PW-SYS-072, TS/TPS Robotics

TSNA Training Team

TPS/I ROBOTICS
21 SEPT 2015

Fronius USA
Perfect Welding
PW-SYS-072, TS/TPS Robotics

CONTENT

/ TPS/i Robotics Concept / Interaction Power source – Interface –

/ CU – Cooling Units and Options Options
/ Hosepacks, Ground cables and / Basic configurations
PowerConnector / Troubleshooting & Feedback
/ Configuration wire support
/ Wire coil support
/ WF mounting
/ WF wire feeders and options
/ FSC Pin assignment
/ Flanges and CrashBox
/ WireBrake & TX
/ Robacta Drive & Split Box
/ Torch necks
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concept
TPS/i Robotics
 Configuration number: P03667
PW-SYS-072, TS/TPS Robotics

TPS/I CONV WATERCOOLED

Part number Name
44,0350,3494 MTB 500i W R /22°
44,0350,3568 Holding clamp TPS/i
42,0001,4244 Indexdisc 22°
44,0350,3589 CrashBox /i
Part number Name
42,0100,1403 RFP i 40 4M6 50
4,049,035 WF 25i R /G/W/4R/FSC
4,051,010 MPH 700i W R/FSC/0,95
4x44,0001,1407 Feeder roll 1,2mm
44,0350,5120 BasicKit Fe Ø1,2 G/W/5m
4,100,740 WF mounting
4,047,881 HP 95i CON R /W/4m
40,0001,0505 Wire feed hose
43,0004,0581 Earth cable 90mm² 4m
4,100,669 WF OPT/i QC VR5000
4,075,180 TPS 500i PULSE
4,100,670 WF OPT/i QC VR1500
4,044,014 RI FB Inside/i
4,100,489 Wire coil mountiing
41,0018,0084 RI MOD/i CC EtherNET /IP-2P
4,100,808,IK 2. NT241
4,048,004,633 CU 1400i Pro/MC
4,077,001 TU Podium
4,078,013 Robot Dummy
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 Configuration number: P03669
PW-SYS-072, TS/TPS Robotics

TPS/I PAP WATERCOOLED

Part number Name

44,0350,3494 MTB 500i W R /22°
44,0350,3663 CrashBox /i PAP
Part number Name
42,0100,0571 RFP i 56 PAP 6M4
4,049,036 WF 25i PAP /G/W/4R/FSC
4,047,918 MHP 700i R/W/PAP/FSC/1,06
4x44,0001,1407 Feeder roll 1,2mm
44,0350,5120 BasicKit Fe Ø1,2 G/W/5m
4,100,748 WF mounting quick slide
4,047,881 HP 95i CON R /W/4m
40,0001,0505 Wire feed hose
4,100,572 Mounting extension hose pack
4,100,669 WF OPT/i QC VR5000
43,0004,0581 Earth cable 90mm² 4m
4,100,670 WF OPT/i QC VR1500
4,075,180 TPS 500i PULSE
4,100,489 Wire coil mountiing
4,044,014 RI FB Inside/i
41,0018,0084 RI MOD/i CC EtherNET /IP-2P
4,100,808,IK 2. NT241
4,048,004,633 CU 1400i Pro/MC
4,077,001 TU Podium
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4,078,013 Robot Dummy

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Cooling units
PW-SYS-072, TS/TPS Robotics

COOLING UNITS

CU Cooling Unit
1100 / 1400 Cooling power [W]
i Intelligent Revolution
Basic without control – continuous operation
Pro Professional (EC pump) for multi shift operation
MV Multivoltage 200-230V and 400 – 480V
460 V for 460V mains supply (USA)
MC MultiControl (flow control, temperature and level sensor)
RVP Rotary Vane Pump
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PW-SYS-072, TS/TPS Robotics

OVERVIEW
Field of
Variant Art No. Cert. Pump Benefit for PS
application
CU 1100i Basic 4,048,006 CE
400 V AC rotary proven
CU 1100i 4,048,003 CE pump (Speck) pump
CU 1100i /MV 4,048,003,830 CE/CSA system
TPS 320i
Manual
TPS 400i
Applications
TPS 500i
(metalworking,
Basic steel
MV CU 1100i Basic /460V 4,048,006,800 CE/CSA 400 V AC rotary Pump construction,
460V CU 1100i /460V 4,048,003,800 CE/CSA vane pump accepted in plant
CU 1100i /MV RVP 4,048,003,850 CE/CSA (Procon) the US construction)
market single shift

24 V EC long life cycle

Pumpe
Robotic- / TPS 320i
energy- automated
CU 1400i Pro 4,048,004 CE/CSA TPS 400i
efficient applications
CU 1400i Pro MC 4,048,004,633 CE/CSA TPS 500i
TPS 600i
Magnetically 3-shift
Pro ECO-Mode +
driven pump operation
Pro MC dynamic 2nd NT241
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control of the
pump
PW-SYS-072, TS/TPS Robotics

Display System Data – Software V 1.5.0

Parameters for cooling unit

/ Coolant flow
/ Coolant return temperature

Limits
/ Coolant flow: < 0,7l/min. (Kühlkreis.Water-Flow-Sensor.No Kühlkreis.Water available)
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/ Return temperature: >= 70°C (Cooling Unit.Temperature Sensor.hot water)

PW-SYS-072, TS/TPS Robotics

EXTENSION POSSIBILITIES SPEEDNET

TPS 4x Switch
SpeedNet
3 additional SpeedNet ports
(one plug is included in the
set)

Options 2nd SpeedNet

connector TPS/i
one additional
SpeedNet connector
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SPEEDNET 3 PORT EXTENSION

3 Port Extension
SpeedNet Ports for robot control, wire feeder and
remote control …
One SpeedNet Connector (4,100,910) included

NOTE: 2nd SpeedNet Connector TPS/i (4,100,930)

is not possible

SpeedNet Connector (4,100,910)

Additional SpeedNet Connector for Port Extension
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SPEEDNET EXTENSIONS – COMPARISON

/ 2nd SpeedNet Port

/ TPS 4x Switch
SpeedNet
/ pc board: ScratSW
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Interface

WF Reel
RC Panel
AI IO
RI IO
RI IO Pro

RC Panel Std. RI FB Pro

RC Panel Basic

4,100,812,IK ,CK
WF Reel 2R RI FB Pro
WF Reel 4R

OPT/i TPS 2. SpeedNet Connector

RC Panel Std. RI FB Inside
RC Panel Basic

WF Reel 2R RI FB Inside

SpeedNet
WF Reel 4R

4,100,886,IK ,CK
OPT/i TPS 4x Switch
RC Panel Std. AI IO
RC Panel Basic RI IO
RI IO Pro
CONFIGURATION SAMPLES

WF Reel 2R AI IO
WF Reel 4R RI IO
RI IO Pro
&

WF Reel 2R RC Panel Std. RI FB Pro

WF Reel 4R RC Panel Basic
4,100,910,IK ,CK
4,100,886,IK ,CK
OPT/i TPS 4x Switch SpeedNet

WF Reel 2R RC Panel Std. RI FB Inside

OPT/i TPS SpeedNet Connector

WF Reel 4R RC Panel Basic

WF Reel 2R RC Panel Std. AI IO

WF Reel 4R RC Panel Basic RI IO
RI IO Pro
&

2 pieces
4,100,910,IK ,CK
4,100,886,IK ,CK
OPT/i TPS 4x Switch SpeedNet

OPT/i TPS SpeedNet Connector

RI FB Pro

RI FB Inside
PW-SYS-072, TS/TPS Robotics

OVERVIEW INTERFACES

Automation interface Analog Interface

Interfaces Fieldbus
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AUTOMATION INTERFACE

4 Input signals:
/ 3 configurable input signals
/ Welding start (24V – 36V) – not configurable

1 Output signal:
/ configurable, eg. Arc stable

pc board:
/ ROI

Assembly:
/ 2m control cable
/ 5m systembus cable
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AUTOMATION INTERFACE

Separate tab for signal

configuration

Example for adjustable signals – eg. for

SW 1.5.1:

Gas Test Wire forward

Wire backward Job Mode
Job Number bit 0 Job number bit 1
Job Number bit 2

/ ONLY configurable signals are visible in Web-

Browser!
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Check LEDs:
AUTOMATION INTERFACE
PW-SYS-072, TS/TPS Robotics

RI IO/I

/ simple robot-interface

/ Control via analog setpoints – NO

Job selection

/ NO configureable signals

/ Mode change between Standard and OC (open

collector) by jumpers

/ Cable harness NOT compatible with Rob4000

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(not pin-compatible)
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RI IO/I

/ Signal level:
Low (0) … 0 – 2,5V
High (0) … 18 – 30V

/ Functions:
/ Control via analog setpoints (0 – 10V) for welding power and
arc lengths correction
/ Mode selection via robot control
/ Maincurrent-signal
/ Input for reserve parameters
/ Output for reserve parameters
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RI IO/I
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RI IO PRO/I
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RI IO PRO/I
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RI FB INSIDE/I

/ Interface between Power source and fieldbus CC module

/ Signal transit time < 10ms (non deterministic)
/ Not suitable for compact power sources

/ Required options:
Dip-switches for setup: / CC Fieldbus Modul (z.B. DeviceNet, EtherCat, …)
/ Process image (Standard, Economy, Retrofit)
/ node address / IP adress
/ pc board: ROBCompact
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IMAGE / SIGNALS
Retrofit Image Economy Image
Replica of the TPS process Default setting is Economy
image, Range depends on image, 128 Bit
fieldbus module

3 Images Standard Image

TPS/i process image, 320 Bit

/ No Intel – Motorola switching necessary (robot control specifies the format)

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/ Image contains external inputs

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RI FP Inside/i - ROBCompact

during Interface-Update:
- LED L1: flashes red
- LED L2: flashes green
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Difference between signed and unsigned

System TPS – unsigned (USINT) System TPS/i – signed (SINT)
Type: unsigned 16-Bit integer (16Bit) Type: signed 16-Bit integer (15Bit + 1Bit  sign bit)

range: 0 till 65535 range: -32767 till +32767

0000 ............ -10 ......... (0000000000000000) 0000 ............. 0 ......... (0000000000000000)

32767 ............ 0 .......... (0111111111111111) 56 ............... 56 ........ (0000000000111000)
65535 .......... +10 ........ (1111111111111111) -64 ............. -64 ........ (1111111111000000)

Advantage: Advantage:
Supported from any robot manufacturer No conversion necessary anymore  scaling
Direct input of the setpoint

Disadvantages: Disadvantages:
Setpoint must be scaled May not be supported by older robots
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No direct input of the value

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SIGNAL OVERVIEW - INPUTS No Source Error Reset - Signal

- is realized via Robot ready siganl
- Signal reacts to rising edge

Working mode (instead

of Mode-Bits)

00000 Parameter selection internal

00001 Synergic line mode special 2-step
00010 Job mode
01000 Synergic line mode 2-step

External inputs included

in Image
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SIGNAL OVERVIEW - OUTPUTS

Heartbeat powersource

– pulses with 1 Hz, if

interface is connected

Touchsignal

- is set together with

arc stable signal
- Special for
Motomann robots
(they have a
separate input for
Touchsignal)

- Otherwise, Arc stable

signal must be used
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INTERFACE OPTIONS
PW-SYS-072, TS/TPS Robotics

HMS - MODULES
Fronius OEM-Modules Original HMS-Modules
Fronius article number

Fronius Logo Modules are grey

Fronius modules are black
Same functionality as HMS-Modules All HMS modules for which there is also a Fronius
article number are supported!

/ By using the Anybus technology, a multi protocoll fieldbusinterface for automation/robot is covered via one module link.
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PW-SYS-072, TS/TPS Robotics

FIELDBUS MODULES

Hint: Hint:
If address is set to If address is set to
0 with dip switches, 0 with dip switches,
the address is the address is
adjustable via bus adjustable via bus
master. master.

/ all modules are equipped with integrated electrical isolation and CompactFlash connection
standard connectors

/ Interbus is not supportet by the HMS Anybus CompactCom modules!

Solution: use of a Gateway

All Fronius original OEM-modules are also available as HMS original modules.
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1-Port-modules are not supported!

PW-SYS-072, TS/TPS Robotics

Distinction between SpeedNet / Connector with color coding

SpeedNet connector Connector with color coding

different codings (red, blue)

Sensor plug: RED

Plug for Emergency Stop / Halt: BLUE
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PW-SYS-072, TS/TPS Robotics

Wire feeders &

WF mountings
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WF Mountings
/ Same system as used for TransSteel Robotics
/ Insulation plate is already mounted
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PW-SYS-072, TS/TPS Robotics

ROBOT WIRE FEEDERS

On PAP variants, the connections for

intermediate hose pack and welding
torch hose pack are lead on front side
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CONVENTIONAL ROBOT WIRE FEEDERS

WF 25i R /4R/G/W/FSC WF 30i R /4R/W/FSC
WF 15i R 4R/W/FSC
WF 25i R /L/4R/G/W/FSC WF 30i R /L/4R/W/FSC

0,5 – 15 m/min 1 – 25 m/min 1 – 30 m/min

0,8 – 2,4 mm 0,8 – 1,6 mm 0,8 – 1,6 mm

Rod motor with spur gear Rod motor with spur gear Rod motor with spur gear
water-cooled no cooling water-cooled

100% dc 500A 100% dc 360A 100% dc 500A

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PAP ROBOT WIRE FEEDERS

WF 15i R /PAP/4R/W/FSC WF 25i R /PAP/4R/G/W/FSC WF 30i R /PAP/4R/W/FSC

0,5 – 15 m/min 1 – 25 m/min 1 – 30 m/min

0,8 – 2,4 mm 0,8 – 1,6 mm 0,8 – 1,6 mm

Rod motor with spur gear Rod motor with spur gear Rod motor with spur gear
water-cooled no cooling water-cooled

100% dc 500A 100% dc 360A 100% dc 500A

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ROD MOTOR WITH SPUR GEAR – water cooled

42 Volt AC​
• Device ID
• Temperature sensor on the Flange​

WF 30i R /W/4R/FSC
WF 30i R /L/W4R/FSC
WF 30i R /PAP/W/4R/FSC
Ratio 15,5 : 1

WF 15i R /W/4R/FSC
WF 15i R /PAP/W/4R/FSC
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Ratio 27,6 : 1
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ROD MOTOR WITH SPUR GEAR – no cooling

42 Volt AC​
• Device ID
• Temperature sensor on the Flange​

WF 25i R /4R/G/W/FSC
WF 25i R /L/4R/G/W/FSC
WF 25i REEL R /4R/G/W WF 25i R /PAP/4R/G/WFSC
Ratio 15,5 : 1 Ratio 15,5 : 1
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REEL WIRE FEEDER

WF 25i REEL R /4R/G/W WF 30i REEL R /2R/G/W WF 25i REEL R /sa/2R/G/W

1 – 25 m/min 1 – 30 m/min 1 – 30 m/min

0,8 – 1,6 mm 0,8 – 1,6 mm 0,8 – 1,6 mm

Rod motor with spur gear 3phase step motor 3phase step motor
no cooling no cooling no cooling
/sa … stand alone
(independent of power source)

100% dc 100% dc 100% dc

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3phase step motor with encoder

42 Volt AC​
• Device ID
• Temperature sensor on the Motor​

WF 25i REEL R /sa/2R/G/W

WF 30i REEL R /2R/G/W

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WF 25i REEL sa / 2R
PW-SYS-072, TS/TPS Robotics

FRONIUS Innovation WF 25i REEL R/sa

WF 25i REEL sa ... 2 roller drive | only drum feeding | step motor
(no cooling necessary)
Wire feed speed: max. 25 m/min
STAND ALONE Version Wire diameter at WF25i Reel: 0,8 – 1,6 mm
WF 25i REEL
„not synchronized“
Power Supply: 100-240 V
Adjustable over potentiometer
(wire feed speed, torque) New QuickConnect with
Wire brake (Option)
2Roller Drive
Wall mounting &
Wire drum mounting

STAND ALONE
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FUNCTION

/ The WF25i REEL sa is a

torque driven dereel drive. Torque given value potentiometer

/ The wire feeder is not controlled

by a welding system. not
Inching speed potentiometer
syncronized->Stand Alone

/ Optimal aligment of the wire

feeding by an adjustable torque
potentiometer.
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OPERATING MODES WF 25I R REEL /SA

Operation modes and error codes are displayed by dual LEDs

Torque mode / Inching mode

Start / Stop Wire back & forward

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R&D Robotics / 02.09.2013
PW-SYS-072, TS/TPS Robotics

ADVANTAGES & APPLICATIONS

robustness

Easy operation Stable motor plate / robust housing

Torque of wire feeding can

be set easily in accordance to
the required application

Easy installation
compatibility High dynamic 3 phase
step motor
Can be used at every system (e.g. TPS, Brushless motor
No control line necessary / (maintenance free)
TS, TSt, competitors)
independent regulation from
the welding system, therefore
no push pull alignment
needed/ availability Application
Q3 2014 Automation / if long feeding
distances are required /
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DRIVE ROLLERS

Driving Roll Pressure Roll

ø Article Number ø Article Number

0,8mm 42,0001,4579 0,8mm 44,0001,3427
0,9mm 42,0001,4580 0,9mm 44,0001,3428
1,0mm 42,0001,4581 1,0mm 44,0001,3429
1,2mm 42,0001,4582 1,2mm 44,0001,3430
1,4mm 42,0001,4583 1,4mm 44,0001,3431
1,6mm 42,0001,4584 1,6mm 44,0001,3132
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OPTIONS
 WF Mounting Wall: 4,100,846  WF Mounting Drum: 4,100,845

Easy to mount the feeder on the wall Easy and quick possibility to mount the feeder on a wire drum
Easy to exchange the wire drum (Marathon Pack)

 WF R EXT.ROBOT STARTS.: 4,100,941

To start or stop the wire feeder external from a robot

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TECHNICAL DATA
WF 25i REEL sa /2R
Supply Voltage 100 - 240 V AC
Mains voltage tolerance -10 % / +10 %
Mains frequency 50 / 60 Hz
Current input 0,7 - 1,7 A
Fuse 3,15 A slow blow
Fault current protection device Typ A
1 - 25 m/min
Wire feed speed
39,37 - 984,3 ipm.
Wire drive 2-roller drive
0,8 - 1,6 mm
Wire diameter
0,03 - 0,06 in.
Degree of protection IP 21
Marks of conformity CE, CSA
250/210/190 mm
Dimension l*w*h
9,8/8,3/7,5 in.
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4,6 kg
Weight
10,14 Ib.
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Wire feeding route

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ONE-WIRE-BUS
IROB resp. RDIO2
- Master for 1-wire-bus
- Software update possible (bootfähig)

SR 63 IROB Torch-ID
- brown 1-wire busline
2-wire 2-wire GND
- yellow Touch
torch bus GND - green 1-wire bus line
torch bus bus
24 V
GND
touch 1-wire

Touch-Signal is equipped 1-wire bus

- serial data bus
as default
- communication with BID / WB BID / TX BID
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- Up to 3 nodes possible
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PUSH CrashBox L WireBrake TX/i

(WB BID) (TX BID)
WF

Brown one wire bus line GND

Yellow gas nozzle touch sensing
Green one wire bus line
White Pin K – FSC – n.c.
Gray Pin J – FSC – n.c.
Pink +24V TX/WB
IROB

One-wire bus
A – 2-wire-torch bus
B – 2-wire-torch bus
C – 24V ext.
D – GND
E – CrashBox torch
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F – Touch (yellow) (BID)

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RobactaDrive
PULL CrashBox XL
with RDIO2 TX /i
(TX BID)
Split
Box
Systembus RDIO2
1-wire bus

A – 2-wire-torch bus
B – 2-wire-torch bus
C – 24V ext. (green)
Brown 1-wire bus GND
D – GND (brown) Yellow Touch
Touch
Brown GND
E – CrashBox 24V Touch Green one wire bus line
F – Touch (yellow) Yellow Touch White n.c.
G – Motor line 1 Green 24V DC Gray n.c.
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H – Motor line 2 Motor line 1 Pink +24V TX/WB

I – Motor line 3 Motor line 2
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HIGHLIGHTS / WHY NEW CRASHBOXES

Different setting angles

Different setting of angles
possible with indexdiscs.

Increased repeat ability

Position repeatability of ± 0,05mm
Smaller design

Torch body
Availability protection
Q3 2014
In case of crash no force on the welding
torch body.
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SYSTEM DESIGN – CONVENTIONEL

Robot flange  CrashBox  Indexdisc  Option: Holding  Holding clamp
clamp extension
Halteschellen-
Verlängerung

TSt

CrashBox/i

TPS

CrashBox /d
same TCP as in existing Binzel CAT Boxes
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SYSTEM DESIGN – PAP

Robot flange  CrashBox

CrashBox/i PAP
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FLANGE
/ Naming convention

RFP i 56 PAP 8M4 62

Robot Pitch circle diameter of ProcessArmPeriphery 8 pieces M4 bolts Diameter of the
Flange Platform bolt hole (no separate flange on the robot-
Plastic specification for conv.) side where the
flange is centered

/ Compatibility
/ New Roboterflanges are required to mount the new crash boxes
/ CrashBox/i and Crashbox /d are able to mount on hollow wrist robot with a PAP
flange
21 SEPT 2015
PW-SYS-072, TS/TPS Robotics

CRASHBOX/i

/ New magnetic Crashboxes for conventional and PAP

/ No more forces on torch components when Crashbox releases
/ Versions Standard, XL and XXL with different release forces
/ Smaller ergonomic design (shorter assembly time, smaller interference contour at the 6th
axes)

conventional PAP
21 SEPT 2015
PW-SYS-072, TS/TPS Robotics

POSITION REPEATABILITY & MAX. EXCURSION

/ Position repeatability:

/ Position repeatability of the TCP at

300mm distance from robot flange (36°
standard torch body with PAP system):
±0,05mm

L=300mm ±0,05mm

/ Max. excursion:

/ Crashbox releases at 2,5mm TCP transfer (=0,5°)

/ Max. excursion: approx. 100mm (=20°)
21 SEPT 2015
PW-SYS-072, TS/TPS Robotics

TCP WITH DIFFERENT INDEXDISCS

Indexdisc
22° TPS/i 36° TPS/i 45° TSt & TPS/i 36° TSt 22° TSt
42,0001,4244 42,0001,4245 42,0001,4246 44,0350,3762 44,0350,3761
22° TCP in 6. axis TCP above 6. TCP above 6. axis TCP above 6. axis 45° torch neck position
axis
Torch neck

36° TCP below 6. TCP in 6. axis TCP above 6. axis 45° torch neck position TCP below 6. axis
axis
45° TCP below 6. TCP below 6. TCP in 6. axis & TCP below 6. axis TCP below 6. axis
axis axis 45° torch neck position

TCP
21 SEPT 2015

TCP in 6. axis torch neck position 45°

21 SEPT 2015 PW-SYS-072, TS/TPS Robotics

42,0100,0571
42,0100,0570
42,0100,0569
42,0100,0568
42,0100,0567
42,0100,0566
42,0100,0565

RFP i 56 PAP 6M4

RFP i 56 PAP 8M4 62
RFP i 58 PAP 6M4 65
RFP i 58 PAP 6M4 68
RFP i 63 PAP 4M6 80
RFP i 80 PAP 6M8 100
RFP i 66 PAP 11M5 75

x
Fanuc AM100iC

x
Fanuc AM100iC 6L

x
Fanuc AM120iC

x
Fanuc AM120iC 10L

x
Yaskawa EA1400N / MA1400 / VA1400

x
Yaskawa SSA200

x
Yaskawa MA1550
ARTICLE NUMBERS FLANGE PAP

x
Yaskawa EA1800N / MA1800
x Yaskawa EA1900N / MA1900
x

ABB IRB 1520ID

x

ABB IRB1600ID
x

ABB IRB2600ID
x

Kuka KR5arc HW
x

Kuka KR16arc HW
x

Kuka KR16 L8 arc HW

x

Reis RV20-6HW
x

Reis RV20-10HW
x

Reis RV30-10HW
x

SMART5 ARC4
21 SEPT 2015 PW-SYS-072, TS/TPS Robotics

42,0100,1405
42,0100,0577
42,0100,1404
42,0100,1403
42,0100,1402

RFP i 63 4M6 80
RFP i 50 6M6 63
RFP i 40 4M6 50

RFP i 50 6M6 31,5

RFP i 31,5 4M5 40
ABB IRB 1600
ABB IRB 1600-5/1,2
ABB IRB 1600-5/1,45
ABB IRB 1600-7/1,2
ABB IRB 1600-7/1,45
ABB IRB 2600
ABB IRB 4400 L/10
ABB IRB 4600-20/2.50
FANUC ArcMate 0iA
FANUC ArcMate 50iC
FANUC ArcMate 100
FANUC ArcMate 100iB
FANUC ArcMate 120
FANUC ArcMate 120iB
FANUC ArcMate
120iB/10L
FANUC LR Mate 200iC
REIS RV6
REIS RV10-6
REIS RV20-6
REIS RV30-16
YASKAWA MH6
YASKAWA MH6-10
YASKAWA HP6
YASKAWA HP6-10
YASKAWA UP6
ARTICLE NUMBERS FLANGE CONVENTIONEL

YASKAWA HP20
YASKAWA UP20
YASKAWA HP20D
YASKAWA HP20-6
YASKAWA HP20D-6
YASKAWA HP20RD
KUKA KR5
KUKA KR16
KUKA KR16 L6
PW-SYS-072, TS/TPS Robotics

ARTICLE NUMBERS OF CRASH-BOXES

Article-Number Label additional Information
44,0350,3589 CrashBox/i L-edition

44,0350,3760 CrashBox/i XL XL-edition

44,0350,3752 CrashBox/i Dummy

44,0350,3663 CrashBox/i PAP L-edition

44,0350,3759 CrashBox/i PAP XL XL-edition

44,0350,3753 CrashBox/i PAP Dummy

44,0350,3855 CrashBox /d L-edition, replacement of existing CrashBox

44,0350,3856 CrashBox /d XL XL-edition, replacement of existing CrashBox

44,0350,3943 CrashBox /d XXL XLL-edition, replacement of existing CrashBox

44,0350,3590 CrashBox mag. CMT PAP FL
21 SEPT 2015
PW-SYS-072, TS/TPS Robotics

ARTICLE NUMBERS OF INDEX-DISCS

Article-Number Label
42,0001,4244 Indexdisc 22° TPS/i

42,0001,4245 Indexdisc 36° TPS/i

42,0001,4246 Indexdisc 45° TPS/i TSt

44,0350,3762 Indexdisk 36° TSt

44,0350,3761 Indexdisk 22° TSt
21 SEPT 2015
PW-SYS-072, TS/TPS Robotics

ARTICLE NUMBERS OF CLAMP-LENGTHENINGS &

HOLDING CLAMPS
Article-Number Label additional Information
44,0350,3731 Clamp MHP TSt Holding clamp

44,0350,3729 Clamp-Lengthening/i 80mm additional clamp lengthening

44,0350,3730 Clamp-Lengthening/i 120mm additional clamp lengthening
21 SEPT 2015
PW-SYS-072, TS/TPS Robotics

OPT/i WB MHP = Option Wire Brake

/ For mechanical fixing of the wire (for touch sensing)

/ In Touch Mode the wire is fixed (at Push-Systems)
/ Exact detection of the work piece possible – precise welding position
/ TCP-displacement: 47 mm at retrofitting

/ Robacta Drive has wire break function as standard

/ The fixing of the wire is done by current feed of the motor
Cut
/ Option blow out has to be ordered separately
21 SEPT 2015
PW-SYS-072, TS/TPS Robotics

EXCHANGE COUPLING AND TORCH BODY FOR

ROBACTA TX/I
/ Control for torch change works with an electrical Signal via iRob (digital Output from the
Robot)
/ Pneumatic activation of the span piston ( > 5bar)
/ Blow out High-End possible
/ Mechanical unlocking possible
/ Information from TorchDevice ID are guided through the coupling
/ TCP-displacement: 47mm at retrofitting
21 SEPT 2015
PW-SYS-072, TS/TPS Robotics

Options matrix WF & unreeling devices

Wire feeder WF 15/25/30i R SB 500i R WF 30i REEL R /2R WF 25i REEL R /2R/sa WF 25i REEL R /4R
OPTION
4,100,881 OPT/i WF R Key Lock X X X X X
4,100,880 OPT/i WF Drahtrichtstrecke X X X X X
4,100,867 OPT/i WF Ausblasen 16 bar X X
OPT/i WF Ext. Koll.Box.Sig.
4,100,882 X X
(Nur in Verbindung mit 4,100,868)
4,100,855 OPT/i WF Gasdüsenposition X X
4,100,879 OPT/i WF R DE Marathonp X X X X X
4,100,878 OPT/i WF R Ringsensor X X X X X
4,100,869 OPT/i WF R Drahtende X X X X X
4,100,775 OPT/i WF Gastest & Drahteinf. X
4,100,774 OPT/i Ext. Sensorstecker X X X X X
4,100,868 OPT/i WF R Optionsplatine X X
4,100,813 OPT/i Gasdruck-Sensor X X
4,100,XXX OPT/i Gasdruchfluss-Regler X X
4,100,870 OPT/i WF Drahtistwert Motorpl. X X X
4,100,845 WF MOUNTING Drum X X X
4,100,846 WF MOUNTING Wall X X X
4,100,941 OPT/i WF R Ext.Roboter Starts. X
21 SEPT 2015

4,100,930 OPT/i WF 2.SpeedNet Connector X X X X X

21 SEPT 2015 PW-SYS-072, TS/TPS Robotics

Torches
PW-SYS-072, TS/TPS Robotics

Torch bodies MTB G R / MTB W R = MIG/MAG Torch

Body Gascooled / Watercooled Robot

MTB 250i G R MTB 250i W R

MTB 330i W R

MTB 320i G R MTB 400i W R

MTB 400i G R MTB 500i W R

MTB 700i W R
21 SEPT 2015

70
Angles: 22° / 36° / 45°
PW-SYS-072, TS/TPS Robotics

Hose packs MHP R G / MHP R W = MIG/MAG Hose Pack

Roboter Gascooled / Watercooled

Gascooled: Watercooled:
MHP 400i R G MHP 700i R W
MHP 400i R G PAP MHP 700i R W PAP
21 SEPT 2015

71
Lengths: CONV: 0,95m / 1,10m / 1,25m / 1,45m PAP: Length especially adapted for robot type
PW-SYS-072, TS/TPS Robotics

Robacta Drive
Hose packs MHP RD G / W = MIG/MAG Hose Pack Robacta Drive Gas / Water
WF 25i Robacta Drive / G / W = WireFeeder

MHP 400i RD/G (conventional) e unit for MHP 400i RD/G/PAP

riv
One d & PAP
MHP 700i RD/W (conventional) C ON V MHP 700i RD/W/PAP
+ WF 25i Robacta Drive + WF 25i Robacta Drive
Lengths: RD CONV: 1,10m / 1,2m / 1,5m / 1,75m RD PAP: Length especially adapted for robot type
21 SEPT 2015

Important: Split Box required for controling the Robacta Drive

72 Fronius International GmbH / Aitzetmüller Christian / TPSi Roboterschweißbernner

PW-SYS-072, TS/TPS Robotics

Sleeve system for steel applications

Watercooled:
Gascooled:

Spatter guard

Sleeve system

/ Cleaning with milling tool up to the gas holes possible

/ Longer gas nozzle at sleeve sytem for improved gas protection
/ Available for all torch body types (except MTB 250i G/W R)
21 SEPT 2015

/ Ordering: OVT version of torch body + wear parts of sleeve system as separate positions
/ MTB 700i W R only available with sleeve system
73 Fronius International GmbH / Aitzetmüller Christian / TPSi Roboterschweißbernner
PW-SYS-072, TS/TPS Robotics

New innerliners for perfect process stability

Bare steel inner liners gas- and water cooled:

/ ø 0,8: external diameter 4,3mm
th e meter
s old by , 50m
/ ø 1,0 – 1,6: external diameter 4,8mm liner s , 1 5m
Inner lengths: 5m
CrNi-bare inner liners for CrNi gas- and water cooled: rd w are
Ya
/ ø 0,8: external diameter 4,3mm
/ ø 1,0 – 1,6: external diameter 4,8mm

Combi inner liners for Al gas cooled and CuSi for gas and water cooled
/ ø 0,8 – 1,6: external diameter 4,8mm
= 40mm liners
Combi inner liners for Al water cooled L ner
embled in
/ ø 0,8 – 1,6: external diameter 4,8mm As s
21 SEPT 2015

74
PW-SYS-072, TS/TPS Robotics

Inner liner Robacta Drive for hose pack and torch body
Bare steel inner liners gas- and water cooled:
/ ø 0,8: external diameter 4,3mm
h e m eter
s old by t , 50m
/ ø 1,0 – 1,6: external diameter 4,8mm lin e r s , 1 5 m
Inner lengths: 5m
CrNi-bare inner liners for CrNi gas- and water cooled : rd w are
Ya
/ ø 0,8: external diameter 4,3mm b y m eter
li ne r s sold m, 100m
/ ø 1,0 – 1,6: external diameter 4,8mm p hit inner : 10m , 30
Gr a
re l engths
a
Graphit inner liners for Aluminum Yard w
/ ø 0,8 – 1,6: external diameter 4,8mm for hose pack
/ TBL = Torch body liner for torch body
= 40mm
L
/ für Aluminum gascooled & CuSi
/ für Aluminum watercooled

For a perfect welding process we use also a diameter specific inner liner in the hose pack
21 SEPT 2015

now.
75
PW-SYS-072, TS/TPS Robotics

SAME WEAR PART SYSTEM MANUAL AND ROBOT

WELDING TORCHES

Difference basic equipment: gas nozzle

Manual: Gas nozzle ends 2mm in front of the contact tip
Robot: Gas nozzle and contact tip are ending straight at the same position.

Advantage: Customer has only one type of wear parts on stock, if manual
and robotic welding torches are in use (except gas nozzle)
21 SEPT 2015

76
PW-SYS-072, TS/TPS Robotics

Packages – now color coded

/ Labels have diameter specific color code now.

21 SEPT 2015

77 Fronius International GmbH / Aitzetmüller Christian / TPSi Schweißbrenner / 12.09.2012

PW-SYS-072, TS/TPS Robotics

Characteristics torch body

/ Stainless steel outer tube for maximum stability

/ Line for gas nozzle touch sensing is integrated as standard
/ Insulation for the torch body below the outer tube (no external insulation required)

Torch Device ID – Intelligent up to the front

/ Torch type is identified from the power source
/ Temperature sensor – Safety shutdown if torch coupling is too hot  no overheating of the
torch possible
/ Example: If gascooled torch body is mounted on a watercooled hose pack, the system
21 SEPT 2015

detects the fault.

78 Fronius International GmbH / Aitzetmüller Christian / TPSi Roboterschweißbernner
PW-SYS-072, TS/TPS Robotics

User Interface Robacta Drive

Gas test F1 = free programmable

Wire forward Wire back

Dot-matrix display
Possible displays (not fixed yet):
/ error message (E)
/ touchsensing (t)
21 SEPT 2015

/ gas test (G)

79 /… /Fronius International GmbH / Aitzetmüller Christian / TPSi Roboterschweißbernner
PW-SYS-072, TS/TPS Robotics

Options
TPS/i
21 SEPT 2015

80 Fronius International GmbH / TPS/i Robotics

PW-SYS-072, TS/TPS Robotics

Options

/ Additional plus welding power connection on the front side

/ 4,100,804,CK IK OPT/i TPS 2nd plus socket

/ Additional earth welding power connection on the back side

/ 4,100,805,CK IK OPT/i TPS 2nd earth socket

/ Second NT241 = power supply for CU 1400i

/ 4,100,808,CK IK OPT/i TPS 2nd NT241 CU1400i

/ Additional motor supply for multi motor systems

/ 4,100,809,IK OPT/i TPS motor supply +
21 SEPT 2015

81 Fronius International GmbH / TPS/i Robotics

PW-SYS-072, TS/TPS Robotics

Options

/ Dust filter for heavy environments

/ 4,100,811,IK OPT/i TPS dust filter

/ Second SpeedNet Connector for connection to remote control or standard I/O interfaces
/ 4,100,812,IK OPT/i TPS 2.SpeedNet Connector

/ Switch for 5 additional SpeedNet ports

/ 4,100,886,IK OPT/i TPS 5x Swich SpeedNet
21 SEPT 2015

82 Fronius International GmbH / TPS/i Robotics

PW-SYS-072, TS/TPS Robotics

External STOP (Emergency STOP)

Safety STOP (Emergency Shutdown)

PS TPS 270i C TPS320i C

TPS320/400/500/60
TPS400 LSC ADV RI FB PRO/i
0
OPTION
4,101,009 OPT/I Safety Stop PL d X X X
4,101,011 OPT/I TPS Ext. Stop X X X
4,101,012 OPT/I RI Safety Stop OUT X

Function 4,101,011 - OPT/i TPS Ext. Stop Function 4,101,009 - OPT/i Safety Stop PL d

Performance Level: B  1 channel switch off Performance Level: D  2 channel switch off
Function: Emergency STOP Function: Emergency STOP & Emergency Shutdown
Inching enable: YES Inching enable: NO
21 SEPT 2015

83 Fronius International GmbH / Andreas Hummelbrunner / TPSi Robotics Workshop / 03.02.2015

PW-SYS-072, TS/TPS Robotics

Configurations
21 SEPT 2015

84 Fronius International GmbH / TPS/i Robotics

PW-SYS-072, TS/TPS Robotics

Configuration PAP
TPS/i -- STANDARD
Gascooled version:
4,047,9xx MHP 400i R/G/PAP/FSC/
4,049,036 WF 25i PAP /G/W/4R/FSC 44,0350,3465 MTB 400i G R/22°/L241
4x 44,0001,1407 Feeder Roll FSR U 1,2mm 44,0350,5120 BK Fe ø1,2 G/W/5m
Watercooled version:
4,100,xxx Wire feeder bracket
4,047,9xx MHP 700i R/W/PAP/FSC
Gascooled version: 44,0350,3494 MTB 500i W R/22°/L241
4,047,879 HP 95i CON R /G/8m 44,0350,5120 BK Fe ø1,2 G/W/5m
4,100,xxx Bracket Connection hose pack
Watercooled version:
4,047,884 HP 95i CON R /W/8m
42,0100,05xx RFP i
4,100,xxx Bracket Connection hose pack
44,0350,3663 CrashBox /i PAP

40,0001,0527 Wire feed hose OD 10mm

4,100,890 WF OPT/i QC DFS AD10
4,100,899 WF OPT/i QC VR AD10
PowerSource:
4,100,xxx Wire coil mounting 4,075,174 TPS400i
4,066,013 WP Pulse
4,044,014 RI FB Inside
41,0018,0084 RI MOD/i CC EtherNET IP
4,100,808,IK OPT/i TPS 2. NT241
4,048,004 CU 1400i
4,077,001 TU Podium
21 SEPT 2015

43,0004,2070 Earth cable 70mm2 5m + earth clamp

42,0510,0011 Pressure control valve Ar/CO2 3-30l/min.

85 Version 2
PW-SYS-072, TS/TPS Robotics

Configuration conventional
TPS/i -- STANDARD
4,049,035 WF 25i R /G/W/4R/FSC Gascooled version:
4x 44,0001,1407 Feeder Roll FSR U 1,2mm 4,051,9xx MHP 400i G R/FSC/xxxm
44,0350,3465 MTB 400i G R/22°/L241
4,100,xxx Wire feeder bracket
44,0350,5120 BK Fe ø1,2 G/W/5m
Watercooled version:
Gascooled version:
4,051,9xx MHP 700i W R/FSC/xxxm
4,047,879 HP 95i CON R /G/8m
44,0350,3494 MTB 500i W R/22°/L241
Watercooled version:
44,0350,5120 BK Fe ø1,2 G/W/5m
4,047,884 HP 95i CON R /G/8m

44,0350,3568 Clamp MHP TPS/I

40,0001,0527 Wire feed hose OD 10mm
42,0001,4244 Indexdisk 22° TPS/i
4,100,890 WF OPT/i QC DFS AD10
4,100,899 WF OPT/i QC VR AD10 42,0100,05xx RFP i
44,0350,3589 CrashBox /i
4,100,xxx Wire coil mounting
PowerSource:
4,075,174 TPS400i
4,066,013 WP Pulse
4,044,014 RI FB Inside
41,0018,0084 RI MOD/i CC EtherNET IP
4,100,808,IK OPT/i TPS 2. NT241
4,048,004 CU 1400i
4,077,001 TU Podium
21 SEPT 2015

43,0004,2070 Earth cable 70mm2 5m + earth clamp

42,0510,0011 Pressure control valve Ar/CO2 3-30l/min.

86 Version 1
PW-SYS-072, TS/TPS Robotics

PAP PushPull configurations

21 SEPT 2015

87 Fronius International GmbH / TPS/i Robotics

PW-SYS-072, TS/TPS Robotics

PAP PowerDrive configuration

21 SEPT 2015

88 Fronius International GmbH / TPS/i Robotics

 Configuration number: P03666
PW-SYS-072, TS/TPS Robotics

TPS/I CONV AIRCOOLED

Part number Name

44,0350,3465 MTB 400i G R/22°
44,0350,3568 Holding clamp TPS/i
Part number Name
42,0001,4244 Indexdisc 22°
4,049,035 WF 25i R /G/W/4R/FSC
44,0350,3589 CrashBox /i
4x44,0001,1407 Feeder roll 1,2mm
42,0100,1403 RFP i 40 4M6 50
4,100,740 WF mounting
4,051,007 MPH 400i G R/FSC/0,95
40,0001,0505 Wire feed hose
44,0350,5120 BasicKit Fe Ø1,2 G/W/5m
4,100,669 WF OPT/i QC VR5000
4,047,876 HP 70i CON R /G/4m
4,100,670 WF OPT/i QC VR1500
43,0004,0581 Earth cable 90mm² 4m
4,100,489 Wire coil mountiing
4,075,179 TPS 400i PULSE
4,044,014 RI FB Inside/i
41,0018,0084 RI MOD/i CC EtherNET /IP-2P
4,077,001 TU Podium
4,078,013 Robot Dummy
21 SEPT 2015

89
 Configuration number: P03668
PW-SYS-072, TS/TPS Robotics

TPS/I PAP AIRCOOLED

Part number Name

Part number Name 44,0350,3465 MTB 400i G R/22°
4,049,036 WF 25i PAP /G/W/4R/FSC 44,0350,3663 CrashBox /i PAP
4x44,0001,1407 Feeder roll 1,2mm 42,0100,0571 RFP i 56 PAP 6M4
4,100,748 WF mounting quick slide 4,047,902 MHP 400i R/G/PAP/FSC/1,06
40,0001,0505 Wire feed hose 44,0350,5120 BasicKit Fe Ø1,2 G/W/5m
4,100,669 WF OPT/i QC VR5000 4,047,876 HP 70i CON R /G/4m
4,100,670 WF OPT/i QC VR1500 4,100,572 Mounting extension hose pack
4,100,489 Wire coil mountiing 43,0004,0581 Earth cable 90mm² 4m
4,075,179 TPS 400i PULSE
4,044,014 RI FB Inside/i
41,0018,0084 RI MOD/i CC EtherNET /IP-2P
4,077,001 TU Podium
4,078,013 Robot Dummy
21 SEPT 2015

90
PW-SYS-072, TS/TPS Robotics

FANUC ARCMATE 120iC

TPS/i -- STANDARD
Gascooled version:
4,047,905 MHP 400i R/G/PAP/FSC/
4,049,036 WF 25i PAP /G/W/4R/FSC 44,0350,3465 MTB 400i G R/22°/L241
4x 44,0001,1407 Feeder Roll FSR U 1,2mm 44,0350,5120 BK Fe ø1,2 G/W/5m
Watercooled version:
4,100,752 Wire feeder bracket Fanuc
4,047,921 MHP 700i R/W/PAP/FSC
Gascooled version: 44,0350,3494 MTB 500i W R/22°/L241
4,047,879 HP 95i CON R /G/8m 44,0350,5120 BK Fe ø1,2 G/W/5m
4,100,581 Bracket Connection hose pack
Watercooled version:
4,047,884 HP 95i CON R /W/8m
42,0100,0570 RFP i 56 PAP 8M4 62
4,100,581 Bracket Connection hose pack
44,0350,3663 CrashBox /i PAP

40,0001,0527 Wire feed hose OD 10mm

4,100,890 WF OPT/i QC DFS AD10
4,100,899 WF OPT/i QC VR AD10
PowerSource:
4,100,560 Wire coil mounting 4,075,174 TPS400i
4,066,013 WP Pulse
4,044,014 RI FB Inside
41,0018,0084 RI MOD/i CC EtherNET IP
4,100,808,IK OPT/i TPS 2. NT241
4,048,004 CU 1400i
4,077,001 TU Podium
21 SEPT 2015

43,0004,2070 Earth cable 70mm2 5m + earth clamp

42,0510,0011 Pressure control valve Ar/CO2 3-30l/min.

91 Version 2
PW-SYS-072, TS/TPS Robotics

ABB IRB 1600

TPS/i -- STANDARD
4,049,035 WF 25i R /G/W/4R/FSC Gascooled version:
4x 44,0001,1407 Feeder Roll FSR U 1,2mm 4,051,008 MHP 400i G R/FSC/1,25m
44,0350,3465 MTB 400i G R/22°/L241
4,100,745 Wire feeder bracket IRB 1600
44,0350,5120 BK Fe ø1,2 G/W/5m
Watercooled version:
Gascooled version:
4,051,011 MHP 700i W R/FSC/1,25m
4,047,879 HP 95i CON R /G/8m
44,0350,3494 MTB 500i W R/22°/L241
Watercooled version:
44,0350,5120 BK Fe ø1,2 G/W/5m
4,047,884 HP 95i CON R /G/8m

44,0350,3568 Clamp MHP TPS/I

40,0001,0527 Wire feed hose OD 10mm
42,0001,4244 Indexdisk 22° TPS/i
4,100,890 WF OPT/i QC DFS AD10
4,100,899 WF OPT/i QC VR AD10 42,0100,1403 RFP i 40 4M6 50
44,0350,3589 CrashBox /i
4,100,552 Wire coil mounting ABB
PowerSource:
4,075,174 TPS400i
4,066,013 WP Pulse
4,044,014 RI FB Inside
41,0018,0084 RI MOD/i CC EtherNET IP
4,100,808,IK OPT/i TPS 2. NT241
4,048,004 CU 1400i
4,077,001 TU Podium
21 SEPT 2015

43,0004,2070 Earth cable 70mm2 5m + earth clamp

42,0510,0011 Pressure control valve Ar/CO2 3-30l/min.

92 Version 1