EN
General 85
Safety 85
Assembly sequence, conventional robot 85
Fitting the SplitBox SB 500i R 86
Fitting the wirefeeder holder 86
Fitting the SB 500i R 86
Fitting the CrashBox /i to the robot 87
Fitting the CrashBox /i to the robot 87
Installing the CrashBox/i Dummy on the robot 88
Fitting the WF Robacta Drive to a conventional robot 90
Fitting the hosepack to the WF Robacta Drive (conventional) 90
Fitting the WF Robacta Drive to the robot (conventional) 91
Fitting the WF Robacta Drive to the robot 93
Optimum hosepack arrangement 94
Fitting the interconnecting hosepack 95
Fitting the Standard interconnecting hosepack to the robot 95
Connecting the MHP W hosepack 96
Connecting the MHP W hosepack 96
Connecting the SplitBox SB 500i R to the system components 99
Safety 99
General 99
Connecting the SplitBox SB 500i R to the system components 99
Assembling system components - PAP robot 101

Axis rotation and service life of the torch hosepack 103
General 103
Recommended axis rotation 103
Maximum axis rotation 104
Hosepack service life depending on the axis rotation in the fifth and sixth robot axis 105
General 106
Safety 106
Assembly sequence, PAP robot 106
Fitting the SplitBox SB 500i R PAP 107
Fitting the SB 500i R PAP 107
Installing the CrashBox Drive /i PAP on the robot 108
Installing the CrashBox Drive /i PAP on the robot 108
Installing the CrashBox Drive /i PAP Dummy on the robot 109
Fitting the WF Robacta Drive to a PAP robot 111
Fitting the hosepack to the WF Robacta Drive (PAP) 111
Fitting the WF Robacta Drive to the robot (PAP) 112
Fitting the interconnecting hosepack 114
Fitting the PAP interconnecting hosepack to the robot 114
Connecting the SplitBox SB 500i R PAP to the system components 115
Safety 115
General 115
Connecting the SplitBox SB 500i R PAP to the system components 115
Assembling further system components 117

Fitting the SplitBox SB 60i R 119
Fitting the SB 60i R to the robot 119
Fitting the SB 60i R to the balancer 119
Mounting the SB 60i R on the wall 121
Connecting the torch hosepack to the SplitBox SB 60i R 122
Fitting the TPSi wire buffer 123
Fitting the TPSi wire buffer 123
Connecting the control line to the wire buffer 124
Fitting the unreeling wirefeeder 125
Fitting the unreeling wirefeeder 125
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Connecting the extension hosepack 126
Connecting the extension hosepack 126
Fitting the torch body to the WF Robacta Drive 129
Fitting the gas-saver nozzle 129
Fitting the inner liner inside the torch body 130
Fitting the torch body to the WF Robacta Drive 132
Fitting the OPT/i camera mount 133
Load-bearing capacity of the OPT/i camera mount 133
Safety 133
Fitting the OPT/i camera mount 134
Fitting the inner liner 135
Fitting the inner liner (unreeling wirefeeder - SplitBox SB 500i R) 135
Fitting the inner liner (unreeling wirefeeder- WF Robacta Drive with external wirefeeding 135
hose)
Fitting the PowerLiner (unreeling wirefeeder - WF Robacta Drive with external wirefeed- 136
ing hose)
Fitting the inner liner (unreeling wirefeeder - wire buffer) 137
Fitting the inner liner (SplitBox - WF 25i with internal inner liner) 138
Fitting the inner liner (wire buffer - SplitBox SB 500i for WF Robacta Drive with internal 139
wirefeeding hose)
Fitting the inner liner (wire buffer - WF Robacta Drive with external wirefeeding hose) 140
Fitting the inner liner inside the torch hosepack 141
Start-up 143
Inserting/replacing feed rollers 145
General 145
WF 25i Reel 4R: inserting/replacing feed rollers for the 4-roller drive 145
WF 30i Reel 2R: inserting/replacing feed rollers for the 2-roller drive 146
Inserting/replacing the WF 25i Robacta Drive feed rollers 147
Inserting/replacing the WF 60i Robacta Drive CMT feed rollers 149
Feeding in the wire electrode 152
Insulated routing of wire electrode to wirefeeder 152
Feeding in the wire electrode 152
Setting the contact pressure for the WF 25i Robacta Drive 153
Setting the contact pressure for the WF 60i Robacta Drive CMT 154
Start-up 155
Requirements 155
General 155
Troubleshooting, maintenance and disposal 157

Troubleshooting 159
Safety 159
Fault diagnosis 159
Care, maintenance and disposal 163
General 163
Safety 163
Every start-up 163
Special care of O-rings 163
Whenever the welding torch or torch hosepack is changed 164
Changing the torch hosepack, changing the interconnecting hosepack 164
Every 6 months 164
Recognising faulty wearing parts 165
Replacing the WF 25i Robacta Drive clamping lever 165
Replacing the WF 60i Robacta Drive CMT clamping lever 166
Replacing the WF Robacta Drive gas-saver nozzle 166
Replacing the SB 60i R inner liner 167
Replacing the TPSi wire buffer wire guide 169
Changing the direction of operation of the TPSi wire buffer 170
Replacing the TPSi wire buffer lever 171
Fitting wearing parts to the torch body 173
Fitting wearing parts to the torch body - MTW 700 i 173
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Removing the CrashBox PAP from the robot 174
Disposal 175
EN
Technical data 177
SB 500i R, R left variant, PAP 179
SB 500i R, R left-hand version, PAP 179
SB 60i R 180
SB 60i R 180
CrashBox /i 181
CrashBox /i 181
PushPull hosepack 184
Gas-cooled PushPull hosepacks 184
Water-cooled PushPull hosepacks 185
WF 25i Robacta Drive 187
WF 25i Robacta Drive /G 187
WF 25i Robacta Drive /W 187
WF 60i Robacta Drive CMT 188
WF 60i Robacta Drive CMT /G 188
WF 60i Robacta Drive /W CMT 188
WF 25i REEL R /4R/G/W 190
WF 30i REEL R /2R/G/W 191
Robot welding torch 192
Gas-cooled robot welding torches 192
Water-cooled robot welding torches 193
Interconnecting hosepacks 195
HP 70i 195
HP 95i 195
HP 120i 195
HP 70i, HP PC Cable HD 70 195
7
Safety rules
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

recognised safety standards. If used incorrectly or misused, however, it can
cause:
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operating
company,
- inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing the

device must:
- be suitably qualified,
- have sufficient knowledge of automated welding, and
- read and carefully follow these operating instructions as well as the operat-
ing instructions for all system components.
The operating instructions must always be at hand wherever the device is being
used. In addition to the operating instructions, attention must also be paid to any
generally applicable and local regulations regarding accident prevention and en-
vironmental protection.
All safety and danger notices on the device

- must be in a legible state,
- must not be damaged,
- must not be removed,
- must not be covered, pasted or painted over.
For the location of the safety and danger notices on the device, refer to the sec-
tion headed "General" in the operating instructions for the device.
Before commissioning the device, rectify any faults that could compromise
safety.
This is for your personal safety!
8
Intended use The devices and components described in these Operating Instructions are in-
EN
tended exclusively for automated MIG/MAG applications in conjunction with
Fronius components.
Any use above and beyond this purpose is deemed improper. The manufacturer
shall not be held liable for any damage arising from such usage.
Proper use also includes:

- Carefully reading and following all the instructions given in the Operating In-
structions
- Studying and obeying all safety instructions and danger notices carefully
- Performing all stipulated inspection and servicing work
The manufacturer likewise accepts no liability for inadequate or incorrect results.
Environmental Operation or storage of the device outside the stipulated area will be deemed as
conditions not in accordance with the intended purpose. The manufacturer shall not be held
liable for any damage arising from such usage.
Ambient temperature range:

- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
Relative humidity:
- up to 50% at 40 °C (104 °F)
- up to 90% at 20 °C (68 °F)
The surrounding air must be free from dust, acids, corrosive gases or substances,
etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)
Obligations of The operator must only allow persons to work with the device who:
the 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 sec-
tion "safety rules", and have confirmed as much with their signatures
- are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are
working in a safety-conscious manner.
Obligations of Before using the device, all persons instructed to do so undertake:

personnel - to observe the basic instructions regarding safety at work and accident pre-
vention
- to read these operating instructions, especially the "Safety rules" section and
sign to confirm that they have understood them and will follow them.
Before leaving the workplace, ensure that people or property cannot come to any
harm in your absence.
Mains connec- Devices with a higher rating may affect the energy quality of the mains due to
tion their current consumption.
9
This may affect a number device types in terms of:
- Connection restrictions
- Criteria with regard to the maximum permissible mains impedance *)
- Criteria with regard to the minimum short-circuit power requirement *)
*) at
the interface with the public grid
see "Technical data"
In this case, the plant operator or the person using the device should check
whether the device may be connected, where appropriate by discussing the mat-
ter with the power supply company.
IMPORTANT! Ensure that the mains connection is earthed properly
Protecting your- 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 us-
ing cardiac pacemakers
- Risk of electrocution from mains current and welding current
- Greater noise pollution
- Harmful welding fumes and gases
Suitable protective clothing must be worn when working with the device. The
protective clothing must have the following properties:
- Flame-resistant
- Insulating and dry
- Covers the whole body, is undamaged and in good condition
- Safety helmet
- Trousers with no turn-ups
Protective clothing refers to a variety of different items. Operators should:

- Protect eyes and face from UV rays, heat and sparks using a protective visor
and regulation filter
- Wear regulation protective goggles with side protection behind the protect-
ive visor
- Wear stout footwear that provides insulation even in wet conditions
- Protect the hands with suitable gloves (electrically insulated and providing
protection against heat)
- Wear ear protection to reduce the harmful effects of noise and to prevent in-
jury
Keep all persons, especially children, out of the working area while any devices
are in operation or welding is in progress. If, however, there are people in the vi-
cinity:
- Make them aware of all the dangers (risk of dazzling by the arc, injury from
flying sparks, harmful welding fumes, noise, possible risks from mains cur-
rent and welding current, etc.)
- Provide suitable protective equipment
- Alternatively, erect suitable safety screens/curtains.
Danger from tox- The fumes produced during welding contain harmful gases and vapours.
ic gases and va-
pours 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.
10
Keep your face away from welding fumes and gases.
EN
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.
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 toxicity 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
identifying working conditions can be found on the European Welding Associ-
ation website under Health & Safety (https://european-welding.org).
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radi-
ation 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 accord-
ance 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
welding current Do not touch live parts either inside or outside the device.
11
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,

insulated 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 di-
mensioned. Replace loose connections and scorched, damaged, or inadequately
dimensioned cables and leads immediately.
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 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
electrodes 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 regula-
tions 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.
12
Meandering If the following instructions are ignored, meandering welding currents can devel-
EN
welding currents op with the following consequences:
- Fire hazard
- Overheating of parts connected to the workpiece
- 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 envir-
onments, such as insulation against conductive floor or insulation to conductive
racks.
If power distribution boards, twin-head mounts, etc., are being used, note the fol-
lowing: 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.
In the case of automated MIG/MAG applications, ensure that only an insulated

wire electrode is routed from the welding wire drum, large wirefeeder spool or
wirespool to the wirefeeder.
EMC Device Devices in emission class A:

Classifications - 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
emissions, 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 recti-
fy the situation.
Check and evaluate the immunity to interference of nearby devices according to

national and international regulations. Examples of equipment that may be sus-
ceptible to interference from the device include:
- Safety devices
- Network, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
13
Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite the correct mains connec-
tion, additional measures are necessary (e.g. use of a suitable line filter)
2. Welding power-leads
- must be kept as short as possible
- must be laid 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. Shield, if necessary
- Shield other devices nearby
- Shield the entire welding installation
EMF measures Electromagnetic fields may pose as yet unknown risks to health:
- Effects on the health of persons in the vicinity, e.g. those with pacemakers
and hearing aids
- Individuals with pacemakers must seek advice from their doctor before ap-
proaching the device or any welding that is in progress
- For safety reasons, maintain as large a distance as possible between the
welding power-leads and the head/torso of the welder
- Do not carry welding power-leads and hosepacks over the shoulders or wind
them around any part of the body
Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example:
- Fans
- Cogs
- Rollers
- Shafts
- Wirespools and welding wires
Do not reach into the rotating cogs of the wire drive or into rotating drive com-
ponents.
Covers and side panels may only be opened/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
wirefeeder) and wear suitable protective goggles.
Never touch the workpiece during or after welding - risk of burns.
Slag can jump off cooling workpieces. The specified protective equipment must
therefore also be worn when reworking workpieces, and steps must be taken to
ensure that other people are also adequately protected.
Welding torches and other parts with a high operating temperature must be al-
lowed to cool down before handling.
Special provisions apply in areas at risk of fire or explosion

- observe relevant national and international regulations.
14
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
EN
such areas.
Risk of scalding from escaping coolant. Switch off cooling unit before discon-
necting coolant flow or return lines.
Observe the information on the coolant safety data sheet when handling coolant.
The coolant safety data sheet may be obtained from your service centre or down-
loaded from the manufacturer's website.
Use only suitable load-carrying equipment supplied by the manufacturer when

transporting devices by crane.
- Hook chains or ropes onto all suspension points provided on the load-carry-
ing equipment.
- Chains and ropes must be at the smallest angle possible to the vertical.
- Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).
If the wirefeeder is attached to a crane holder during welding, always use a suit-
able, 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, counter-
balanced lift truck or other mechanical hoist.
All lifting tackle (straps, handles, chains, etc.) used in connection with the device
or its components must be tested regularly (e.g. for mechanical damage, corro-
sion or changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national
standards and directives as a minimum.
Odourless and colourless shielding gas may escape unnoticed if an adapter is

used for the shielding gas connection. Prior to assembly, seal the device-side
thread of the adapter for the shielding gas connection using suitable Teflon tape.
Requirement for Especially with ring lines, contaminated shielding gas can cause damage to
the shielding gas equipment 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.
shielding gas cyl- As the shielding gas cylinders are part of the welding equipment, they must be
inders handled with the greatest of care.
Protect shielding gas cylinders containing compressed gas from excessive heat,
mechanical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instructions
to prevent 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.
15
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 correct 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
cylinder.
The manufacturer's instructions must be observed as well as applicable national

and international regulations for shielding gas cylinders and accessories.
Danger from es- Risk of suffocation from the uncontrolled escape of shielding gas
caping shielding
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 tak-
ing place.
- Check the shielding gas cylinder or main gas supply for uncontrolled gas
leakage before every start-up.
Safety measures A device toppling over could easily kill someone. Place the device on a solid, level
at the installa- surface such that it remains stable
tion location and - The maximum permissible tilt angle is 10°.
during 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 regard-
ing 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
following components:
- Wirefeeder
- Wirespool
- Shielding gas cylinder
16
After transporting the device, the device must be visually inspected for damage
before commissioning. Any damage must be repaired by trained service techni-
EN
cians before commissioning the device.
Safety measures Only operate the device when all safety devices are fully functional. If the safety
in normal opera- devices 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 function-
ing 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 compatibil-
ity, 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.
The manufacturer accepts no liability for damage resulting from use of other sys-
tem 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 con-
tainers and keep well away from any sources of ignition.
Used coolant must be disposed of properly in accordance with the relevant na-
tional and international regulations. The coolant safety data sheet may be ob-
tained from your service 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 manufac-
maintenance and tured to meet the demands made of them, or that they satisfy safety require-
repair ments.
- 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
manufacturer'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.
17
Only use original housing screws in the correct number and tightened to the spe-
cified torque.
Safety inspec- The manufacturer recommends that a safety inspection of the device is per-
tion formed 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 stand-
ards 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 re-
quire.
Disposal Waste electrical and electronic equipment must be collected separately and re-
cycled in an environmentally responsible manner in accordance with the EU Dir-
ective and national law. Used equipment must be returned to the distributor or
through a local, authorised collection and disposal system. Proper disposal of the
old device promotes sustainable recycling of material resources. Ignoring this
may lead to potential health/environmental impacts.
Packaging materials
Collected separately. Check your municipality’s regulations. Reduce the volume
of the box.
Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage
and electromagnetic 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 following address: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant
standards 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 pur-
18
chaser. If you have any suggestions for improvement, or can point out any mis-
takes that you have found in the instructions, we will be most grateful for your
EN
comments.
19
Description of For certain device versions, warning notices are affixed to the device.
the warning no-
tices on the The arrangement of the symbols may vary.
device
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 electric 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.
20
2.2 Use forced-air ventilation or a local extraction system to remove welding
fumes.
EN
2.3 Remove welding fumes with a fan.
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 neces-
sary, 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 col-
lar with button. Use a welding helmet with the correct tinting. Wear suit-
able 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
21
22
System configurations
23
24
System configurations - conventional robot
EN
PowerDrive with (6)
wire drum (7)*
(8)
(1)* (9)**
(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) SplitBox SB 500i R
(7) MHP /i R torch hosepack
(8) WF 25i Robacta Drive
(9) MTB /i R robot welding torch
Maximum wirefeed length:

max. 6 m between wire drum and drive unit
(max. 8 m with PowerLiner)
Possible wire diameters:

0.8 - 1.2 mm
Welding process:
Standard, Pulse, LSC, PMC, PMC-MIX-DRIVE
IMPORTANT! Do not use a wire straightening section or guide roller in this con-
figuration.
* Use the largest inner liner (incl. basic kit)

** Use the inner liner corresponding to the wire diameter (incl. basic kit)
25
PowerDrive with (6)
wire drum and
(7)*
external
wirefeeding hose (8)
(1)* (9)**
(2)
(3)
(4)
(5)
(3) CU cooling unit
(4) Upright console
(7) MHP /i R welding torch hosepack with external wirefeeding hose


0.8 - 1.2 mm
Welding process:
figuration.

26
PushPull with 4-
EN
(3) (8)
roller unreeling (1)*
(9)*
wirefeeder and
wire drum (10)
(1)* (2) (11)**
(4)
(5)
(6)
(7)
(2) SpeedNet cable COM
(3) Unreeling wirefeeder WF 25i REEL 4R
(5) CU cooling unit
(6) Upright console

- max. 15 m between drive unit and unreeling wirefeeder
- max. 8 m between unreeling wirefeeder and wire drum
Minimum length between unreeling wirefeeder and drive unit:

4m

0.8 - 2.0 mm
Welding process:
Standard, Pulse, LSC, PMC

27
PushPull with 4- (8)
roller unreeling (7)* (9)*
wirefeeder and
wirespool (10)
(11)**
(2)
(1)
(3)
(4)
(5)
(6)

+ OPT/i WF Reel carriage D300
(4) CU cooling unit
(5) Upright console

max. 15 m between drive unit and unreeling wirefeeder

0.8 - 2.0 mm
Welding process:

28
PushPull with
EN
SB 60i, 4-roller (9)
unreeling
wirefeeder and (10)
wirespool
(8) (11)**
(2)
(1)
(7)**
(3)
(4)
(5)
(6)

(4) CU cooling unit
(5) Upright console
(6) HP interconnecting hosepack SB 60i

- max. 4 m between drive unit and SB 60i R
- max. 6 m between SB 60i R and unreeling wirefeeder
Minimum length between SB 60i R and drive unit:

1m

0.8 - 1.6 mm
Welding processes:

29
PushPull with 2- (7)*
roller unreeling
wirefeeder, wire (8) (9)
drum and ex-
ternal wirefeed- (10)
ing hose (2) (11)**
(1
(1)
(3)
(4)
(5)
(6)

+ WF Mounting Drum
(4) CU cooling unit
(5) Upright console
(11) MHP /i R robot welding torch


0.8 - 1.6 mm
Welding process:
IMPORTANT!
- This configuration is only possible with wire drum. A wirespool cannot be
used.
- Do not use a wire straightening section or guide roller in this configuration.

30
CMT with SB 60i,
EN
(9)*
4-roller unreel-
ing wirefeeder
and wire drum (3) (10)
(1
(8) (11)**
(1
(1)* (2)
(1)**
(4)
(5)
(6)
(7)
(5) CU cooling unit
(6) Upright console
(10) WF 60i Robacta Drive CMT

Minimum length between wirefeeder and drive unit:

1m

0.8 - 1.6 mm aluminium, 0.8 - 1.4 mm steel
Welding process:
Standard, Pulse, LSC, PMC, PMC-MIX-DRIVE, PMC-RIPPLE-DRIVE, CMT

31
CMT with SB
500i, 4-roller un- (10)*
reeling wirefeed-
er, wire drum and (9)
(3) (11)
(1
external
wirefeeding hose (1
(12)**
(8)
(1)* (2)
(1)***
(4)
(5)
(6)
(7)
(5) CU cooling unit
(6) Upright console
(8) Wire buffer

- max. 4 m between drive unit and wire buffer
- max. 6 m between wire buffer and unreeling wirefeeder

1m

Welding process:
Standard, Pulse, LSC, PMC, CMT

32
CMT with SB 60i,
EN
4-roller unreel- (9)*
ing wirefeeder
and wirespool (10)
(8) (11)**
(2)
(2)
(1)
(7)**
(3)
(4)
(5)
(6)

(4) CU cooling unit
(5) Upright console


1m

Welding processes:

33
System configurations - PAP
PowerDrive with
wire drum (6) (7)*
(8)
(1)*
(9
(9)**
(2)
(3)
(4)
(5)
(3) CU cooling unit
(4) Upright console


0.8 - 1.2 mm
Welding process:
figuration.

34
PushPull with 4-
EN
(3) (8)
roller unreeling (1)* (9)*
wirefeeder and
wire drum (10)
(1
(1)* (2)
(11)**
(1
(4)
(5)
(6)
(7)
(5) CU cooling unit
(6) Upright console

- max. 15 m between drive unit and unreeling wirefeeder

4m

0.8 - 2.0 mm
Welding process:

35
PushPull with 4- (8)
wirefeeder and
wirespool (7)*
(10)
(2) (11)**
(1
(1)
(3)
(4)
(5)
(6)

(4) CU cooling unit
(5) Upright console


4m

0.8 - 2.0 mm
Welding process:

36
PushPull with 2-
EN
(8) (9)*
wirefeeder and
wire drum (10)
(1
(2)
(11)**
(1
(1)
(4)
(5)
(6)
(7)

+ WF Mounting Drum
(5) CU cooling unit
(6) Upright console
(11) MHP /i R robot welding torch


4m

0.8 - 1.6 mm
Welding process:
IMPORTANT! This configuration is only possible with wire drum. A wirespool

cannot be used.

37
PushPull with
wire buffer, 4- (8) (10)*
roller unreeling
wirefeeder and (3)
wire drum (1)** (11)
(1)* (2) (1)* (12)**
(9)
(4)
(5)
(6)
(7)
(5) CU cooling unit
(6) Upright console
(9) Wire buffer


Welding process:

38
PushPull with
EN
(9) (10)*
wire buffer, 4-
(7)*
roller unreeling
wirefeeder and (11)
wire spool (2)
(12)**
(1
(8)
(1)
(7)**
(3)
(4)
(5)
(6)

(4) CU cooling unit
(5) Upright console
(8) Wire buffer


1m

0.8 - 1.6 mm
Welding process:

39
CMT with SB 60i,
(9)*
4-roller unreel-
ing wirefeeder (3)
and wire drum (10)
(1
(1)* (2) (11)**

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


1m

Welding process:

40
CMT with SB
EN
(8) (10)*
500i, 4-roller un- (1)*
reeling wirefeed- (3)
er and wire drum (11)
(1
(12)**
(1
(1)* (2)
(9)
(1)**
(4)
(5)
(6)
(7)
(5) CU cooling unit
(6) Upright console
(9) Wire buffer


1m

Welding process:

41
CMT with SB (8) (10)*
500i, 4-roller un- (7)*
reeling wirefeed-
er and wire spool (1
(11)
(2)
(12)**
(1
(9)
(1)
(7)**
(3)
(4)
(5)
(6)

(4) CU cooling unit
(5) Upright console


1m

Welding process:

42
System components
43
44
SplitBox SB 500i R
EN
Device concept The SplitBox (SB) 500i R, SB 500i R / L and SB 500i R PAP devices bring togeth-
er the welding media for automated MIG/MAG welding and have been specially
designed for mounting onto the robot. Two versions of the devices are available:
- R = for applications in which the hosepack is externally mounted on the ro-
bot
- PAP = for applications in which the hosepack is mounted in the robot arm
Proper use The device is designed exclusively for bringing together the welding media 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 damage 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 the stipulated inspection and maintenance work
Safety
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
▶ All the work and functions described in this document must only be carried
out by technically trained and qualified personnel.
▶ Read and understand this document in full.
▶ Read and understand all safety rules and user documentation for this device
and all system components.
45
Warning notices The device is fitted with safety symbols and a rating plate. The safety symbols
on the device and rating 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.
SB 500i R /G/W/FSC
Part No.: 4,040,080

www.fronius.com
Ser.No.: XXXXXXXXXX
IEC 60 974-1/-10 Cl.A IP 43
U11 60 V I11 0.8 A
U12 24 V I12 0.5 A
I2 500 A/100% 600 A/60% 650A/40%
Caution: Parts may be at welding

voltage
Attention: Les pièces peuvent être
à la tension de soudage
40,0006,3035
Welding is dangerous. The following basic requirements must be met to ensure

the equipment is used properly:
- Welders 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.
Do not use the functions described here until you have fully read and understood
the following documents:
- These Operating Instructions
- All the Operating Instructions for the system components, especially the
safety rules
46
EN
Keep hands, hair, clothing and tools away from moving parts. For example:
- Cogs
- Feed rollers
Do not reach 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.
47
SplitBox SB 60i R
Device concept The SB 60i R and SB 60i R /L are devices for bringing together the welding media
in automated MIG/MAG welding and are specially designed for mounting on ro-
bots.
SB 60i R:
Right version of the appliance, for fitting to the right side of the robot
SB 60i R /L:
Left version of the appliance, for fitting to the left side of the robot
Proper use The device is designed exclusively for bringing together the welding media 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 damage arising from such usage.

- performing all the stipulated inspection and maintenance work
Safety
WARNING!
48
EN
and damage.

- Welders must be sufficiently qualified
safety rules
49
50
TPSi wire buffer
EN
General As its name implies, the wire buffer
acts as a buffer zone for the rapid re-
versing movements of the wire elec-
trode needed during the CMT welding
process.
The wire buffer can also be used to

help coordinate two drive systems that
work in different ways. The rear drive
system steadily feeds the wire elec-
trode into the wire buffer, while the
front highly dynamic drive motor
moves it to and fro up to 70 times per
second.
The wire electrode is therefore fed to

the front drive unit with hardly any
force being applied, thus guaranteeing
a high-quality welding process.
The wire buffer is suitable for mounting on the side arm or on the balancer.
51
CrashBox /i
General
A CrashBox Drive /i PAP mounted onto the ro- A CrashBox Drive /i mounted onto the robot arm
bot arm with Robacta Drive and MTB with clamp system, Robacta Drive und MTB
The CrashBox Drive /i is a protection device for the torch body, the drive unit and
the welding torch interchangeable coupling. In the event of a collision, the
CrashBox sends a signal to the robot control, which stops the robot immediately.
The clamp system is used to hold the drive unit on conventional robots.
NOTE!
Always adjust the holding force of the CrashBox to the system weight.
Select the CrashBox size according to the following criteria:
▶ L:
for push systems with a torch body length of up to 249 mm.
▶ XL:
for push systems with a torch body length of up to 249 mm and with exten-
sion;
for push systems with a torch body length of 250–391 mm;
for push/pull systems with a torch body length of up to 249 mm.
▶ XXL:
for push/pull systems with a torch body length of 250–391 mm;
for push/pull systems with a torch body length of up to 249 mm and with ex-
tension.
▶ If there is a TX/i torch-neck changeover system or WireBrake in the welding
system, select the next larger CrashBox.
▶ When cleaning the welding torch with the TC 2000, also select the next lar-
ger CrashBox.
A robot-specific, isolated robot flange is necessary for fitting the CrashBox

Drive /i.
52
Note on the cor-
EN
NOTE!
rect operation of
CrashBoxes To avoid damage to the welding torch or the torch hosepack, or to prevent false
triggering of the CrashBox, consider the following points:
▶ Avoid strong accelerations and maximum speeds during robot movements.
▶ Ensure the free movement of the torch hosepack during all robot move-
ments;
The torch hosepack must not tighten in any position and thus exert a strain
on the CrashBox.
▶ The torch hosepack must not whip around or get stuck when moving.
▶ If possible, clarify all movement situations with Fronius system components
in a simulation as early as the concept phase.
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
53
Device concept The CrashBox Drive /i is designed specifically for fitting to the robot arm and for
holding gas-cooled and water-cooled robot hosepacks with robot drive units. For
PAP systems, the torch hosepack runs through the CrashBox and then through
the robot arm. In conventional 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.
Areas of utilisa- The clamp system can be used for the following PushPull robot hosepacks:
tion - MHP /i G/W RD 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 Drive /i PAP scope of supply Conventional CrashBox /i scope of supply
(1) CrashBox Drive /i holder

(2) 1-ear clamp *
(3) Locking ring, 2-part *
(4) Bellows
(5) Cheese-head screws, M4 x 16 mm
(6) Magnetic ring
* A two-part locking ring and a 1-ear clamp are supplied fitted to the bel-
lows (4).
Do not fit the CrashBox Drive /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 magnetism.
54
WF Robacta Drive
EN
General The WF 25i Robacta Drive and WF 60i
Robacta Drive CMT are designed for
gas or water-cooled systems. The built-
in motor ensures precise wirefeeding
(pull system). The torch body is fitted
to the Robacta Drive.
and damage.
WF 25i Robacta Drive rating plate WF 60i Robacta Drive CMT rating plate

- Anyone performing automated welding must be sufficiently qualified
safety rules
55
PushPull hosepack
General The Robacta MHPi RD hosepack is designed for gas-cooled and water-cooled ro-
bot applications. It connects the SplitBox to the wirefeeder.
The length of the hosepack depends on the robot.
The following combinations are available:

- Robacta MHPi RD conventional
- SB500i -> WF 25i Robacta Drive
- SB60i -> WF 60i Robacta Drive CMT
- Robacta MHPi RD PAP
- Robacta MHPi RD conventional with external wirefeeding hose
Scope of supply
Robacta MHPi RD conventional hosepack Robacta MHPi RD PAP hosepack
Not supplied:
- Inner liners
- Inlet nozzles
Robacta MHPi RD hosepack with external

wirefeeding hose
56
Robot welding torch
EN
Safety
CAUTION!
Risk of burns from hot torch body, hot torch body coupling and other hot weld-
ing 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 com-
ponents to cool down to room temperature (+25 °C, +77 °F)
▶ Wear electrically insulated and heat protective gloves
▶ Use a suitable tool
General The following torch bodies are recommended for the CMT process:
- MTB 250i / 320i / 400i / 500i / 700i: 22–36°
- MTB 330i: 22°
The following maximum angles are permitted during the CMT process:
- MTB 250i / 320i / 400i / 500i / 700i: 45°
- MTB 330i: 36°
Standard OVT TXi TXM OPT CAM*
*Optional (no torch body)
The robot welding torch transmits the arc power to the workpiece. The gas-
cooled or water-cooled TPS /i welding torch is designed for use with the Crash-
Box /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
57
OPT CAM:
Prepared for the camera recording option
58
WF 25i REEL R /4R, WF 30i REEL R /2R
EN
Safety
WARNING!
Incorrect operation or shoddy workmanship can cause serious injury and dam-
age.
▶ The following documents must be completely read and understood before
commissioning 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 preci-
sion 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 sys-
tem.
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 weld-
ing 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 damage arising from such usage.

- performing all stipulated inspection and maintenance work
59
and damage.
40,0006,3035
Example: WF 30i REEL R /2R/G/W

- Anyone performing automated welding must be sufficiently qualified
safety rules
60
EN
Keep hands, hair, clothing and tools away from moving parts. For example:
- Cogs
- Feed rollers
Do not reach into the rotating cogs of the wire drive or into rotating drive com-
ponents.
Covers and side panels may only be opened / removed while maintenance or re-
pair work is being carried out.
Wear eye protection
61
Interconnecting hosepack
General
The interconnecting hosepack connects the power source to the wirefeeder. With
the TPS/i welding system the interconnecting hosepack is available in two ver-
sions - 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)
General
The interconnecting hosepack connects the power source to the SplitBox SB 60i
R.
The interconnecting hosepack is fixed in position on the SplitBox SB 60i R and is
available in the following preconfigured lengths:
- 3 m (extension - split variant)
- 4 / 6 / 8 m (connection - continuous variant)
62
PowerLiner
EN
General
The PowerLiner is a wirefeeder system for all standard wire types. Wire diamet-
ers of 0.6 mm to 1.6 mm may be used.
The PowerLiner does not need an inner liner. The wire electrode is guided by
rollers set at an angle of 90 degrees. Seventy-six rollers are used for each metre
of wirefeeding hose. As a result, rolling friction rather than slip friction occurs
during wirefeeding.
The PowerLiner can be made up to any length. For Robacta Drive applications,
lengths of up to 10 m can be realised. For CMT applications, lengths of up to 6 m
can be realised between the unreeling wirefeeder and wire buffer and 4 m
between the wire buffer and drive unit.
A connection can be established to large spool systems, wire drums, welding
torches or wirefeeders using QuickConnect.
Pay attention to the wirefeeding direction when fitting the PowerLiner.
NOTE!
Use of the PowerLiner between the unreeling wirefeeder and SplitBox or
between the unreeling wirefeeder and wire buffer does not produce any advant-
ages in terms of wirefeeding, but is technically feasible.
63
WireSense
General If OPT/i WireSense software activation is available on the power source, the sur-
face, edges and weld seams of a workpiece can be measured with the wire elec-
trode.
The wire electrode functions as a sensor that can precisely scan a component by
means of high-frequency reversing wire movement.
Component geometries are recorded and the position of the individual sheets in
relation to each other is precisely determined.
Advantages:
- Quick and easy reaction to real component deviations
- No re-training - time and cost savings
- No additional hardware and a cost-effective alternative to laser sensors or
other optical measuring systems
- No need to calibrate TCP and sensor
- Robust and compact measuring system without additional space require-
ments
Requirements WireSense only works

- With automated applications
- In conjunction with CMT system components WF 60i Robacta Drive CMT,
SB 500i R with wire buffer or SB 60i R and WFi Reel.
The CMT Welding Package is not required for the WireSense function.
How it works A sensor voltage with limited current is applied to the wire electrode. If the wire
electrode touches the component, a short circuit is created without welding. The
short circuit is broken again by lifting the wire electrode.
The change in position of the wire electrode up to the short circuit is analysed by
the power source and sent as a height measurement signal to the robot control.
The height measurement signal is compared with the current position data of the
robot control.
If there are differences, the robot can correct the Tool Center Point (TCP) or the
respective coordinate system and compensate component position changes ac-
cordingly.
64
WireSense - - The WireSense edge detection is activated and an edge height between 0.5
EN
edge detection and 20 mm is selected.
- The touch signal is output when the defined edge height is detected. In this
way the position of the edge can be recorded.
- The WireSense Position signal indicates the height of the edge.
- The air gap detection can also be calculated based on the height value.
Signal sequence overview
1. The robot sets the minimum edge height from which the edge detection is
triggered
(WireSense Edge Detection)
2. Signal from robot to start or stop WireSense

(WireSense Start)
3. Signal from the power source for detected short circuit after contact
(ArcStable)
4. Signal from the power source for the detected edge position
(Touch signal)
5. Signal from the power source for edge height measurement

(WireSense Position)
NOTE!
Detailed information on the signals can be found in the "Signal descriptions for
TPS/i interface" (42.0426.0227.xx) Operating Instructions.
65
WireSense - con- - WireSense contour detection is active when WireSense edge detection =
tour detection OFF or < 0.5 mm.
- The touch signal is not active.
- The WireSense Position signal provides the actual height values (live values).
- The additional WireSense Break signal stops the forward movement of the
wire electrode and stores the zero reference value
(The zero reference value is useful for overcoming the distance to the com-
ponent without wirefeeding if the reference value is not set directly on the
component).
Signal sequence overview
1. For contour detection, WireSense edge detection must be disabled

(WireSense Edge Detection = OFF or < 0.5 mm)
2. Signal from the robot to start or stop contour detection

(WireSense Start)
3. Signal from the power source for detected short circuit after contact
(ArcStable)
4. When contour detection is active, no touch signal is output from the power
source
(no touch signal)
5. When contour detection is active, the WireSense Position signal always

transmits the current position of the wire electrode (live values)
(WireSense Position)
NOTE!
Detailed information on the signals can be found in the "Signal descriptions for
TPS/i interface" (42.0426.0227.xx) Operating Instructions.
66
Technical details
EN
Edge detection Contour detection
Edge detection and ac- Height signals
tual height signal
The system outputs a The system supplies the
touch signal when the height information as ac-
edge is detected and tual values of the
provides the height value sampled path.
of the detected edge.
Sampling rate approx. 100 Hz approx. 100 Hz
Min. sheet thickness: 0.5 mm -
Max. sheet thickness 20 mm -
Height measurement ac- 0.3 mm 0.3 mm
curacy
Reproducibility max. +/-0.2 mm max. +/-0.2 mm
(20 times without weld- (20 times without weld-
ing) ing)
Robot speed 50 cm/min up to 3 m/ -
min
recommended: approx.
1.5 m/min
Recommended sense - max. 30 s
time
67
OPT/i camera mount
General
Application example of a mounted OPT/i camera mount (44,0350,0080)
The OPT/i camera mount can be used to mount seam tracking systems, cameras
or similar on the robot welding torch.
The camera mount is fitted instead of the torch body union nut; the TCP remains
the same.
The seam tracking system or camera is protected by the CrashBox.

The position of the mounted seam tracking system or camera is reproducible, as
it is positioned with a dowel pin.
Seam tracking system or camera can be mounted in six different places.
The scope of supply of the OPT/i camera mount includes a mounting key (size 60
mm).
Drilling template The following holes are provided as standard on the six surfaces of the OPT/i
camera mount:
- 4 M4 threaded holes with a depth of 9 mm
- 2 holes Ø 4 mm G7, depth = 6 mm
68
Controls, connections and mechan-
ical components
69
70
General
EN
Safety
WARNING!
General NOTE!
Depending on the system configuration, either the unreeling wirefeeder or the
robot hosepack drive unit is controlled by the gas-test, wire retract and wire
threading buttons.
71
SplitBox SB 500i R / SB 500i R PAP
Controls, con-
nections, and
mechanical com-
ponents of the
SB 500i R
Front of SB 500i R, right-hand version Back of SB 500i R, right-hand version
(3) (1) (6) (8) (7) (5)
(9) (4) (10) (2)

Front of SB 500i R, left-hand version Back of SB 500i R, left-hand version
No. Function
(1) Dummy cover for option 3
(4) Welding torch connection
(5) SpeedNet connection

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

For connecting the power cable from the interconnecting hosepack
(10) Wire infeed tube
72
No. Function
EN
(11) Cover
(12) Feed-through
(13) Operating status LED + gas-

test / wire threading / wire re-
turn buttons
(option)
For a functional description of the wire

return, wire threading, and gas-test
buttons, see page 81 onwards.
Side view (right-hand version)
Controls, con-
nections, and
mechanical com-
ponents of the
SB 500i R PAP
Front Back
No. Function
(1) (+) current socket

For connecting the power cable from the interconnecting hosepack
(2) Shielding gas connection

For connecting the SpeedNet cable from the interconnecting hosepack
73
No. Function
(11) Cover
(12) Feed-through
(13) Operating status LED + gas-

turn buttons
(option)
For a functional description of the wire

Side view
74
SplitBox SB 60i R
EN
SB 60i R: (1) Hole for mounting on the robot
Controls, con- (2) Cover
nections, and (3) Hole for mounting on the robot
mechanical com-
(4) Dummy cover
ponents
or
Operating status LED + gas-
turn buttons
(option)
B
A For a functional description of the wire
Front

(6) Coolant hoses to the welding
torch
(7) Dummy cover (SpeedNet or ex-
ternal sensor option)
A - Welding torch side

(via QuickConnect and
wirefeeding hose)
(9) Gas purging 16 bar (option)
(10) Hosepack (fixed)
Gas / water
preconfigured 3 / 4 / 8 m
B - Power source side
75
SB 60i R /L: (1) Hole for mounting on the robot
Controls, con- (2) Cover
nections, and (3) Hole for mounting on the robot
mechanical com-
(4) Dummy cover
ponents
or
Operating status LED + gas-
turn buttons
(option)
B
A For a functional description of the wire
Front

(6) Coolant hoses to the welding
torch
(7) Dummy cover (SpeedNet or ex-
ternal sensor option)
A - Welding torch side

(via QuickConnect and
wirefeeding hose)
(9) Gas purging 16 bar (option)
(10) Hosepack (fixed)
Gas / water
preconfigured 3 / 4 / 8 m
B - Power source side
76
WF 25i Robacta Drive / WF 60i Robacta Drive
CMT
EN
Control panel No. Function
WF 25i Robacta
Drive / WF 60i (1) (2)
(1) Gas-test button*
Robacta Drive
CMT (5)
(3)
(4)
No. Function
(2) F1 key
No function at present
(3) Wire return button*
(4) Wire threading button*
(5) Display
Status indicator
The status indicators are described in the following section
* For a functional description of the wire return, wire threading, and gas-
test buttons, see page 81 onwards.
Status indicators The following statuses may be indicated on the display of the WF 25i Robacta
Drive / WF 60i Robacta Drive CMT:
Normal operation
Error in
Stop / Robot not ready
Gas testing is active
No connection to the control

Update
77
Teach mode active
Wire threading active
Wire retract active
In applications with a double-head wirefeeder, when process line 1 is

selected.
2 and 3 light up on the other process lines but are smaller in size

selected.

selected.
For applications with WireSwitch, when process line 1 is active
For applications with WireSwitch, when process line 2 is active
78
WF 25i REEL R /4R, WF 30i REEL R /2R
EN
Control ele-
ments, 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
100 mm
3.9 in.
50 mm
2.0 in.
4 x M5
(13)(12)
Top/underside
79
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) Operating status LED + Gas-test / wire threading / wire retract buttons
The function of the wire retract, wire threading and gas-test buttons is de-
scribed from page 81 onwards.
(9) Blanking cover for optional component
(12) M20 thread

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

Wire infeed (underside)
Wire outfeed (upper side)
80
Function of the gas-test, wire retract and wire
threading buttons
EN
Function of the Operating status LED
gas-test, wire re-
tract and wire Shows steady green when the device is ready for use
threading but-
tons Gas-test button
After pressing the gas-test button, gas flows out for 30 seconds. Press the but-
ton again to stop the gas flow prematurely.
Wire retract button
The wire electrode can be retracted using one of two methods:
Method 1
Retracting the wire electrode at the preset wire retract speed:
- Press and hold the 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)
- Do not hold the wire retract button for more than 1 second (tap it)
NOTE!
Do not allow long lengths of wire electrode to be retracted, as the wire electrode
is not wound onto the wirespool when retracted.
NOTE!
If there was a ground earth connection with the contact tip before the wire re-
tract 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.
Wire threading button
Wire threading can be performed using one of two methods:
Method 1
Threading the wire electrode using the preset feeder inching speed:
81
- Press and hold the wire threading button
- The wire electrode will be threaded 1 mm (0.039 in.) after the wire threading
button is pressed
- 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
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)
- Do not press the wire threading button for more than 1 second (tap it)
- 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.)
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 but-
ton 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 con-
tact tip.
82
Assembling system components -
conventional robot
83
84
General
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 per-
sonnel.
▶ 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
WARNING!
Danger from electric current due to defective system components and incor-
rect operation.
▶ All cables, leads and hosepacks must always be securely connected, undam-
aged and correctly insulated.
▶ Only use adequately dimensioned cables, leads and hosepacks.
Assembly se- Individual components must be fitted to the robot in the following order:
quence, conven- 1. Robot holder(s) must have already been fitted first
tional robot 2. SplitBox
3. Only for CMT applications and for highly dynamic processes in combination
with a 4-roller unreeling wirefeeder: Wire buffer
4. CrashBox /i
5. WF Robacta Drive
6. Torch hosepack
7. Interconnecting hosepack
85
Fitting the SplitBox SB 500i R
Fitting the NOTE!

wirefeeder hold-
er Depending on the robot, please also note the instructions and information on in-
stalling the wirefeeder in the User Information.
Fitting the SB 1
500i R
2 3
86
Fitting the CrashBox /i to the robot
EN
Fitting the 1 Observe the torques when fitting the
CrashBox /i to robot flange:
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
87
6 7
Installing the 1 Observe the torques when fitting the

CrashBox/i robot 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
88
2 3
EN
6 Nm / 4.43 lb-ft
3,3 Nm / 2.43 lb-ft
89
Fitting the WF Robacta Drive to a conventional
robot
Fitting the IMPORTANT! Only fit the drive unit when the power source is switched off.
hosepack to the
WF Robacta
CAUTION!
Drive (conven-
tional) Danger of property damage due to dirty or wet coupling point.
▶ Whenever the hosepack is fitted or removed, ensure that the coupling point
is clean and dry.
▶ Remove any coolant that has escaped from the coupling point.
Do not damage the control plug with the gas pin!
90
3
EN
Fitting the WF 1 2
Robacta Drive to
the robot (con-
ventional)
10 Nm / 7.38 lb-ft
M6 x 12 mm
91
3 4
42 Nm / 30.98 lb-ft
92
Fitting the WF
EN
1
Robacta Drive to
the robot
Mount the index disk 45° from the scope of delivery of the extension
NOTE!
CB (for CrashBox) is stamped on one side of the extension.
▶ This side must be fitted to the index disk that has already been fitted.
2 3
42 Nm
30.98 lb-ft
CB 42 Nm
30.98 lb-ft
Fit the extension to the index disc that has

already been fitted in such a way that the
stamped ‘CB’ on the extension points to the in-
dex disc!
93
Optimum hosep-
ack arrangement
R
R
R < 200 mm R ≥ 200 mm
94
Fitting the interconnecting hosepack
EN
Fitting the 1 2
Standard inter- SB 500i
connecting
hosepack to the 3 Nm
robot 2.21 lb-ft
95
Connecting the MHP W hosepack
Connecting the IMPORTANT! Whenever the torch hosepack is fitted or removed, ensure that the
MHP W hosep- coupling point is clean and dry. Remove any coolant that has escaped from the
ack coupling point.
1 2
* Push in hosepack as far as it will go
96
5 6
EN
IMPORTANT! Always route coolant hoses below the hosepack and then guide
them to the connection socket:
WFi R / SB 500i SB 60i
97
(1) Coolant return (red)
(2) Coolant flow (blue)
IMPORTANT! Connect the coolant

hoses to the cooling unit correctly!
Disconnecting the coolant hoses
1 2
PUSH
98
Connecting the SplitBox SB 500i R to the system
components
EN
Safety
WARNING!

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

▶ All cables, leads and hosepacks must be properly secured, undamaged, insu-
lated 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.
SplitBox SB 500i coupling point is clean and dry. Remove any coolant that has escaped from the
R to the system coupling point.
components
SB 500i R (right variant)
99
1
2
1 6
5
3
SB 500i R (left variant)
2 NOTE!
If present, lead the coolant hoses
from the interconnecting hosepack
under the SB 500i R and connect
them to the torch hosepack.
100
Assembling system components -
PAP robot
101
102
Axis rotation and service life of the torch hosep-
ack
EN
General In addition to environmental and operating conditions, the service life of the PAP
welding torch hosepack is heavily influenced by the axis rotation in the fifth and
sixth robot axis.
For details, see the following sections:

- Recommended axis rotation
- Maximum axis rotation
- Hosepack service life depending on the axis rotation in the fifth and sixth ro-
bot axis
Recommended NOTE!
axis rotation
The PAP welding torch hosepack reaches its optimal service life when operated
within the recommended axis rotations.
Any axis rotation beyond these limits accelerates wear and thus reduces the ser-
vice life of the PAP torch hosepack.
▶ The expected hosepack service life is shown in the diagram "Hosepack ser-
vice life depending on the axis rotation in the fifth and sixth robot axis" start-
ing on page 105.
(4)
-175°
+90°
(5)
(6) +175°
-200° -90°
+200°
(4) Fourth robot axis: +/- 175°
(5) Fifth robot axis: +/- 90°
(6) Sixth robot axis: +/- 200°
(4)+(6) Fourth + sixth robot axis: +/- 360° in total.
103
Maximum axis NOTE!
rotation
Operating at the maximum values of the axis rotations reduces the service life
of the PAP welding torch hosepack.
▶ The expected hosepack service life is shown in the diagram "Hosepack ser-
vice life depending on the axis rotation in the fifth and sixth robot axis" start-
ing on page 105.
▶ Operating outside the limits invalidates any warranty claim.
(4)
-175°
+120°
(5)
(6) +175°
-360° -120°
+360°
Maximum axis rotations reduce the hosepack service life.
(4) Fourth robot axis: +/- 175°
(5) Fifth robot axis: +/- 120°
(6) Sixth robot axis: +/- 360°
(4)+(6) Fourth + sixth robot axis: max. +/- 535° in total.
104
Hosepack ser-
EN
vice life depend-
ing on the axis 45°
rotation in the 90° 120°
fifth and sixth
robot axis
A B C
A
RLT [%]
± AR [°]
RLT = relative service life [%], ± AR6 = axis rotation in the sixth robot axis [°]
= recommended axis rotation in the sixth robot axis
Example:
With an axis rotation in the sixth robot axis of 280° and at a tilt angle of 90° in
the fifth robot axis, the relative service life of the hosepack is 76-77%.
IMPORTANT! The values specified in the diagram are standard values that may
vary depending on the environmental and operating conditions.
The values were determined at an axis rotation of 0° in the fourth robot axis.
105
General
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 per-
sonnel.
▶ The Operating Instructions for system components, particularly the chapter
entitled "Safety rules", must be observed.
WARNING!

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
WARNING!
Danger from electric current due to defective system components and incor-
rect operation.
Assembly se- Individual components must be fitted to the robot in the following order:
quence, PAP ro- 1. Robot holder(s) must have already been fitted first
bot 2. SplitBox PAP
3. Only for CMT applications and for highly dynamic processes in combination
with a 4-roller unreeling wirefeeder: Wire buffer
4. CrashBox Drive /i PAP
5. WF Robacta Drive
6. Torch hosepack PAP
7. Interconnecting hosepack
106
Fitting the SplitBox SB 500i R PAP
EN
Fitting the SB 1 2
500i R PAP
107
Installing the CrashBox Drive /i PAP on the robot
Installing the 1 * Dowel pin in the robot flange

CrashBox
Drive /i PAP on
Observe the torques when fitting the
the robot
robot flange:

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
108
6 7
EN
8
Installing the 1 * Dowel pin in the robot flange

CrashBox
Drive /i PAP
Observe the torques when fitting the
Dummy on the
robot 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
109
2 3
4 Nm / 2.95 lb-ft 8 Nm / 5.90 lb-ft
110
Fitting the WF Robacta Drive to a PAP robot
EN
Fitting the IMPORTANT! Only fit the drive unit when the power source is switched off.
hosepack to the
WF Robacta
CAUTION!
Drive (PAP)
Danger of property damage due to dirty or wet coupling point.
▶ Whenever the hosepack is fitted or removed, ensure that the coupling point
is clean and dry.
1 2
Do not damage the control plug with the gas pin!
111
4
Fitting the WF 1 2
Robacta Drive to
the robot (PAP)
3 4
BY2,0201,4896
42,0411,1315
112
5
EN
18 Nm
13.28 lb-ft
113
Fitting the interconnecting hosepack
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 Installa-
tion Instructions for the respective robot.
1 2
3 Lay the interconnecting hosepack in the clamps

4 Close the clamps
114
Connecting the SplitBox SB 500i R PAP to the
system components
EN
Safety
WARNING!

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

▶ All cables, leads and hosepacks must be properly secured, undamaged, insu-
lated 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.
SplitBox SB 500i coupling point is clean and dry. Remove any coolant that has escaped from the
R PAP to the sys- coupling point.
tem components
1 2
115
3 4
116
Assembling further system com-
ponents
117
118
Fitting the SplitBox SB 60i R
EN
Fitting the SB NOTE!
60i R to the ro-
bot Depending on the robot, please also note the instructions and information in the
User Information on installing the holding plate for the SplitBox.
The installation of the SplitBox SB 60i R is illustrated using the right version of
the appliance. The left version of the appliance should be installed the other way
around.
1 2
Fitting the SB NOTE!

▶
60i R to the bal-
Use a balancer with a load capacity of at least 18 kg
ancer
▶ Use a second balancer for hosepacks longer than 1.75 m. Position the balan-
cer halfway along the length of the hosepack.
119
1
120
3
EN
Mounting the SB 1 2
60i R on the wall
* = Depending on the surface, different fixings are required for fitting the wall
bracket.
The installer is responsible for selecting the correct fixings.
121
3 NOTE!
Use a balancer for hosepacks longer
than 1.75 m.
Position the balancer halfway along
the length of the hosepack.
10,5 Nm
7.74 lb-ft
torch hosepack coupling point is clean and dry. Remove any coolant that has escaped from the
to the SplitBox coupling point.
SB 60i R
The connection of the torch hosepack to the SplitBox SB 60i R is illustrated us-
ing the right version of the appliance.
The left version of the appliance should be connected to the torch hosepack the
other way around.
1 2
1
2
3 4
122
Fitting the TPSi wire buffer
EN
Fitting the TPSi 1
wire buffer
Fitting to the robot
Fitting to a balancer
123
Connecting the NOTE!
control line to
the wire buffer Carefully place the control line in the strain-relief device provided (Figure 2).
1 2
124
Fitting the unreeling wirefeeder
EN
Fitting the un-
WARNING!
reeling wirefeed-
er An electric shock can be fatal.
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

fitted in the correct direction. The
threading direction of the wire elec-
trode 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 unreel-
ing wirefeeder
3 Use Fronius SpeedNet to connect the unreeling wirefeeder to the power
source in the welding system
125
Connecting the extension hosepack
Connecting the
WARNING!
extension hosep-
ack Danger from electric current due to defective system components and incor-
rect operation.
▶ Check that they are tight at least every three months.
1 * Only on water-cooled hosepack
CON = Interconnecting hosepack
EXT = Extension hosepack
Connect all connections so they are

hand-tight.
Check for tightness.
Tightening the power connection

hand-tight corresponds to 7-8 Nm.
126
2 If the components are not bundled in
the protective bag, all interfaces must
EN
be fixed so they are immovable.
NOTE!
Reduced service life at a bending radius of r < 200 mm.
Note the bending radius.
▶ Do not use a bending radius smaller than r = 200 mm.
127
NOTE!
Note the current load.
Dimensioning of the correct hosepack according to the following table:
Welding current
40% d.c. / 40 °C Cross-section up to 10 m Cross-section up to 50 m
150 A 16 mm² 25 mm²

200 A 25 mm² 35 mm²
250 A 35 mm² 50 mm²
300 A 50 mm² 70 mm²
400 A 70 mm² 95 mm²
500 A 95 mm² 120 mm²
600 A 120 mm² 120 mm²
128
Fitting the torch body to the WF Robacta Drive
EN
Fitting the gas- 1 2
saver nozzle
Torx 40
42,0411,0160
3 4
1 Nm
0.74 lb-ft
1 Nm / 0.74 lb-ft
42,0411,0160
42,0411,0160
129
Fitting the inner IMPORTANT! For the MTB 330i welding torch, the plastic inner liner is fitted
liner inside the from the front.
torch body
Plastic inner liner:
1 2
130
Steel inner liner:
EN
1 2
131
Fitting the torch
CAUTION!
body to the WF
Robacta Drive Danger of property damage due to dirty or wet coupling point.
▶ Whenever the torch body is fitted or removed, ensure that the coupling point
is clean and dry.
1 2
45,0200,1261
42,0411,1315
18 Nm
13.28 lb-ft
132
Fitting the OPT/i camera mount
EN
Load-bearing ca-
CAUTION!
pacity of the
OPT/i camera Danger due to mechanical overload of the system components
mount This can result in injury and damage to property.
▶ Load the OPT/i camera mount with a maximum of 1.5 kg.
▶ Always observe the relationship between weight and mounting distance
shown below.
0mm 50mm 100mm 150mm 200mm 250mm

1,6kg
1,5kg
1,4kg
1,3kg
1,2kg
1,1kg
1,0kg
0,9kg
0,8kg
0,7kg
0,6kg
0,5kg
0,4kg
0,3kg
0,2kg
0,1kg
0kg
Safety
CAUTION!
Risk of burns from hot torch body, hot torch body coupling and other hot weld-
ing 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 com-
ponents to cool down to room temperature (+25 °C, +77 °F)
▶ Wear electrically insulated and heat protective gloves
▶ Use a suitable tool
133
Fitting the OPT/i 1 2
camera mount
3 4
134
Fitting the inner liner
EN
Fitting the inner 1 2
liner (unreeling
wirefeeder -
SplitBox SB 500i
R)
3 4

liner (unreeling
wirefeeder- WF
Robacta Drive
with external
wirefeeding
hose)
135
3
Fitting the 1 2
PowerLiner (un-
1
reeling wirefeed-
er - WF Robacta
Drive with ex-
ternal wirefeed- 1
ing hose)
2
3
3
3 2
3
* Fasten screw only slightly (do not tighten)
3 4
45
0 ,34
,0 35
44
136
5
EN
6

liner (unreeling
wirefeeder - wire
buffer)
137
3 4
Fitting the inner 1

liner (SplitBox -
WF 25i with in-
ternal inner
liner)
138
2 3
EN
4

liner (wire buffer
- SplitBox SB
500i for WF
Robacta Drive
with internal
wirefeeding
hose)
139
3 4

liner (wire buffer
- WF Robacta
Drive with ex-
ternal wirefeed-
ing hose)
140
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.
141
4
0
2
4
142
Start-up
143
144
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 suit-
able 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
3
2
4
CAUTION!
Risk of crushing due to exposed feed rollers.

▶ Always fit the protective cover of the 4-roller drive after changing feed
rollers.
145
3 4
2
6
1
5
4 4
8
3
9
3
1
5
5
2
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
146
5
EN
Inserting/repla- 1 2
cing the WF 25i
Robacta Drive
feed rollers
3 4
0 mm *
* If the roller holder is opened as far as it will go

beyond the slight resistance, the roller holder re-
mains in this position.
147
5 6
7 8
9 10
Torx 40
1 Nm
0.74 lb-ft
148
11 12
EN
1
2
Inserting/repla- 1 2
cing the WF 60i
Robacta Drive
CMT feed rollers
3 4
0 mm *
* If the roller holder is opened as far as it will go

beyond the slight resistance, the roller holder re-
mains in this position.
149
5 6
42,0411,0160
12 mm
7 8
9 10
42,0411,0160
12 mm
5 Nm
3.69 lb-ft
2
150
11 12
EN
1
151
Feeding in the wire electrode
Insulated rout-
WARNING!
ing of wire elec-
trode to Risk of serious injury and damage or an inferior weld as a result of earth contact
wirefeeder 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
conductive 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 en-
sure 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.
152
CAUTION!
EN
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 re-
main in place during operation.
1 2
1 3
Setting the con- NOTE!

tact pressure for
the WF 25i Set the contact pressure in such a way that the wire electrode is not deformed
Robacta Drive but nevertheless ensures proper wirefeeding.
IMPORTANT! In the event of a large change in contact pressure, a system calib-

ration must be carried out.
How to perform the system calibration is explained in the power source Operat-
ing Instructions.
Contact pressure standard values for

steel rollers:
Al, 1-2
AlSi
AlMg 2-4
FCW 3-5
CuSi 5-7
Steel 6-8
CrNi 6-8
153
Setting the con- NOTE!
tact pressure for
the WF 60i Set the contact pressure in such a way that the wire electrode is not deformed
Robacta Drive but nevertheless ensures proper wirefeeding.
CMT
IMPORTANT! In the event of a large change in contact pressure, a system calib-
ration must be carried out.
How to perform the system calibration is explained in the power source Operat-
ing Instructions.
Contact pressure standard values for

steel rollers:
Al, 1-2
AlSi
AlMg 2-4
FCW 3-5
CuSi 5-7
Steel 6-8
CrNi 6-8
154
Start-up
EN
Requirements When commissioning the welding system, the following requirements must be
met:
- All components are installed and connected as described in the "Installa-
tion" 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.
155
156
Troubleshooting, maintenance and
disposal
157
158
Troubleshooting
EN
Safety
WARNING!
WARNING!
Danger from electric current.

▶ Before starting work, switch off all the devices and components involved and
disconnect them from the grid.
▶ Secure all the devices and components involved to prevent unintentional re-
starting.
▶ After opening the device, use a suitable measuring instrument to check that
electrically charged components (such as capacitors) have been discharged.
WARNING!
Danger due to hot system components and/or equipment.

Can result in serious burns or scalding.
▶ Before starting work, allow all hot system components and/or equipment to
cool to +25°C/+77°F (e.g., coolant, water-cooled system components,
wirefeeder drive motor, etc.)
▶ Wear suitable protective equipment (e.g., heat-resistant gloves, safety
goggles, etc.) if cooling down is not possible.
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
159
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
160
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
Wire buffer empty

Cause: Counter lever on main wirefeeder open
Remedy: Close counter lever on main wirefeeder
Acknowledge service code by pressing wire threading button
Cause: Main wirefeeder slipping

Remedy: Check wearing parts on wirefeeder
Use suitable feed rollers
Decrease wire braking force
Increase contact pressure on main wirefeeder
Acknowledge service code by pressing wire threading button
Cause: End of wire reached

Remedy: Check whether sufficient wire is available
Acknowledge service code using wire threading button
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: Welding torch is inadequately dimensioned
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
161
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
connection, 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
162
Care, maintenance and disposal
EN
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!
WARNING!
Danger from electric current.

▶ Before starting work, switch off all the devices and components involved and
disconnect them from the grid.
▶ Secure all the devices and components involved to prevent unintentional re-
starting.
▶ After opening the device, use a suitable measuring instrument to check that
electrically charged components (such as capacitors) have been discharged.
WARNING!
Danger due to hot system components and/or equipment.

Can result in serious burns or scalding.
▶ Before starting work, allow all hot system components and/or equipment to
cool to +25°C/+77°F (e.g., coolant, water-cooled system components,
wirefeeder drive motor, etc.)
▶ Wear suitable protective equipment (e.g., heat-resistant gloves, safety
goggles, etc.) if cooling down is not possible.
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 dam-
aged components.
- 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.
Special care of IMPORTANT! When replacing O-rings, grease the new O-ring before fitting it.
O-rings
163
When repeatedly connecting and disconnecting the coolant hoses on the torch
hosepack, 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 coup-
welding torch or ling point is clean and dry. Remove any coolant that has escaped from the coup-
torch hosepack ling point.
is changed
Changing the If a robot wirefeeder or a media splitter is mounted in the third robot axis, take
torch hosepack, the following into account when changing the torch hosepack or interconnecting
changing the in- hosepack:
terconnecting
hosepack
CAUTION!
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 connections 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
Every 6 months
CAUTION!
Danger from compressed air at close range.

Electronic components may be damaged.
▶ 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.
164
Recognising
EN
1. 2. 3. 4. 5.
faulty wearing
parts
1. Insulating parts
- Burned-off outside edges, notches
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
Replacing the 1 2
WF 25i Robacta
Drive clamping
lever
165
Replacing the 1 2
WF 60i Robacta
Drive CMT
clamping lever
Replacing the
CAUTION!
WF Robacta
Drive gas-saver Danger of property damage due to dirty or wet coupling point.
nozzle
▶ Whenever the welding torch is fitted or removed, ensure that the coupling
point is clean and dry.
1 2
45,0200,1261
42,0411,1315
3 4
Torx 40
42,0411,0160
166
5 6
EN
1 Nm / 0.74 lb-ft
42,0411,0160
18 Nm
13.28 lb-ft
Replacing the SB Removing the inner liner

60i R inner liner
1 2
167
3 4
Inserting the inner liner
1 2
3 4
168
Replacing the
EN
NOTE!
TPSi wire buffer
wire guide Before starting work, thread the wire electrode out of the wire buffer.
IMPORTANT! If using a wire electrode with a diameter of 1.6 mm (1/16 in.), fit
the "original equipment kit 1.6 mm (1/16 in.)" to the sliding contact and wire
guide in the wire buffer.
1 2
3 4
169
Changing the NOTE!
direction of op-
eration of the After conversion, make sure the control line is fitted properly in the strain-relief
TPSi wire buffer device provided.
1 2
3 4
4 5
170
5 6
EN
6 7
Replacing the NOTE!

TPSi wire buffer
lever Before fitting the new wire buffer lever, turn the locating sleeve into the central
position (Figure 3).
1 2
171
3 4
5 6
172
Fitting wearing
EN
1 2
parts to the
torch body
Fitting wearing 1 2
parts to the
torch body -
MTW 700 i
173
Removing the 1 2
CrashBox PAP
from the robot
BY2,0201,4896
3 4
5 6
174
7 8
EN
1
9 10
Disposal Dispose of in accordance with the applicable national and local regulations.
175
176
Technical data
177
178
SB 500i R, R left variant, PAP
EN
SB 500i R, R Supply voltage 24 V DC / 60 V DC
left-hand ver-
sion, PAP Nominal current 0.5 A / 0.8 A
Welding current at 10 min / 40 °C 40% ED* 650 A
(104 °F) 60% ED* 600 A
100% ED* 500 A
Maximum pressure of shielding gas 7 bar/101.53 psi
Coolant Original Fronius
Maximum pressure of coolant 5 bar/72.53 psi
Degree of protection IP 43
Mark of conformity CE, CSA
Dimensions l × w × h 658 x 282 x 362 mm
25.91 x 11.10 x 14.25 in.
Weight 3.6 kg/7.9 Ib
* ED = Duty cycle
179
SB 60i R
SB 60i R Supply voltage 24 V DC / 60 V DC

Nominal current 0.5 A / 0.8 A
Welding current at 10 min / 40 °C
(104 °F)
70 mm² 40% ED* 400 A
60% ED* 365 A
100% ED* 320 A
95 mm² 40% ED* 500 A

60% ED* 450 A
100% ED* 360 A
Maximum pressure of shielding gas 7 bar/101.53 psi
Coolant Original Fronius
Maximum pressure of coolant 5 bar/72.53 psi
Mark of conformity CE
Dimensions l × w × h 480 x 252 x 114 mm
18.90 x 9.92 x 4.49 in.
Weight 2.818 kg/6.21 Ib
* ED = Duty cycle
180
CrashBox /i
EN
CrashBox /i
Item numbers
CrashBox /i 44,0350,3589
CrashBox /i XL 44,0350,3760
CrashBox /i XXL 44,0350,3380
CrashBox Drive /i PAP 44,0350,3379
CrashBox Drive /i PAP XXL 44,0350,3754
Degree of repeatability (1) ± 0.05 mm a)
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 Drive /i PAP 21 Nm / 15.49 lb-ft
CrashBox Drive /i PAP XXL 42 Nm / 30.98 lb-ft
Maximum displacement in x/y direc-
tion
CrashBox /i ~ 45°
CrashBox /i XL ~ 45°
CrashBox /i XXL ~ 45°
CrashBox Drive /i PAP ~ 30°
CrashBox Drive /i PAP XXL ~ 30°
Weight
CrashBox /i 1200 g
CrashBox /i XL 1200 g
CrashBox /i XXL 1200 g
CrashBox Drive /i 920 g
CrashBox Drive /i PAP XXL 920 g
Dimensions
CrashBox /i Ø90 mm x 60 mm b)
181
CrashBox /i XL Ø90 mm x 60 mm b)
CrashBox /i XXL Ø90 mm x 60 mm b)
CrashBox Drive /i PAP Ø90 mm x 84.5 mm b)
CrashBox Drive /i PAP XXL Ø90 mm x 84.5 mm b)
a) A distance of 300 mm away from the robot flange

b) with bellows: Ø110 mm
182
Triggering Weight (distance [mm]) [kg] Activated within 300 mm distance Max. possible displacement
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 14.00 10.50 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 0.684 8 1.5275 ~ 45 ~ 30
CrashBox Drive /i PAP 21 Nm 42.0 21.0 10.5 7.00 5.25 2.0 0.382 3.5 0.6684 ~ 30 ~ 30
CrashBox Drive /i PAP XXL 42 Nm 84.0 42.0 21.0 14.00 10.50 2.0 0.382 3.5 0.6684 ~ 30 ~ 30
(3)
(2) (1) CrashBox /i

Crashbox Drive /i PAP
(2) CrashBox /i XL
CrashBox Drive /i PAP XXL
Weight [kg]
(3) CrashBox /i XXL
(1)
Triggering torques and weight-distance diagram
The values listed only apply when in a static state!

Distance to the 6th robot axis [mm]
183
EN
PushPull hosepack
Gas-cooled MHP 400i RD / G

PushPull hosep-
acks Welding current at 10 min / 40 °C
M21 (EN ISO 14175) 40% ED* / 400 A
60% ED* / 320 A
100% ED* / 260 A
C1 (EN ISO 14175) -

60% ED* / 400 A
100% ED* / 320 A
Wire diameter 0.8 - 1.6 mm
0.030 - 0.062 in.
Length 0.935 / 1.085 /1.235 / 1.435 / 1.735 /
2.235 / 1.935 / 2.735 / 3.235 / 3.735 m
3.07 / 3.56 / 4.05 / 4.71 / 5.69 / 7.33 /

6.35 / 8.97 / 10.60 / 12.25 ft
Voltage rating (V-Peak) for machine- 141 V
guided welding torches
This product meets the requirements set out in standard IEC 60974-7
* ED = Duty cycle
MHP 400i RD / G / PAP

Welding current at 10 min / 40 °C 40% ED* / 400 A
M21 (EN ISO 14175) 60% ED* / 320 A
100% ED* / 260 A
C1 (EN ISO 14175) -

60% ED* / 400 A
100% ED* / 320 A
0.030 - 0.062 in.
Length 0.915 / 0.925 / 0.945 / 1.025 / 1.045 /
1.075 / 1.105 / 1.115 / 1.135 / 1.165 /
1.175 / 1.185 / 1.205 / 1.295 / 1.335 /
1.355 / 1.385 / 1.415 / 1.495 / 1.575 /
1.935 / 1.985 / 2.115 / 2.265 / 2.385 /
2.585 / 3.415 m
3.00 / 3.03 / 3.1 / 3.36 / 3.43 / 3.35 /

3.63 / 3.66 / 3.72 / 3.82 / 3.86 / 3.89 /
3.95 / 4.25 / 4.38 / 4.45 / 4.54 / 4.64 /
4.9 / 5.17 / 6.35 / 6.51 / 6.94 / 7.43 /
7.82 / 8.48 / 11.20 ft
* ED = Duty cycle
184
Water-cooled
EN
MHP 500i RD / W
PushPull hosep-
acks Welding current at 10 min / 40 °C
M21 (EN ISO 14175) 100% ED* / 500 A
C1 (EN ISO 14175) 100% ED* / 500 A
0.032 - 0.063 in.
Lowest cooling capacity as per IEC Length
standard 60974-2 as function of
hosepack length
550 0.935 m / 3.07 ft
600 1.085 m / 3.56 ft
650 1.235 m / 4.05 ft
700 1.435 m / 4.71 ft
800 1.735 m / 5.69 ft
850 1.935 m / 6.35 ft
950 2.235 m / 7.33 ft
1000 2.735 m / 8.97 ft
1200 3.235 m / 10.60 ft
1400 3.735 m / 12.25 ft
Minimum coolant flow Qmin 1 l/min
0.26 gal (US) / min
Minimum coolant pressure pmin 3 bar
43 psi
Maximum coolant pressure pmax 5 bar
72 psi
* ED = Duty cycle
185
MHP 500i RD / W / PAP
Welding current at 10 min / 40 °C
M21 (EN ISO 14175) 100% ED* / 500 A
C1 (EN ISO 14175) 100% ED* / 500 A
0.032 - 0.063 in.
Lowest cooling capacity as per IEC Length
standard 60974-2 as function of
hosepack length
550 W 0.915 m (3.00 ft) / 0.925 m (3.03 ft) /
0.945 m (3.1 ft) / 1.025 m (3.36 ft) /
1.045 m (3.43 ft)
600 W 1.075 m (3.53 ft) / 1.105 m (3.63 ft) /
1.115 m (3.66 ft) / 1.135 m (3.72 ft) /
1.165 m (3.82 ft) / 1.175 m (3.86 ft) /
1.185 m (3.89 ft) / 1.205 m (3.95 ft)
650 W 1.295 m (4.25 ft) / 1.335 m (4.38 ft) /
1.355 m (4.45 ft) / 1.385 m (4.54 ft)
700 W 1.415 m (4.64 ft) / 1.495 m (4.9 ft) /
1.575 m (5.17 ft)
850 W 1.935 m (6.35 ft) / 1.985 m (6.51 ft) /
2.585 m (8.48 ft)
900 W 2.115 m (6.94 ft)
950 W 2.265 m (7.43 ft) / 3.415 m (11.20 ft)
1000 W 2.385 m (7.82 ft)
0.26 gal (US) / min
43 psi
72 psi
* ED = Duty cycle
186
WF 25i Robacta Drive
EN
WF 25i Robacta Welding current at 10 min / 40 °C
Drive /G M21 (EN ISO 14175) 60% ED* / 260 A
100% ED* / 210 A
C1 (EN ISO 14175) 60% ED* / 320 A

100% ED* / 260 A
0.032 - 0.063 in.
Supply voltage 60 V DC
Nominal current 3A
Wire speed 1 - 25 m/min
39.37 - 984.25 ipm
* ED = Duty cycle

Drive /W M21 (EN ISO 14175) 100% ED* / 500 A
C1 (EN ISO 14175) 100% ED* / 500 A
0.032 - 0.063 in.
0.26 gal (US) / min
43 psi
72 psi
Nominal current 3A
39.37 - 984.25 ipm
* ED = Duty cycle
187
WF 60i Robacta Drive CMT

Drive CMT /G M21 (EN ISO 14175) 60% ED* / 260 A (standard)
100% ED* / 210 A (standard)
60% ED* / 260 A (CMT)
100% ED* / 210 A (CMT)
C1 (EN ISO 14175) 60% ED* / 320 A (standard)

100% ED* / 260 A (standard)
60% ED* / 260 A (CMT)
100% ED* / 210 A (CMT)
0.032 - 0.063 in.
Nominal current 1.5 A RMS
39.37 - 2362.20 ipm
* ED = Duty cycle

Drive /W CMT M21 (EN ISO 14175) 100% ED* / 500 A (standard)
100% ED* / 280 A (CMT)
C1 (EN ISO 14175) 100% ED* / 500 A (standard)

100% ED* / 280 A (CMT)
0.032 - 0.063 in.
0.26 gal (US) / min
43 psi
72 psi
Nominal current 1.5 A RMS
39.37 - 2362.20 ipm
188
* ED = Duty cycle
EN
189
WF 25i REEL R /4R/G/W
Supply voltage 24 V DC / 60 V DC
39.37 - 984.25 ipm.
Wire drive 4-roller drive
0.03 - 0.09 in.
Dimensions l x w x h 250 x 210 x 190 mm
9.8 x 8.3 x 7.5 in.
Weight 4.8 kg
10.58 Ib.
190
WF 30i REEL R /2R/G/W
EN
Supply voltage 24 V DC / 60 V DC
39.37 - 1181.10 ipm.
Wire drive 2-roller drive
0.03 - 0.06 in.
Dimensions l x w x h 250 x 210 x 190 mm
9.8 x 8.3 x 7.5 in.
Weight 4.6 kg
10.14 Ib.
191
Robot welding torch
Gas-cooled ro- MTB 250i G/R (TX, TXM)

bot welding
torches Welding current at 10 min/40° C
M21 (EN ISO 14175) 40 % ED* / 250 A
60 % ED* / 200 A
100 % ED* / 170 A
C1 (EN ISO 14175) -

60 % ED* / 250 A
100 % ED* / 200 A
0.030 - 0.045 inch
MTB 320i G/R (TX, TXM)
Welding current at 10 min/40° C

M21 (EN ISO 14175) 40 % ED* / 320 A
60 % ED* / 260 A
100 % ED* / 210 A
C1 (EN ISO 14175) -

60 % ED* / 320 A
100 % ED* / 260 A
0.030 - 0.062 inch

M21 (EN ISO 14175) 40 % ED* / 330 A
60 % ED* / 270 A
100 % ED* / 220 A
C1 (EN ISO 14175) -

60 % ED* / 330 A
100 % ED* / 270 A
0.030 - 0.062 inch
Welding current at 10 min/40° C)

M21 (EN ISO 14175) 40 % ED* / 350 A
60 % ED* / 300 A
100 % ED* / 250 A
C1 (EN ISO 14175) -

60 % ED* / 350 A
100 % ED* / 300 A
192
0.030 - 0.062 inch
EN
Welding current at 10 min/40° C)

M21 (EN ISO 14175) 40 % ED* / 400 A
60 % ED* / 320 A
100 % ED* / 260 A
C1 (EN ISO 14175) -

60 % ED* / 400 A
100 % ED* / 320 A
0.030 - 0.062 inch
* ED = Duty cycle
Water-cooled ro- MTB 250i W/R

bot welding
torches Welding current at 10 min/40° C
M21 (EN ISO 14175) 100 % ED* / 250 A
C1 (EN ISO 14175) 100 % ED* / 250 A
Wire diameter 0.8 - 1.2 mm / 0.032 - 0.047 inch
MTB 330i W/R (TX, TXM)

M21 (EN ISO 14175) 100 % ED* / 330 A
C1 (EN ISO 14175) 100 % ED* / 330 A

M21 (EN ISO 14175) 100 % ED* / 400 A
C1 (EN ISO 14175) 100 % ED* / 400 A

M21 (EN ISO 14175) 100 % ED* / 500 A
C1 (EN ISO 14175) 100 % ED* / 500 A
193

M21 (EN ISO 14175) 100 % ED* / 700 A
C1 (EN ISO 14175) 100 % ED* / 500 A
* ED = Duty cycle
194
Interconnecting hosepacks
EN
HP 70i Welding current at 10 min / 40 °C 40% ED* / 400 A
(104 °F) 60% ED* / 365 A
100% ED* / 320 A
* ED = Duty cycle

(104 °F) 60% ED* / 450 A
100% ED* / 360 A
* ED = Duty cycle

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

Cable HD 70 (104 °F) 100% ED* / 500 A
* ED = Duty cycle
195

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Operating

Controls, connections and mechanical components 69

Assembling system components - conventional robot 83

Assembling system components - PAP robot 101

Assembling further system components 117

Troubleshooting, maintenance and disposal 157

Indicates a potentially hazardous situation.

Indicates a situation where damage or injury could occur.

General The device is manufactured using state-of-the-art technology and according to

All persons involved in commissioning, operating, maintaining and servicing the

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:

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.

Otherwise, a welding helmet with an air supply must be worn.

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

Always set the wirefeeder up on a sufficiently insulated surface or use a suitable,

Arrange for the mains cable to be checked regularly by a qualified electrician to

Operation of the device on a mains supply without ground conductor and on a

If necessary, provide adequate earthing for the workpiece.

Switch off unused devices.

Wear a safety harness if working at height.

Attach a clearly legible and easy-to-understand warning sign to the device to

After opening the device:

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

In the case of automated MIG/MAG applications, ensure that only an insulated

EMC Device Devices in emission class A:

Devices in emission class B:

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

Check and evaluate the immunity to interference of nearby devices according to

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

Special provisions apply in areas at risk of fire or explosion

Use only suitable load-carrying equipment supplied by the manufacturer when

Odourless and colourless shielding gas may escape unnoticed if an adapter is

Use filters if necessary.

Never hang a welding torch on a shielding gas cylinder.

Never touch a shielding gas cylinder with an electrode.

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

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

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.

3 Welding sparks can cause an explosion or fire.

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