Fronius CMT-A 4000 MV Operation/Reference Manual Download Page 37

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/ Battery Charging Systems /

Welding Technology

/ Solar Electronics

Overlap / Weld Bead Rollover

Weld metal cold and lapped at toe or root

Possible Cause(s⁄

Amperage too high
Travel speed too slow
Electrode too large

Porosity

Pinholes

Possible Cause(s⁄

Dirty, painted, or galvanized base metal
Arc length too long
Moisture in weld
Insufficient shielding gas coverage

Slag Inclusions

Slag trapped in weld

Possible Cause(s⁄

Improper manipulation of covered electrode
Improper cleaning and/or slag removal between

passes

Cracking

Cracks in the weld and/or base metal

Possible Cause(s⁄

Using the wrong electrode
Using excessively high amperage
Underfill or improper crater geometry (crater

cracking⁄
Moisture in low hydrogen processes

Excessive Spatter

Possible Cause(s⁄

Amperage too high
Electrode angle too extreme
Arc length too short/long
Process driven

Weld Process

Discontinuity

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34 ----

Summary of Contents for CMT-A 4000 MV

Page 1: ...P 12 Fronius USA Fronius USA Fronius USA Fronius USA Office 1 877 376 6487 www fronius usa com Battery Charging Systems Welding Technology Solar Electronics Operations Reference Guide MIG Welding Equi...

Page 2: ......

Page 3: ...page 28 Torch Movement and Position page 32 Discontinuity page 33 Use and Operation Initial Set up and Turn on page 35 Quick Reference Sheet TPS page 36 Weld Correction Value page 41 Front Panel TPS...

Page 4: ...12 70 76 20 35 14 82 88 90 40 16 93 101 60 45 19 05 114 30 50 21 17 127 00 55 23 28 139 70 60 25 40 152 40 65 27 51 165 10 70 29 63 177 80 75 31 75 190 50 80 33 86 203 2 85 35 98 215 90 90 38 10 228 6...

Page 5: ...2 2 2 2...

Page 6: ...30 or 460V AC 6 6 6 6 Front Panel 7 7 7 7 Gas Tank 8 8 8 8 Remote Control Unit RCU 9 9 9 9 Robot Interface 10 10 10 10 Cooler 11 11 11 11 PC Interface Tool Component Layout Weld System Component Manag...

Page 7: ...elding power source This configuration can be applied with either robotic or manual systems This configuration allows for the following features The connections between the wire feeder to the power so...

Page 8: ...d between the welder and the torch location This placement may or may not be permanent This configuration allow for Varying distances between the power source and wire feeder Enables the wire feeder t...

Page 9: ...e of configuration has no built in mechanism for manually starting the torch and is intended only for robotic automated applications Interconnecting hose packs can vary in length The length must be ac...

Page 10: ...s capable of pulse welding pre loaded with pulse designed synergic lines Fully digital inverter based technology that provides stable reproducible arc through ENTIRE arc range Welder comes pre loaded...

Page 11: ...ges available 350 and 500 Multi voltage model available Welder is designed specifically for steel welding offering a large variety of options at a low price Fully digital inverter based technology tha...

Page 12: ...tion of the welder the full part number and a unique serial number Using the format below the serial number can be used to determine the approximate age of the welding power supply This technique can...

Page 13: ...kVA 12 4 13 9 kVA 13 0 16 0 kVA Electrical Efficiency 88 91 90 91 88 91 88 91 n a Welding Current Range MIG Stick TIG 3 270 A 10 270 A 3 270 A 3 320 A 10 320 A 3 320 A 3 400 A 10 400 A 3 400 A 3 500 A...

Page 14: ...Welding TIG Welding TIG Welding TIG Welding Connect the welding ground to this socket STICK Welding STICK Welding STICK Welding STICK Welding Connect the electrode cable to this socket depending on t...

Page 15: ...Connection LocalNet Connection LocalNet Connection Blanking Cover s Blanking Cover s Blanking Cover s Blanking Cover s Front Panel Front Panel Front Panel Front Panel Gas Connection Gas Connection Ga...

Page 16: ...nnection Ground Connection Power Switch Power Switch Power Switch Power Switch Mains Connection Mains Connection Mains Connection Mains Connection LocalNet Connection LocalNet Connection LocalNet Conn...

Page 17: ...ins Mains Mains Mains Connection Connection Connection Connection LocalNet LocalNet LocalNet LocalNet Connection Connection Connection Connection Gas Purch Wire Gas Purch Wire Gas Purch Wire Gas Purch...

Page 18: ...s equally suited to both manual and robotic automated needs A wire spool holder is integrated to the feeder allowing for both spool and drum use This feeder is designed to operate with either a push o...

Page 19: ...ing System Built with highly reliable impact resistant materials This provides reasonable protection from dragging dropping and hanging Multiple control options to handle both manual and synergic weld...

Page 20: ...ls Drive Rolls Drive Rolls Drive Rolls top Drive Rolls Drive Rolls Drive Rolls Drive Rolls bottom Wire Guide Insert Wire Guide Insert Wire Guide Insert Wire Guide Insert steel or synthetic Main Drive...

Page 21: ...Current Gas Connection Current Gas Connection Current Gas Connection Current Gas Connection torch Coolant Feed Coolant Feed Coolant Feed Coolant Feed hot hot hot hot torch Gas Purge Button Gas Purge...

Page 22: ...eed Coolant Feed Coolant Feed cold cold cold cold torch Coolant Feed Coolant Feed Coolant Feed Coolant Feed cold cold cold cold welder Coolant Feed Coolant Feed Coolant Feed Coolant Feed hot hot hot h...

Page 23: ...rent Connection welder Motor Motor Motor Motor plate plate plate plate Gas Connection Gas Connection Gas Connection Gas Connection bottle PAP System Only Wire Inch Button Wire Inch Button Wire Inch Bu...

Page 24: ...plate plate Spool Window Spool Window Spool Window Spool Window Handle Handle Handle Handle Weld Control Weld Control Weld Control Weld Control Panel Panel Panel Panel Synergic Selection Synergic Sele...

Page 25: ...e feeder connections Fronius F F Fronius System Connector FSC Euro E Tweeko Z Will have Robacta in the description BAAN Price BAAN Price BAAN Price BAAN Price book Description Examples book Descriptio...

Page 26: ...voltage damage Flow sensor to verify proper coolant movement Variable flow measurements to account for lengthy hose packs FK 4000 FK 5000 FK 4000 FK 5000 FK 4000 FK 5000 FK 4000 FK 5000 Standard water...

Page 27: ...ece s Shielding is obtained from a gas Pressure may or may not be used and filler may or may not be used TIG welding Performed with a constant current CC power source equipped with a GTA welding torch...

Page 28: ...differences between laboratory testing and production Synergic Line An arc characteristic curve that links a number of welding parameters together giving the most ideal values for a specific filler m...

Page 29: ...ransfer This is an uncontrolled spray transfer mode When CO2 or Argon CO2 is used a molten ball tends to form on the end of the electrode and may grow in size until its diameter is greater than the di...

Page 30: ...balls typically larger than conventional GMAW spatter ball size Advantages include High deposition rates Lower heat inputs Viable solution to many welding situations Less spatter when compared to conv...

Page 31: ...of natural gas Argon Helium Mix The advantages disadvantage of each gas increases and decreases in relation to the proportion within the mix ACTIVE GASES ACTIVE GASES ACTIVE GASES ACTIVE GASES ACTIVE...

Page 32: ...ntal Positional Welding Very Good Very Good Good More CO2 better fusion penetration Good Critical Pores Very Little Normal More CO2 fewer pores Pore sensitive Arc Stability Poor except KL Good Very Go...

Page 33: ...nly responsible for the shape of the arc and the resulting behavior of it fusion penetration pore creation etc 18 CO2 Wider arc range Wider fusion penetration Little pore creation 5 CO2 Narrow arc ran...

Page 34: ...s due to their lighter weights Correct flow rate Excessive flow rate Gas Pressure Sensor 4 100 343 Manually set gas valve that reports a gas error to the weld system when flow is too low Only errors o...

Page 35: ...EDIUM MEDIUM MEDIUM Push Travel Angle Arc heats and transmits it s total power into the weld pool Stable quiet arc Fusion penetration is SHALLOW SHALLOW SHALLOW SHALLOW Weld Width is WIDE WIDE WIDE WI...

Page 36: ...e Cause s Amperage too high Arc length too long voltage too high Improper work angle Insufficient Leg undersized weld Insufficient Leg undersized weld Insufficient Leg undersized weld Insufficient Leg...

Page 37: ...s Slag Inclusions Slag Inclusions Slag Inclusions Slag trapped in weld Possible Cause s Possible Cause s Possible Cause s Possible Cause s Improper manipulation of covered electrode Improper cleaning...

Page 38: ...extras in a safe place for later use Step 5 Step 5 Step 5 Step 5 Perform a resistance test Step 5 Step 5 Step 5 Step 5 If using a non CMT push pull gun perform a PPU alignment Step 6 Step 6 Step 6 Ste...

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Page 40: ...37 37 37 37...

Page 41: ...38 38 38 38...

Page 42: ...39 39 39 39...

Page 43: ...40 40 40 40...

Page 44: ...ge 5 Less SC2 Current Colder melt pool 0 Standard Plasma WFS 0 Standard SC2 Current 30 Higher droplet detach freq Less voltage 5 More SC2 Current Hotter melt pool Standard CMT Aluminum and Stainless 3...

Page 45: ...on Used in conjunction with other buttons to get into various other menu s Can also be used to exit any menu Purge Button Purge Button Purge Button Purge Button Used to test the gas flow One press wil...

Page 46: ...ator if equipped When lit the torch motor current is shown on the first 3 digit display 3 3 3 3 Segment Display Segment Display Segment Display Segment Display When lit the first 3 digit display is ac...

Page 47: ...e Release trigger to move to normal welding current Press and hold trigger to move to ending current value Finally release torch trigger to stop the arc Spot Mode Spot Mode Spot Mode Spot Mode Press a...

Page 48: ...on Used in conjunction with other buttons to get into various other menu s Can also be used to exit any menu Purge Button Purge Button Purge Button Purge Button Used to test the gas flow One press wil...

Page 49: ...if equipped When lit the torch motor current is shown on the first 3 digit display 3 3 3 3 Segment Display Segment Display Segment Display Segment Display When lit the first 3 digit display is active...

Page 50: ...d hold trigger to move to ending current value Finally release torch trigger to stop the arc Spot Mode Spot Mode Spot Mode Spot Mode Press and release torch trigger to start the weld it will run until...

Page 51: ...the MATERIAL SELECTION button Release both buttons One of four numbers will appear UST Firmware UST Firmware UST Firmware UST Firmware 4 25 016 sample number Welding Database Welding Database Welding...

Page 52: ...this happens Step 6 Step 6 Step 6 Step 6 Press and release the STORE button to return to the main screen 2 4 2 4 2 4 2 4 1 3 5 1 3 5 1 3 5 1 3 5 6 6 6 6 Editing a Job Editing a Job Editing a Job Editi...

Page 53: ...Step 6 Step 6 Step 6 Step 6 Use the process select up arrow to cycle through the parameters until r appears in the display Step 7 Step 7 Step 7 Step 7 Ensure that no one is touching any part of the we...

Page 54: ...ire feed button D on the front panel The display should change to St 1 Step 7 Step 7 Step 7 Step 7 Open all drive rolls on the wire feeder and torch Step 8 Step 8 Step 8 Step 8 Press the torch trigger...

Page 55: ...teel PPU 60 PPU 60 PPU 60 PPU 60 Fronius PT Drive 045 steel PPU 61 PPU 61 PPU 61 PPU 61 Fronius PT Drive 030 steel Processes PPU Additional Information PPU Error Codes PPU Error Codes PPU Error Codes...

Page 56: ...ep 8 Step 8 Step 8 Press the Store button A twice to return to main display Cooler Verification Cooler Verification Cooler Verification Cooler Verification Step 1 Step 1 Step 1 Step 1 On the front pan...

Page 57: ...heck the left most display D It should be 1 0 amps 20 A A A A B B B B C C C C D D D D Step 1 Step 1 Step 1 Step 1 Press the Parameter Selection button A until the voltage indicator B is lit Step 2 Ste...

Page 58: ...13 SEP 12 Battery Charging Systems Welding Technology Solar Electronics Use and Operation TsT Parameter Reference MIG 55 55 55 55...

Page 59: ...13 SEP 12 Battery Charging Systems Welding Technology Solar Electronics Use and Operation TsT Parameter Reference Stick 56 56 56 56...

Page 60: ...being the maximum Control Knob Control Knob Control Knob Control Knob Voltage This control will vary the voltage the machine is set for and will directly change the value displayed on the 3 digit disp...

Page 61: ...ustment Controls and Indicators Weld Adjustment Controls and Indicators These controls and indicators are used to display and change the weld adjustment values The three segment display will show the...

Page 62: ...rigger to begin welding at the starting value release trigger to change to normal power value press and hold for ending power value and finally release trigger to stop the weld Operating Point Save Se...

Page 63: ...ch longer than the standard rolls Four points of contact on the wire red dots Professional H Rolls Professional H Rolls Professional H Rolls Professional H Rolls Tension 1 5 to 2 Heavy duty drive roll...

Page 64: ...to marring or damage from the liner Graphite Graphite Graphite Graphite Combi Combi Combi Combi Combi liners are graphite liners with a brass end The brass is used in the contact tip end for withstan...

Page 65: ...the wire the tip is designed for This size can be either standard US or metric EU Basic sizes used in the US are Fraction Fraction Fraction Fraction Standard Standard Standard Standard Metric Metric...

Page 66: ...nology Solar Electronics Consumables Fixing Sleeve Nozzle Stock Spatter Guard Contact Tip Gas Nozzle Guide Nozzle if used Clamping Nut Clamping Lock Insulating Ring if used Teflon Liner Combi Liner St...

Page 67: ...ide Nozzle if used Clamping Nut Clamping Lock Insulating Ring if used Teflon Insert Liner Combi Insert Liner Steel Insert Liner Ceramic Insert Liner Brass Insert Liner Teflon Liner Graphite Liner Stee...

Page 68: ...Tip Gas Nozzle Guide Nozzle if used Clamping Nut Clamping Lock Insulating Ring if used Teflon Insert Liner Combi Insert Liner Steel Insert Liner Ceramic Insert Liner Brass Insert Liner Teflon Liner Gr...

Page 69: ...tion 2 Be sure liner is fully inserted in the whip and remove all of the free play 3 Cut liner flush with the diffuser and remove any burrs present after cutting 4 Contact tip should apply pressure ag...

Page 70: ...13 SEP 12 Consumables Liner Installation Procedure Feeder End of Torch Fully insert inner liner Cut liner flush Install clamp nut install wire guide 68 68 68 68...

Page 71: ...1 1613 Feeder Roll 035 9 42 0001 0385 Feeder Roll 045 1 2 42 0001 3053 Feeder Roll 052 1 4 42 0001 0386 Feeder Roll 1 16 1 6 TS TPS KD Flux cored K groove 42 0001 0404 Feeder Roll 045 1 2 42 0001 0352...

Page 72: ...re CB 035 9 Contact Tip center bore CB 045 1 2 Contact Tip center bore CB 056 1 4 Contact Tip center bore CB 1 16 1 6 6 42 0001 5128 Gas Nozzle standard AL 5000 1 42 0100 1205 Insulating Ring AL 5000...

Page 73: ...0001 5052 42 0001 5053 42 0001 3485 Contact Tip center bore CB 035 9 Contact Tip center bore CB 045 1 2 Contact Tip center bore CB 056 1 4 Contact Tip center bore CB 1 16 1 6 5 42 0001 5096 Gas Nozzl...

Page 74: ...tact Tip center bore CB 056 1 4 Contact Tip center bore CB 1 16 1 6 5 42 0001 5532 Gas Nozzle standard Robacta 5000 1 42 0001 2970 Fixing Sleeve 2 42 0100 1016 Insulating Ring Robacta 5000 3 42 0001 5...

Page 75: ...16 1 6 6 44 0350 1788 44 0350 1798 Torch Body Insert combi 045 1 2 Torch Body Insert combi 1 16 1 6 7 44 0350 1806 44 0350 1838 Torch body Insert ceramic 045 1 2 Torch body Insert ceramic 1 16 1 2 Pr...

Page 76: ...1 6 4 42 0400 1024 Clamping Nut threaded 5 42 0001 5412 Clamping Piece 6 44 0350 1788 44 0350 1798 Torch Body Insert combi 045 1 2 Torch Body Insert combi 1 16 1 6 7 44 0350 1806 44 0350 1838 Torch b...

Page 77: ...2 Wire Buffer Insert 1 16 1 6 7 44 0350 1788 44 0350 1798 Torch Body Insert combi 045 1 2 Torch Body Insert combi 1 16 1 6 8 44 0350 1806 44 0350 1838 Torch body Insert ceramic 045 1 2 Torch body Inse...

Page 78: ...all interfaces Models Discrete I O Rob 3000 4000 5000 5000 OC Each interface signal is indivually wired into the robot automation controller Source sync signal for on off based interface signals 0 10...

Page 79: ...additional LocalNet connect is provided that connects directly to the ROB 5000 If no LocalNet connection is available a passive distributor 4 100 261 may be used Power source functions are controlled...

Page 80: ...lding process Once this signal goes low the post welding process crater fill and gas post flow will then start automatically Welding Mode This is a combination of three signals joined together to form...

Page 81: ...will form an analog value that will measure the welders wire feed speed or current between 0 and 100 with 0 being the lowest welding value and 100 being the maximum This input is only used when weldi...

Page 82: ...ignal will not be active is a STOP or E STOP is displayed on the power source for any reason Arc Stable This signal is sent to the robot once an arc has been started AND that arc is within acceptable...

Page 83: ...g inputs There are NO job program options CC CV Mode This allows the power source to be operated in a constant current or constant voltage mode TIG Mode This allows the power source to be operated in...

Page 84: ...welder in job mode call out a job number and control the weld travel speed Everything else is typically handled by the welder itself Robot movement usually based off of the process active signal This...

Page 85: ...capable of and the travel speed The welder is only responsible for creating and controlling the arc Robot movement usually based off of the process active signal This mode will only have weld paramet...

Page 86: ...ome basic information including status name IP address and current connection The machine specific screen is made up of several different tabs The core software includes the Overview and Panel tabs Ad...

Page 87: ...e job sets are NOT compatible with other Backup Restore tools The license button is used to see which software options are loaded into the machine Unlocked options are displayed as green locks while l...

Page 88: ...d but also loaded from should the need arise The Docu tab allows you to monitor the weld parameters of one or more welders AFTER they have completed a weld The parameters can be customized based on th...

Page 89: ...in base materials or parts can make the predetermined settings no longer the best viable settings to produce quality welds When trouble shooting weld quality it is very important to go through a numbe...

Page 90: ...Further troubleshooting needed Err IP Primary transformer over current detected Check the secondary power module and the BPS board Err PE Voltage detected on earth ground Check for isolation between w...

Page 91: ...r contaminates Consumables should be checked regularly and cleaned changed as needed Consumables include Gas Nozzle free of spatter build up and excessive conal damage Torch Tip free spatter build up...

Page 92: ...mem error EFD 8 x Main motor or push pull motor current errors EFD 9 x Main motor voltage errors EFD 10 x Internal logic errors between the SR xx and the PM xx board EFD 11 x Main motor and push pull...

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