Fronius CMT Twin Operating Instructions Manual Download Page 90

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Install the torch
hosepack

42 Nm

4 Nm

IMPORTANT!

When connecting the torch hosepack, pay attention to marks 1 and 2 on

the torch hosepack and on the wirefeeder.

1 2

Connect coolant hoses from the welding
torch according to the color markings on
the coolant supply and coolant return con-
nections

Summary of Contents for CMT Twin

Page 1: ...ine free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy TPS i Robotics welding system TWIN Push TWIN Push Pull TWIN CMT EN US Operating instruct...

Page 2: ......

Page 3: ...fety Inspection 16 Disposal 16 Safety symbols 17 Data backup 17 Copyright 17 General information 19 General 21 Application areas 21 Requirements 22 System requirements and minimum equipment TWIN Push...

Page 4: ...meters 58 TWIN process parameters 58 Pulse synchronization ratio 58 Lead trail phase shift 59 Trail ignition delay 59 Welding parameter standard values for fillet welds 61 Standard values for welding...

Page 5: ...oning 102 Requirements 102 Commissioning start of welding 102 Installation and commissioning TWIN Push Pull CMT 103 Safety Installation and Commissioning 105 Safety 105 Insulated Guiding of the Wire E...

Page 6: ...pressure 135 Commissioning 136 Requirements 136 Commissioning start of welding 136 Troubleshooting Maintenance and Disposal 137 Troubleshooting 139 Safety 139 Troubleshooting 139 Displayed Error Codes...

Page 7: ...e operating company Inefficient operation of the equipment All persons involved in the commissioning operation maintenance and servicing of the device must Be suitably qualified Have knowledge of weld...

Page 8: ...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 Ambient air free of dust acids corrosive gases or substanc...

Page 9: ...helmet Cuffless pants Protective clothing involves the following Protecting the face and eyes from UV radiation heat and flying sparks with a face guard featuring a regulation compliant filter Wearin...

Page 10: ...o welding is taking place close the valve of the shielding gas cylinder or the main gas supply Danger from Fly ing Sparks Flying sparks can cause fires and explosions Never undertake welding near flam...

Page 11: ...tem with ground conductor contact for proper operation Operation of the device on a grid without a ground conductor and on a socket without a ground conductor contact is only permitted if all national...

Page 12: ...ce complies with the standard limit values for emis sions it may affect the application area for which it was designed e g when there is sensitive equipment at the same location or if the site where t...

Page 13: ...rom the body devices with wirefeeder and use suitable protective goggles Do not touch the workpiece during or after welding risk of burns Slag may fly off cooling workpieces Therefore also wear regula...

Page 14: ...condensation point 20 C Max oil content 25 mg m Use filters if necessary Danger from Shielding Gas Cylinders Shielding gas cylinders contain compressed gas and may explode if damaged Shielding gas cy...

Page 15: ...nce of 0 5 m 1 ft 7 69 in to allow cooling air to circulate unhindered Take care to ensure that the applicable national and regional guidelines and accident prevention regulations are observed when tr...

Page 16: ...them or that they satisfy safety requirements 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 man...

Page 17: ...U The full text of the EU Declaration of Conformity is available on the follow ing website http www fronius com Devices marked with the CSA test mark satisfy the requirements of the relevant stand ard...

Page 18: ...18...

Page 19: ...General information 19...

Page 20: ...20...

Page 21: ...t welds and profiles in vehicle manufacturing for lap joints and wheel rim welding in automotive engineering in container construction for butt welds longitudinal seams lap joints and circumfer ential...

Page 22: ...PowerLiner max 10 m 8 2 x power source TPS 500i 600i Welding Package Pulse firmware official_TPSi_2 2 3 20789 15069 ffw and above 9 Cooling unit CU 2000i Pro MC 2 part 10 TWIN Controller RI FB Pro i T...

Page 23: ...rmware official_robpro 1 8 0 11 2 x grounding cable System require ments and min imum equipment TWIN CMT 1 TWIN welding torch MTB 2x500 A PA or PB TWIN Basic Kit xx 2 CrashBox 3 TWIN hosepack with TWI...

Page 24: ...version min 2 2 3 TWIN Push or min 3 2 0 TWIN Push Pull CMT Both power sources must have the same software status The IP addresses must be set correctly on the power sources Dimensioning of the robot...

Page 25: ...cables Shared grounding cable grounding bridge Grounding cable with bifilar winding Grounding cable coiled Further information on connecting the grounding cable can be found from page 97 Note about th...

Page 26: ...rail power source In the TWIN welding process the two power sources are referred to as the lead power source and trail power source The lead power source is defined by the welding direction During pul...

Page 27: ...controls to TWIN welding torch change sta tion 6 Power source 1 TPS 500i 600i WP Pulse RI FB Pro i TWIN Controller cooling unit CU 2000i Part 1 remote control RC Panel Pro TU Podium screwed in place...

Page 28: ...ystem overview 1 2 1 2 1 2 1 2 1 2 1 2 3 6 18 19 17 15 12 13 11 8 21 22 15 24 4 5 10 7 9 10a 20 16 14 25 23 1 Robot controls 2 Connection cable from robot controls to RI FB Pro i TWIN Controller 3 Con...

Page 29: ...Welding wire drum 2 Depending on the application two WFi R REEL unwinding wirefeeders can be used additionally for optimal wirefeeding 18 Wirefeeding hose 2 WFi R wire buffer 2 19 Control cable wire b...

Page 30: ...The balancer mounting Y piece can also be used instead of the robot support Y piece 30...

Page 31: ...System components 31...

Page 32: ...32...

Page 33: ...intended exclusively for wirefeeding in automated MIG MAG welding in combination with Fronius system components Any other use does not constitute proper use The manufacturer accepts no liability for a...

Page 34: ...in 39 118 ipm 360A 100 450A 60 500A 40 I2 1 2 A I11 U11 60 V U12 I12 0 5 A 24 V IEC 60 974 5 10 Cl A IP 23 www fronius com Ser No Part No Do not use the functions described here until you have fully r...

Page 35: ...Do not reach into rotating gears of the wire drive or into rotating drive parts Covers and side parts must only be opened removed during maintenance and repair work Gears Feed rollers Wirespools and...

Page 36: ...lectric 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 are...

Page 37: ...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 wear a shirt col lar with button Use a welding helme...

Page 38: ...terconnecting hosepack W water cooled interconnecting hosepack The interconnecting hosepacks connect the power sources to the TWIN wirefeeder or the two robot wirefeeders In TWIN welding systems one w...

Page 39: ...welding torch For TWIN Push Pull and TWIN CMT applications the TWIN drive unit is integrated into the torch hosepack Scope of supply MHP 2x500i R W FSC hosepack TWIN Push MHP 2x450i RD W FSC hosepack...

Page 40: ...for a low force deflection with large deflection path in the event of a crash The clamp system is used to hold the TWIN welding torch If a 45 torch body is used the clamp system positions the welding...

Page 41: ...part 4 Bellows 5 Cylinder head screws M4 x 16 mm 6 Magnetic ring Mounted on bellows 4 on delivery NOTE Do not assemble the CrashBox i holder 1 and magnetic ring 6 before installing on the robot It is...

Page 42: ...robot welding torch transfers the arc power to the workpiece The TWIN welding torches are designed for use with the CrashBox i XXL and are available in two versions PA with contact tips arranged one...

Page 43: ...red for each angle 4 OPT i MTB TWIN 4 0 sym 4 101 105 CK 8 OPT i MTB TWIN 8 0 sym 4 101 108 CK 11 5 OPT i MTB TWIN 11 5 sym 4 101 102 CK NOTE The tilt angle dependent dimensions of the welding torch c...

Page 44: ...44...

Page 45: ...Welding Technology Aspects 45...

Page 46: ...46...

Page 47: ...volume 30 l min set power source 1 to 15 l min and power source 2 to 15 l min TWIN welding torch TWIN mode both solenoid valves are switched TWIN welding torch single wire mode both solenoid valves ar...

Page 48: ...ox 100 115 for aluminum applica tions Stick out SO 1 2 3 4 5 D Stick out SO and distance of the wire electrodes depending on the diameter D of the wire electrode D mm inch SO mm inch 1 0 0 039 15 0 59...

Page 49: ...cess the trail wire electrode moves away from the workpiece and waits for the start signal of the lead wire electrode welding start delay 4 As soon as the trail wire electrode receives the start signa...

Page 50: ...al 3833 Steel 1 2 mm M21 Ar 15 20 CO2 TWIN PCS 3834 Steel 1 2 mm M20 Ar 5 10 CO2 TWIN PCS 3837 Steel 1 2 mm M21 Ar 15 20 CO2 TWIN multi arc 3838 Steel 1 2 mm M20 Ar 5 10 CO2 TWIN multi arc 3840 Steel...

Page 51: ...i arc 4024 CrNi19 1 2 mm M12 Ar 2 5 CO2 TWIN universal 4026 CrNi19 1 2 mm M12 Ar 2 5 CO2 TWIN PCS 4027 CrNi18 1 2 mm M12 Ar 2 5 CO2 TWIN universal 4028 CrNi18 1 2 mm M12 Ar 2 5 CO2 TWIN PCS 4030 NiCrM...

Page 52: ...C CMT Single wire Pulse Standard PMC LSC CMT activation required IMPORTANT There are no TWIN characteristics available for Pulse or Standard welding processes Welding process combinations using Pulse...

Page 53: ...process The relative position of the pulses droplet detachment is stored in the characteristic but can also be freely selected Significantly different outputs at lead and trail wire electrode The TPS...

Page 54: ...d in order to weld with a modified spray arc at the lead wire electrode and a pulsed arc at the trail wire electrode Advantages High penetration by the standard arc of the lead wire electrode Large se...

Page 55: ...for both welding direc tions CMT TWIN CMT TWIN Schematic representation of the material transition In this process variant different characteristics are used for each of the wire electrodes The arc o...

Page 56: ...resentation of the material trans ition for the lead power source t s I A IL IT 0 PMC Pulse t s I A IL IT 0 LSC Standard t s I A IL IT 0 CMT Welding current time curves and schematic representation of...

Page 57: ...N welding torches the solenoid valve for the pausing power source is open The solenoid valve is controlled via the power source PMC Pulse LSC Standard and CMT arcs are possible during single wire weld...

Page 58: ...t the pulse frequency is adjusted in such a way that it differs between lead and trail by an integral multiple Only every second or every third pulse is then executed for the trail arc for example The...

Page 59: ...an be set between the two pulses as a percentage of the period duration The adjustment range of 0 95 corresponds to a phase shift of 0 342 0 Synchronous mode no phase shift between the two process lin...

Page 60: ...on delay of 0 2 seconds can be set The start of the trail arc is synchronized The function can be deactivated In this case the trail arc is ignited immediately and is not synchronized Information on t...

Page 61: ...haracteristic PMC TWIN Universal 3565 a dimension mm Lead L Trail T Wire speed m min Welding current A Welding voltage V Welding speed cm min Energy input kJ cm Deposition rate kg h Sheet thickness mm...

Page 62: ...0 8 0 L T 24 6 10 1 451 259 27 6 27 9 60 19 6 17 7 15 8 5 L T 20 0 10 0 369 238 24 9 27 4 45 20 9 15 3 15 9 0 L T 22 5 9 5 429 258 27 0 26 9 40 26 5 16 4 15 Standard values for welding posi tion PB NO...

Page 63: ...thickness mm Micrograph macro 3 5 L T 18 0 10 0 397 241 23 2 26 2 210 4 4 14 3 3 4 0 L T 20 0 11 0 396 266 27 8 29 7 150 6 8 15 9 6 4 5 L T 23 5 11 2 362 229 24 8 26 5 130 6 8 17 7 6 5 0 L T 20 5 11...

Page 64: ...64...

Page 65: ...Operating controls connections and mechanical components 65...

Page 66: ...66...

Page 67: ...Air in 1 1 2 2 1 2 2 1 8 10 9 11 12 No Function 1 Welding torch connection 1 For connecting the welding torch 2 Current socket with fine thread 1 For connecting the power cable from the interconnectin...

Page 68: ...required gas volume on the pressure regulator 3 Wire return button 1 retract the wire electrode without gas or current 4 Wire threading button 1 for threading the wire electrode into the torch hosepac...

Page 69: ...s retracting the wire electrode if the wire return button is kept pressed down then the speed increases with each further second by 10 m min 393 70 ipm until the preset wire return speed is reached Op...

Page 70: ...ectrode meets a ground earth connection then the wirefeeding is stopped and the wire electrode is retracted again by 1 mm 0 039 in NOTE If there is a ground earth connection with the contact tip befor...

Page 71: ...understand all safety rules and user documentation for this equipment and all system components MHP 2x450i RD W FSC incl WF 60i TWIN Drive W mech anical compon ents 1 2 3 4 5 6 7 8 9 Mechanical compon...

Page 72: ...elected 5 Mode button for selecting the modes 1 2 TWIN External Mode 1 Wire return gas testing and wire threading are only carried out on welding line 1 Mode 2 Wire return gas testing and wire threadi...

Page 73: ...onnecting Hosepack Con nections 1 2 3 4 1 4 3 1 2 W 1 3 4 1 4 3 2 G W water cooled interconnecting hosepack G gas cooled interconnecting hosepack 1 SpeedNet cable 2 Coolant hoses 3 Protective gas shie...

Page 74: ...74...

Page 75: ...Installation and commissioning TWIN Push 75...

Page 76: ...76...

Page 77: ...y rules WARNING An electric shock can be fatal Before starting the described work Switch the power switch on the power source to O Disconnect the power source from the grid Ensure that the power sourc...

Page 78: ...ire electrode that comes into contact with an electrically conductive object during the welding process a lack of insulation between the wire electrode and the grounded housing limit of a robot cell c...

Page 79: ...its on the upright brackets and correctly positioned and fastened in the welding cell The TWIN Controller is available and fastened close to the power sources e g us ing a corresponding bracket direct...

Page 80: ...lding wire drums 2 Connect wirefeeding hoses to the TWIN wirefeeder 3 Insert the feed rollers 4 Close all covers Defining welding lines 1 and 2 on the power sources 1 Switch on power source 2 leave po...

Page 81: ...ons for the wirefeeder holder 1 7x 7 x 6 mm Allen screws Tightening torque 20 Nm 2 6 x 6 mm Allen screws NL wedge lock washers Tightening torque 20 Nm Install hosepack holder 3 2 x 5 mm Allen screws N...

Page 82: ...Installing the side holders for the in terconnecting hosepacks on the robot 1 2 2 1 Installation of the side holder depends on the robot Follow the Installation Instruc tions 82...

Page 83: ...T When connecting the interconnecting hosepacks observe marks 1 and 2 on the interconnecting hosepacks and on the wirefeeder 1 water cooled interconnecting hosepack 2 gas cooled interconnecting hosepa...

Page 84: ...ing hosepack 2 gas cooled interconnecting hosepack NOTE If the interconnecting hosepack is laid incorrectly it can have a significant influ ence on the welding results a stable welding process is not...

Page 85: ...i 2 power source 2 HP CON 1 interconnecting hosepack 1 HP CON 2 interconnecting hosepack 2 Connecting the TWIN Controller to the robot con trols 1 1 R C 1 R C robot controls NOTE For detailed informat...

Page 86: ...on the robot 1 Observe the torques when fitting the robot flange Max tightening torque for screws with 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 1...

Page 87: ...1 Observe the torques when fitting the robot flange Max tightening torque for screws with 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...

Page 88: ...43 lb ft 2 6 Nm 4 43 lb ft 3 Installing the in ner liner in the torch hosepack NOTE So that the inner liner can be correctly installed lay the hosepack out straight when installing the inner liner 1 1...

Page 89: ...at the front in the hosepack IMPORTANT The screws for securing the inner liners must not be loosened 1 2 2 2x 5 2x 6 Screw the clamping nipple onto the inner liner up to the stop The inner liner need...

Page 90: ...connecting the torch hosepack pay attention to marks 1 and 2 on the torch hosepack and on the wirefeeder 1 3 1 1 4 1 2 5 Connect coolant hoses from the welding torch according to the color markings o...

Page 91: ...Prepare torch body with steel inner liner 1 2 NOTE The coupling area of the torch body must always be free of oil grease and dust and be dry 3 4 5 6 91 EN US...

Page 92: ...7 8 9 10 11 12 92...

Page 93: ...Installing wearing parts in the TWIN welding torch 1 6 2 2 4 9 8 3 5 7 1 NOTE For detailed information refer to the In stallation Instructions 42 0410 2487 OPT i TWIN 0 4 8 11 5 93 EN US...

Page 94: ...all the torch body coupling NOTE The coupling areas between the torch body coupling and torch body must always be free of oil grease and dust and be dry 1 2 3 BY2 0201 4863 1 2 0 N m 2 1 42 0411 1315...

Page 95: ...and closes correctly check the manual locking of a torch body in the torch body coupling Flawless operation of the interchangeable coupling can only be guaranteed with a vertic al alignment facing do...

Page 96: ...1 2 4 1 5 96...

Page 97: ...Connect the grounding cable NOTE If the grounding cables are laid incorrectly it can have a significant influence on the welding results a stable welding process is not guaranteed As far as possible m...

Page 98: ...ers which match the wire electrode An overview of the available feed rollers and their possible uses can be found in the Spare Parts Lists Inserting chan ging feed rollers CAUTION Danger due to feed r...

Page 99: ...ct the ground earth connection between the welding system and workpiece CAUTION Danger of damage to the welding torch due to sharp edged end of the wire elec trodes Thoroughly deburr the end of the wi...

Page 100: ...at the tip of the welding torch points away from the face and body Wear suitable protective goggles Do not point the welding torch at people Ensure that the wire electrodes do not touch any electrical...

Page 101: ...values on the sticker on the protective cover to adjust the contact pressure Contact pressure standard values steel rollers Steel 4 5 CrNi 4 5 Al 0 5 1 5 Tubular covered electrodes 2 3 Contact pressur...

Page 102: ...wirefeeder or to the TWIN drive unit Feed rollers corresponding to the wire electrodes to be welded must be inserted in the wirefeeder or the TWIN drive unit Wire electrodes must be threaded in Contac...

Page 103: ...Installation and commissioning TWIN Push Pull CMT 103...

Page 104: ...104...

Page 105: ...y rules WARNING An electric shock can be fatal Before starting the described work Switch the power switch on the power source to O Disconnect the power source from the grid Ensure that the power sourc...

Page 106: ...re electrode that comes into contact with an electrically conductive object during the welding process a lack of insulation between the wire electrode and the grounded housing limit of a robot cell ch...

Page 107: ...are stable on a flat and solid surface The system components have been tested according to at least protection class IP 20 This means Protection against the penetration of solid foreign bodies with a...

Page 108: ...on the Y piece or mount the support Y piece on the robot 2 Mount the side holder on the robot Only for TWIN CMT applications 3 Install wire buffer on the wire buffer holder 4 Install wire buffer with...

Page 109: ...Connect wirefeeding hoses B to the robot wirefeeders 4 Connect wirefeeding hoses B to the wire buffers 5 Connect control lines to the robot wirefeeders and to the wire buffers 6 Connect wirefeeding h...

Page 110: ...6 If necessary carry out system calibration e g if there is a WF REEL unwinding wirefeeder in the system 7 Define the lead trail signal on the robot controls 8 Set TWIN parameters 110...

Page 111: ...nting the balancer mounting on the Y piece Mounting the bal ancer mounting on the Y piece The balancer mounting Y piece is mainly used for TWIN Push Pull systems without wire buffers 1 2 3 4 1 111 EN...

Page 112: ...Mounting the support Y piece on the robot Mounting the support Y piece on the robot 1 2 2 2 2 1 Installation of the support Y piece depends on the robot Follow the Installation Instructions 112...

Page 113: ...robot Installing the side holder on the ro bot The side holder is mainly used for TWIN Push Pull systems without wire buffers 1 2 2 1 Installation of the side holder depends on the robot Follow the In...

Page 114: ...Installing wire buffers on the robot TWIN CMT in stalling wire buf fers on the robot Installation of the side holder depends on the robot Follow the Installation Instructions 1 2 3 114...

Page 115: ...4 NOTE For detailed information on the wire buffer refer to the Operating Instructions 42 0410 1254 wire buffer 115 EN US...

Page 116: ...o the wirefeeder IMPORTANT When connecting the interconnecting hosepacks observe marks 1 and 2 on the interconnecting hosepacks and on the wirefeeder 1 water cooled interconnecting hosepack 2 gas cool...

Page 117: ...hosepack 2 gas cooled interconnecting hosepack NOTE If the interconnecting hosepack is laid incorrectly it can have a significant influ ence on the welding results a stable welding process is not guar...

Page 118: ...TPSi 2 power source 2 HP CON 1 interconnecting hosepack 1 HP CON 2 interconnecting hosepack 2 Connecting the TWIN Controller to the robot con trols 1 1 R C 1 R C robot controls NOTE For detailed infor...

Page 119: ...e robot 1 Observe the torques when fitting the robot flange Max tightening torque for screws with 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...

Page 120: ...he robot 1 Observe the torques when fitting the robot flange Max tightening torque for screws with 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...

Page 121: ...t is already mounted on the torch hosepack on delivery To make things simpler the TWIN drive unit is shown without the torch hosepack in the following illustrations 1 M6 M8 M6 Tightening torque M6 10...

Page 122: ...pin 2x Tightening torque 25 Nm 18 44 lb ft 4 5 6 Connect the CrashBox cable to the drive unit and to the CrashBox Mounting the Y piece from the torch hosepack on the robot support Y piece 3 2 1 1 1 2...

Page 123: ...osepacks during any movement in a robot axis Route hosepacks in a loop Connecting the torch hosepack to the wirefeeder IMPORTANT When connecting the torch hosepack pay attention to marks 1 and 2 on th...

Page 124: ...gs are mounted in vulnerable areas Bridging of cracks or damaged areas on the corrugated protective hose Connection of Y piece to the corrugated protective hose The anti kink protection rings may only...

Page 125: ...Prepare torch body with steel inner liner 1 2 NOTE The coupling area of the torch body must always be free of oil grease and dust and be dry 3 4 5 6 125 EN US...

Page 126: ...7 8 9 10 11 12 126...

Page 127: ...be free of oil grease and dust and be dry 1 Carry out a visual inspection to check that the springs are present 2 Insert inner liner pieces with a length of 74 mm into the TWIN drive unit The inner l...

Page 128: ...TWIN drive unit NOTE The coupling areas between the torch body coupling and torch body must always be free of oil grease and dust and be dry 5 1 4 2 1 1 3 6 6 6 3 3 1 The next steps are the same as f...

Page 129: ...and closes correctly check the manual locking of a torch body in the torch body coupling Flawless operation of the interchangeable coupling can only be guaranteed with a vertic al alignment facing do...

Page 130: ...1 2 4 1 5 130...

Page 131: ...eeder press white button 2 Fit the collet 3 Insert the inner liner until it is visible at the sight hole of the drive unit 4 Cut the inner liner flush to length 5 Fit the inlet nozzle to the brass sec...

Page 132: ...y Connect the grounding cable NOTE If the grounding cables are laid incorrectly it can have a significant influence on the welding results a stable welding process is not guaranteed As far as possible...

Page 133: ...wire alloy to be welded NOTE Danger due to deficient feed rollers This can result in poor quality weld properties Only use feed rollers which match the wire electrode An overview of the available fee...

Page 134: ...commissioning Connecting wirefeeding hoses Connect the wirefeeding hoses in the same way as on the TWIN Push system see page 99 The following wirefeeding hoses are required Wire drum robot wirefeeder...

Page 135: ...re in such a way that the wire electrode is not deformed but nevertheless ensures proper wirefeeding Use the specified standard values on the sticker on the protective cover to adjust the contact pres...

Page 136: ...wirefeeder or to the TWIN drive unit Feed rollers corresponding to the wire electrodes to be welded must be inserted in the wirefeeder or the TWIN drive unit Wire electrodes must be threaded in Contac...

Page 137: ...Troubleshooting Maintenance and Disposal 137...

Page 138: ...138...

Page 139: ...s and components involved so they cannot be switched back on After opening the device use a suitable measuring instrument to check that electric ally charged components such as capacitors have been di...

Page 140: ...pack faulty or not connected correctly Check interconnecting hosepack No communication with the robot controls Check the communication with the robot controls Cause Remedy Cause Remedy No welding curr...

Page 141: ...ck coolant level coolant flow rate coolant contamination etc For more detailed information refer to the Operating Instructions for the cooling unit Cause Remedy Cause Remedy Poor quality weld properti...

Page 142: ...nected correctly Check the connection between the torch hosepack and the TWIN wirefeed er if the torch hosepack is connected correctly inform the service team Cause Remedy 16768 Welding process does n...

Page 143: ...Check that power source 1 is connected to port 1 and power source 2 is connected to port 2 on the TWIN Controller Cause Remedy 18232 It is not possible to thread the wire or weld in TWIN mode Single w...

Page 144: ...ices and components involved so they cannot be switched back on After opening the device use a suitable measuring instrument to check that electric ally charged components such as capacitors have been...

Page 145: ...air nozzle too close to electronic parts Open covers dismantle device side panels and blow the inside of the device clean with dry reduced compressed air After cleaning restore the system to its origi...

Page 146: ...146...

Page 147: ...Technical data 147...

Page 148: ...148...

Page 149: ...ing gas 7 bar 101 53 psi Coolant Original Fronius Maximum pressure of coolant 5 bar 72 53 psi Wire speed 1 30 m min 39 37 1181 10 ipm Wire drive 4 roller drive Recommended wire diameter 1 2 1 6 mm 0 0...

Page 150: ...x Wire electrode distance H Height Angle of curvature L Length 11 5 30 PB PA 45 PB PA SO mm L1 mm s mm x mm L mm H mm L mm H mm 15 60 56 10 44 7 43 327 14 82 00 336 92 136 75 16 61 55 10 44 7 23 328...

Page 151: ...22 67 89 13 65 10 58 333 49 85 67 342 27 140 42 23 68 89 13 65 10 44 334 35 86 17 344 13 140 92 4 0 30 PB PA 45 PB PA SO mm L1 mm s mm x mm L mm H mm L mm H mm 15 61 24 17 32 16 27 327 73 82 34 337 51...

Page 152: ...re diameter 0 8 1 2 mm 0 032 0 047 inches MTB 330i W R TX TXM Welding current at 10 min 40 C M21 EN 439 C1 EN 439 100 ED 330 A 100 ED 330 A Wire diameter 0 8 1 6 mm 0 032 0 063 inches MTB 400i W R TX...

Page 153: ...EN 439 C1 EN 439 100 ED 500 A 100 ED 500 A Wire diameter 1 0 1 6 mm 0 039 0 063 inches MTB 700i W R TX TXM Welding current at 10 min 40 C M21 EN 439 C1 EN 439 100 ED 700 A 100 ED 500 A Wire diameter...

Page 154: ...m 5 ft 1 02 in 1 75 m 5 ft 8 90 in 2 3 m 7 ft 6 55 in 3 3 m 10 ft 9 92 in 1200 W 1250 W 1300 W 1400 W 1700 W Minimum coolant flow rate 1 l min 0 26 gal US min Min coolant pressure 3 bar 43 50 psi Max...

Page 155: ...C1 EN 439 100 ED 2 x 450 A standard 100 ED 2 x 280 A CMT 100 ED 2 x 450 A standard 100 ED 2 x 360 A CMT Wire diameter 0 8 1 6 mm 0 03 0 06 inches Minimum coolant flow Qmin 1 l min 0 26 gal US min Min...

Page 156: ...D Duty cycle HP 70i HP PC Cable HD 70 Welding current at 10 min 40 C 104 F 60 ED 600 A 100 ED 500 A ED Duty cycle HP 95i Welding current at 10 min 40 C 104 F 40 ED 500 A 60 ED 450 A 100 ED 360 A ED Du...

Page 157: ...tance diagram Item number 44 0350 3380 Degree of repeatability 1 0 05 mm a Triggering torques in x y direction See table on the next page Maximum displacement in x y direction 45 Weight 1250 g Dimensi...

Page 158: ...x i 44 0350 3589 CrashBox i PAP 44 0350 3663 distance to the robots flange mm 125 CrashBox i XXL 44 0350 3380 CrashBox 44 0350 3760 The values listed only apply when in a static state x y direction 45...

Page 159: ...159 EN US...

Page 160: ...Froniusstra e 1 4643 Pettenbach Austria contact fronius com www fronius com Under www fronius com contact you will find the adresses of all Fronius Sales Service Partners and locations spareparts fro...

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