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Welding Technology

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INERT GASES

INERT GASES INERT MIXED GASES

INERT MIXED GASES

Argon

Ionizes easily, deep fusion penetration, finger-shaped, low cost to manufacture (filtered out of ambient air⁄.

Helium

Difficult to ionize; high heat conductivity; deep, wide penetration; fluid weld pool; good wetting; more expensive

than argon (filtered out 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 MIXED GASES

ACTIVE MIXED GASES

Reacts with the material, deeper reduced-pore fusion penetration, tends towards spattering, cheap to manufacture

Argon CO2

Combines advantages of its components, the most used gas combination for unalloyed steel and chrome-nickel

Argon Oxygen

Arc more stable, reduced surface tension of weld pool, pore-sensitive, Oxygen 8% maximum

Gas Characteristics

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28 ----

Weld Process

Содержание CMT-A 4000 MV

Страница 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...

Страница 2: ......

Страница 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...

Страница 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...

Страница 5: ...2 2 2 2...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 39: ...36 36 36 36...

Страница 40: ...37 37 37 37...

Страница 41: ...38 38 38 38...

Страница 42: ...39 39 39 39...

Страница 43: ...40 40 40 40...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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