Fronius TPS 2700 MV, TPS 4000 MV, TS 5000 MV, TPS 5000 MV, CMT-A 4000 MV Operation/reference Manual
...
13 SEP 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 Equipment
13 SEP 12
/ Battery Charging Systems / Welding Technology / Solar Electronics
General Information
Table of Contents
Conversion Charts page 1
3d-Drawing page 2
Weld System
Component Layout page 3
Configurations page 4
Power Source
Models page 7
Nameplate page 9
Technical Specifications page 10
Connections and Controls page 11
Wire Feeder
Models page 15
Motor-plate page 17
Connections and Controls page 18
Welding Torch page 22
Cooler page 23
Weld Process
Overview page 24
MIG, short circuit page 26
MIG, pulse page 27
Gas Characteristics 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 42
Front Panel, CMT page 45
Quick Reference Sheet, TsT page 55
Front Panel, TsT page 57
Processes
Synergic Lines page 48
Jobs page 49
Resistance Test page 50
Push-Pull Alignment page 51
Cooler Verification page 53
Output Tests page 54
Consumables
Drive Rolls page 61
Liners page 62
Contact Tips page 63
Torch Breakdown page 64
Changing a Liner page 67
Part Numbers page 69
Interface
Models page 76
General Information page 77
Inputs/Outputs page 78
Signal Interaction page 82
Fronius Xplorer page 85
Basic Troubleshooting page 87
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---- 1
1 1
1 ----
General Information
Conversion Charts
Fraction* Decimal* Millimeters Wire Guage**
2/64 .030 0.8 20
- -- .035 0.9 19
- - - .040 1.0 18
3/64 .045 1.2 17
- - - .052 1.4 16
1/16 .062 1.6 14
- - - .071 1.8 13
5/64 .078 2.0 12
3/32 .094 2.4 11
7/64 .109 2.8 9
¼ .250 6.4 2
1/2 .500 12.7 3/4 .750 19.1 -
1 1.00 25.4 -
Meters Feet
0.25 0.8
0.50. 1.6
0.75 2.5
1.00 3.1
1.25 4.1
1.50 4.9
1.75 5.7
2.0 6.6
2.5 8.2
3.0 9.8
3.5 11.5
4.0 13.1
4.5 14.8
5.0 16.4
10 32.8
15 49.2
20 65.6
25 82.0
30 98.4
35 114.8
40 131.2
45 147.6
50 164
55 180.4
60 196.8
65 213.3
70 229.6
75 246.0
Inch/min Mm/sec Cm/min
5 2.12 12.70
10 4.23 25.40
15 6.35 38.10
20 8.47 50.80
25 10.58 63.50
30 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 38.10 228.60
95 40.21 241.30
100 42.33 254.00
105 44.45 266.70
110 46.56 279.40
115 48.68 292.10
120 50.80 304.80
125 52.91 317.50
130 55.03 330.20
135 57.15 342.90
140 59.26 355.60
145 61.38 368.30
150 63.50 381.00
Conversion Factors
Inch/min to Mm/sec x 0.4233
Inch/min to Cm/min x 2.54
Mm/sec to Inch/min x 2.3622
Cm/min to Inch/min x 0.3937
Ft3/hour to L/min x 0.4719
L/min to Ft3/hour x 2.1189
Meter to Feet x 3.2808
Feet to Meter X 0.3048
Ft3/hour L/min
5 2.36
10 4.72
15 7.08
20 9.44
25 11.80
30 14.16
35 16.52
40 18.88
45 21.24
50 23.60
55 25.95
60 28.31
65 30.67
70 33.03
75 35.39
80 37.75
85 40.11
90 42.47
95 44.83
100 47.19
105 49.55
110 51.91
115 54.27
120 56.63
125 58.99
130 61.35
135 63.71
---- 2
2 2
2 ----
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/ Battery Charging Systems / Welding Technology / Solar Electronics
GGGG
HHHH
EEEE
FFFF
DDDD
IIII
JJJJ
FFFF
CCCC
JJJJ
DDDD
DDDD
AAAA
1111
10
1010
10
2222
3333
4444
9999
8888
5555
DDDD
CCCC
7777
DDDD
6666
11
1111
11
BBBB
DDDD
Components consist of
----1111---- Power Source
----2222---- Wire Feeder
----3333---- Torch
----4444---- Work Surface/Fixture
----5555---- Main Power (230 or 460V AC⁄
----6666---- Front Panel
----7777---- Gas Tank
----8888---- Remote Control Unit (RCU⁄
----9999---- Robot Interface
----10
1010
10---- Cooler
----11
1111
11---- PC Interface Tool
Component Layout
Weld System
Component Management
Controlled by LocalNet (Fronius communication
protocol⁄.
Plug and play configuration
Provides both operating power and
communication to peripheral components.
Connections consist of
----AAAA---- Ground Connection
----BBBB---- Main Power (230 or 460V AC⁄
----CCCC---- Gas
----DDDD---- LocalNet
----EEEE---- Motor Voltage (55V DC⁄
----FFFF---- Main Current
----GGGG---- Pump Voltage (230 or 400V AC⁄
----HHHH---- Data Lines (non LocalNet⁄
----IIII---- Coolant Out
----JJJJ---- Coolant In
---- 3
3 3
3 ----
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Weld System
Data
Control Voltages
Welding Current
Coolant Lines
Data
Control Voltages
Welding Current
Shielding Gas
Wire
Coolant Lines
Power
PowerPower
Power----Source Mounted Wire Feeder
Source Mounted Wire FeederSource Mounted Wire Feeder
Source Mounted Wire Feeder
The wire feeder can be mounted directly on top of the welding 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 source, shielding
gas and coolant are made through the Interconnecting Hose Pack.
The connections between the wire feeder and welder can vary in
length. This allows the operator to relocate the wire feeder if
needed.
Length of the torch and the interconnecting hose pack must be
taken into consideration when determining if the system should be
a push or push/pull orientation.
---- 4
4 4
4 ----
Configurations
13 SEP 12
/ Battery Charging Systems / Welding Technology / Solar Electronics
Weld System
Data
Control Voltages
Welding Current
Shielding Gas
Wire
Coolant Lines
Remote Mounted Wire Feeder
Remote Mounted Wire FeederRemote Mounted Wire Feeder
Remote Mounted Wire Feeder
The wire feeder is placed 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 to torch end distances to be reduced which can reduce the need for a push/pull system.
The wire feeder can be kept within a restricted area while the welder is easily accessible for parameter
monitoring and changes.
Data
Control Voltages
Welding Current
Coolant Lines
---- 5
5 5
5 ----
Configurations
13 SEP 12
/ Battery Charging Systems / Welding Technology / Solar Electronics
Weld System
Data
Control Voltages
Welding Current
Shielding Gas
Wire
Coolant Lines
Robot Mounted Wire Feeder
Robot Mounted Wire FeederRobot Mounted Wire Feeder
Robot Mounted Wire Feeder
The wire feeder can be mounted directly to the robot arm or automated system. This type 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 accommodate for the distance between the
power source and feeder but also for the motion of the robot.
This configuration allows for the wire feeder to be kept within a restricted area while the power source is left
accessible area for monitoring and adjusting parameters.
Data
Control Voltages
Welding Current
Coolant Lines
---- 6
6 6
6 ----
Configurations
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/ Battery Charging Systems / Welding Technology / Solar Electronics
Power Source
Trans Synergic (TS) 3200/4000/5000
Three amp ranges available (320, 400, and 500⁄. Multi-voltage model is available
Fully digital, inverter based technology that provides stable, reproducible arc through ENTIRE arc
range.
Welder comes pre-loaded with over 30 standard synergic lines over a large variety of filler metal,
gas types, and wire diameters
Power source is equally suited to robotic, automated, and manual tasks based on application
demands.
Trans-Pulse Synergic (TPS) 3200/4000/5000
Three amp ranges available (320, 400, and 500⁄. Multi-voltage model is available
Welder is 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 with over 50 standard and pulse synergic lines over a large variety of
filler metal, gas types, and wire diameters
Power source is lightweight, easily updateable, and expanded through a plug and
play interface.
---- 7
7 7
7 ----
Models
TPS 2700
270-amp pulse machine with a built in wire feeder. Multi-voltage model is available
Fully digital, inverter based technology that provides stable, reproducible arc through ENTIRE arc
range.
Welder comes pre-loaded with over 50 standard and pulse synergic lines over a large variety of
filler metal, gas types, and wire diameters
Power source is lightweight, easily updateable, and expanded through a plug and play interface.
13 SEP 12
/ Battery Charging Systems / Welding Technology / Solar Electronics
Power Source
Trans-Steel (TsT) 3500/5000 Robotic
Two amp ranges 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 that provides stable, reproducible arc through ENTIRE arc
range.
Welder comes pre-loaded with over 30 standard synergic lines over a large variety of filler metal,
gas types, and wire diameters
Designed with robotic or automated welding in mind.
---- 8
8 8
8 ----
Models
Trans-Steel (TsT) 3500/5000 Manual
Two amp ranges 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 that provides stable, reproducible arc through ENTIRE arc
range.
Welder comes pre-loaded with over 30 standard synergic lines over a large variety of filler metal,
gas types, and wire diameters
Trans-Steel (TsT) 3500 Compact
350-amp pulse machine with a built in wire feeder. Multi-voltage model is NOT available
Fully digital, inverter based technology that provides stable, reproducible arc through ENTIRE arc
range.
Welder comes pre-loaded with multiple standard synergic lines over a large variety of filler metal,
gas types, and wire diameters
Power source is lightweight, easily updateable, and expanded through a plug and play interface.
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Power Source
Name Plate
The name plate is found on the top of the
machine just underneath the carrying handle.
This label includes identification, technical,
upgrade, and duty-cycle information about the
welding power supply.
The identification portion of the label will give a detailed
description 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 be used to age any Fronius product with an
8-digit serial number.
23080753
23 – subtract “11” to get the year of manufacture
08 – this is the week of manufacture (1 – 52)
0753 – this is the item number for the day of manufacture.
---- 9999 ----
The middle portion of the label include technical that includes
duty cycle, amp drops, input and output voltage ranges, and
maximum outputs.
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Power Source
Tech Specs
TPS 2700 MV TPS 3200 MV TS/TPS 4000 MV TS/TPS 5000 MV CMT-A 4000 MV
Mains Voltage Range
3 x 240
3 x 460
200 – 240 V
380 – 460 V
200 – 240 V
380 – 460 V
200 – 240 V
380 – 460 V
200 – 240 V
380 – 460 V
200 – 240 V
380 – 460 V
Mains Tolerance +/-10% +/-10% +/- 10% +/- 10% +/- 10%
Mains Frequency 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz
Fuse Protection, slow-blow
3 x 460
3 x 240
25 A
16 A
35 A
35 A
63 A
35 A
63 A
35 A
63 A
35 A
Primary Continuous Current (100% dc) 6.4 – 14.2 A 10.6 – 31.2 A 15.3 – 34.4 A 10.1 – 36.1 A n/a
Primary Continuous Power (100% dc) 4.6 – 10.7 KVA 8.7 – 11.5 kVA 10.6 – 12.4 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
10 – 500 A
3 – 500 A
3 – 400 A
10 – 400 A
n/a
Welding Voltage Range
MIG
Stick
TIG
14.2 – 27.5 V
20.4 – 30.8 V
10.1 – 20.8 V
14.2 – 30.0 V
20.4 – 32.8 V
10.1 – 22.8 V
14.2 – 34.0 V
20.4 – 36.0 V
10.1 – 26.0 V
14.2 – 30.0 V
20.4 – 40.0 V
10.1 – 30.0 V
14.2 – 34.0 V
20.4 – 36.0 V
n/a
Max Welding Voltage 34.6 V 49.1 – 63.1 V 48 V 49.2 V n/a
Open Circuit Voltage 50 V 64 – 67 V 68 – 78 V 68 – 78 V 90 V
Duty Cycle 77º F (25º C)
60% @ 270 A
100% @ 210 A
89% @ 320 A
100% @ 304 A
75% @ 400 A
100% @ 365 A
75% @ 500 A
100% @ 450 A
85% @ 400 A
100% @ 380 A
Duty Cycle 104º F (40º C)
60% @ 270 A
100% @ 170 A
40% @ 320 A
60% @ 260 A
100% @ 220 A
40% @ 400 A
60% @ 365 A
100% @ 320 A
40% @ 500 A
60% @ 450 A
100% @ 340 A
40% @ 400 A
60% @ 350 A
100% @ 290 A
---- 10
10 10
10 ----
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((((----⁄ Current Socket Connection
⁄ Current Socket Connection⁄ Current Socket Connection
⁄ Current Socket Connection
The connection depends on the
operating mode of the power source
MIG Welding
MIG WeldingMIG Welding
MIG Welding: Connect the
welding ground to this socket.
TIG Welding
TIG WeldingTIG Welding
TIG Welding: Connect the
current connection on the torch
to this socket.
STICK Welding
STICK WeldingSTICK Welding
STICK Welding: Connect the
electrode cable to this socket
(depending on the type of
electrode being used⁄.
(+⁄ Current Socket Connection
(+⁄ Current Socket Connection(+⁄ Current Socket Connection
(+⁄ Current Socket Connection
The connection depends on the operating mode of the power source
MIG Welding
MIG WeldingMIG Welding
MIG Welding: Connect the current connection of the interconnection
hose pack to this socket.
TIG Welding
TIG WeldingTIG Welding
TIG Welding: Connect the welding ground to this socket.
STICK Welding
STICK WeldingSTICK Welding
STICK Welding: Connect the electrode cable to this socket (depending
on type of electrode being used⁄.
Power Switch
Power SwitchPower Switch
Power Switch
This switch turns the power source on
(1⁄ and off (0⁄.
Current Connection
Current Connection Current Connection
Current Connection
((((
optional
⁄⁄⁄⁄
This connection is reserved for
an optional current socket
Mains Connection
Mains ConnectionMains Connection
Mains Connection
This connection is for the 3phase input power.
LocalNet Connection
LocalNet ConnectionLocalNet Connection
LocalNet Connection
This connection is for the
LocalNet connection to the wirefeeder and/or interface device.
Blanking Cover(s⁄
Blanking Cover(s⁄Blanking Cover(s⁄
Blanking Cover(s⁄
These connections are for
optional upgrades to the power
source.
Front Panel
Front PanelFront Panel
Front Panel
The front panel allows the welder to
control the power sources welding
characteristics.
Connections – TPS 3200/4000/5000
---- 11
11 11
11 ----
Power Source
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Current Connection
Current ConnectionCurrent Connection
Current Connection
Power Switch
Power SwitchPower Switch
Power Switch
Ground Connection (
Ground Connection (Ground Connection (
Ground Connection (
optional
⁄⁄⁄⁄
Mains Connection
Mains ConnectionMains Connection
Mains Connection
LocalNet Connection
LocalNet ConnectionLocalNet Connection
LocalNet Connection
Blanking Cover(s⁄
Blanking Cover(s⁄Blanking Cover(s⁄
Blanking Cover(s⁄
Front Panel
Front PanelFront Panel
Front Panel
Gas Connection (
Gas Connection (Gas Connection (
Gas Connection (
bottle
⁄⁄⁄⁄
Trigger Connection (
Trigger Connection (Trigger Connection (
Trigger Connection (
torch
⁄⁄⁄⁄
Carrying Strap
Carrying StrapCarrying Strap
Carrying Strap
Current Connection (
Current Connection (Current Connection (
Current Connection (
torch
⁄⁄⁄⁄
Ground Connection
Ground ConnectionGround Connection
Ground Connection
Connections – TPS 2700
---- 12
12 12
12 ----
Power Source
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Current Connection
Current ConnectionCurrent Connection
Current Connection
Ground Connection
Ground ConnectionGround Connection
Ground Connection
Power Switch
Power SwitchPower Switch
Power Switch
Mains Connection
Mains ConnectionMains Connection
Mains Connection
LocalNet Connection
LocalNet ConnectionLocalNet Connection
LocalNet Connection
Optional Add
Optional AddOptional Add
Optional Add----ons
onsons
ons
Front Panel
Front PanelFront Panel
Front Panel
Connections – TsT 3500/5000
Power Source
---- 13
13 13
13 ----
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Current
Current Current
Current
Connection
ConnectionConnection
Connection
Ground
Ground Ground
Ground
Connection
ConnectionConnection
Connection
Power
Power Power
Power
Switch
SwitchSwitch
Switch
Mains
Mains Mains
Mains
Connection
ConnectionConnection
Connection
LocalNet
LocalNet LocalNet
LocalNet
Connection
ConnectionConnection
Connection
Gas Purch / Wire
Gas Purch / Wire Gas Purch / Wire
Gas Purch / Wire
Feed Switch
Feed SwitchFeed Switch
Feed Switch
Front Panel
Front PanelFront Panel
Front Panel
Connections – TsT Compact
Power Source
Gas
Gas Gas
Gas
Connection
ConnectionConnection
Connection
Torch
Torch Torch
Torch
Connector
ConnectorConnector
Connector
---- 14
14 14
14 ----
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Wire Feeder
VR 4000
This wire feeder is designed specifically for manual applications.
This device has the trigger connections required for manual torches to operate.
A removable wire-spool holder is mounted to the rear of the feeder.
Robotic/automated connections and controls can easily be added to this wire feeder
A push/pull torch requires an additional, internally installed kit.
VR 7000 CMT
This wire feeder was developed specifically for the Cold Metal Transfer (CMT⁄ process.
The feeder is 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 or a push/pull torch.
Models
VR 1500
This wire feeder is designed specifically for robotic or automated applications.
Using this wire feeder for manual welding is not feasible without special
modifications
A push/pull torch requires an additional, internally installed kit.
---- 15
15 15
15 ----
VR 1550
This wire feeder is designed specifically for robotic or automated applications.
Using this wire feeder for manual welding is not feasible without special
modifications
This feeder can be used for CMT and/or push/pull applications using a series of
specially designed kits.
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Wire Feeder
VR 5000 ROB
Newly developed wire feeder specifically designed for the robotic TransSteel Welding
system.
Designed to have the smallest profile of any Fronius wire feeder while maintaining a high
standard of durability and reliability.
Multiple versions available based on the robot type and design (PAP, standard, etc.⁄ with a
large range of options and fixtures to choose from.
---- 16
16 16
16 ----
Models
VR 5000 Manual
Newly developed wire feeder designed specifically for the TransSteel Welding 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 welding needs
Incredibly precise feed system allowing for perfect wire feed
Specialized current connection with data lines integrated to the connection simplifies setup
and keeps wiring to a minimum.
VR 1500 PAP
This wire feeder is designed specifically for robotic through-the-arm applications.
The size and weight was kept as small as possible, keeping only the mandatory components
in the feeder itself and moving the remainder to the welder.
Using this wire feeder for manual welding is not possible.
A push/pull torch requires an additional, internally installed kit.
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Wire Feeder
Fronius Connector (F++⁄
Fronius Connector (F++⁄Fronius Connector (F++⁄
Fronius Connector (F++⁄
Euro Connector (E⁄
Euro Connector (E⁄Euro Connector (E⁄
Euro Connector (E⁄ Tweeco Connector (T⁄
Tweeco Connector (T⁄Tweeco Connector (T⁄
Tweeco Connector (T⁄
Drive Rolls (
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 Roll
Main Drive RollMain Drive Roll
Main Drive Roll
Torch Connectors
Torch ConnectorsTorch Connectors
Torch Connectors
Tension Knobs
Tension KnobsTension Knobs
Tension Knobs
---- 17
17 17
17 ----
Motor Plate
Fronius System Connector (FSC⁄
Fronius System Connector (FSC⁄Fronius System Connector (FSC⁄
Fronius System Connector (FSC⁄
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Wire Feeder
Connections & Controls – VR 1500
Current Connection (
Current Connection (Current Connection (
Current Connection (
welder
⁄⁄⁄⁄
LocalNet Connection (
LocalNet Connection (LocalNet Connection (
LocalNet Connection (
spare
⁄⁄⁄⁄
LocalNet Connection (
LocalNet Connection (LocalNet Connection (
LocalNet Connection (
welder
⁄⁄⁄⁄
Gas Connection (
Gas Connection (Gas Connection (
Gas Connection (
bottle
⁄⁄⁄⁄
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 ButtonGas Purge Button
Gas Purge Button
Coolant Feed
Coolant Feed Coolant Feed
Coolant Feed ---- cold (
cold (cold (
cold (
torch
⁄⁄⁄⁄
Wire Inch Button
Wire Inch ButtonWire Inch Button
Wire Inch Button
Robacta Connection (
Robacta Connection (Robacta Connection (
Robacta Connection (
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 (
hot (
welder
⁄⁄⁄⁄
---- 18
18 18
18 ----
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Wire Feeder
Connections & Controls – VR 7000
Gas Purge (
Gas Purge (Gas Purge (
Gas Purge (up⁄ / Wire Feed (
⁄ / Wire Feed (⁄ / Wire Feed (
⁄ / Wire Feed (
down
⁄ switch
⁄ switch⁄ switch
⁄ switch
LHSB Connection (
LHSB Connection (LHSB Connection (
LHSB Connection (
torch
⁄⁄⁄⁄
LocalNet Connection (
LocalNet Connection (LocalNet Connection (
LocalNet Connection (
welder
⁄⁄⁄⁄
Gas Connection (
Gas Connection (Gas Connection (
Gas Connection (
bottle
⁄⁄⁄⁄
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
⁄⁄⁄⁄
Spool Holder
Spool HolderSpool Holder
Spool Holder
Coolant Feed
Coolant Feed 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 (
hot (
welder
⁄⁄⁄⁄
LocalNet Connection (
LocalNet Connection (LocalNet Connection (
LocalNet Connection (
spare
⁄⁄⁄⁄
Power Control (
Power Control (Power Control (
Power Control (
WFS, Current, etc.
⁄⁄⁄⁄
Arc Length Control
Arc Length ControlArc Length Control
Arc Length Control
LHSB Connection (
LHSB Connection (LHSB Connection (
LHSB Connection (
welder
⁄⁄⁄⁄
Current Connection (
Current Connection (Current Connection (
Current Connection (
welder
⁄⁄⁄⁄
Trigger Connection (
Trigger Connection (Trigger Connection (
Trigger Connection (
torch
⁄⁄⁄⁄
Buffer Connection (
Buffer Connection (Buffer Connection (
Buffer Connection (
torch
⁄⁄⁄⁄
Robacta Connection (
Robacta Connection (Robacta Connection (
Robacta Connection (
torch
⁄⁄⁄⁄
Motor
MotorMotor
Motor----plate
plateplate
plate
---- 19
19 19
19 ----
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LocalNet Connection (
LocalNet Connection (LocalNet Connection (
LocalNet Connection (
welder
⁄
⁄ ⁄
⁄
PAP System Only -
Current/Gas Connection (
Current/Gas Connection (Current/Gas Connection (
Current/Gas Connection (
torch
⁄⁄⁄⁄
Current Connection (
Current Connection (Current Connection (
Current Connection (
welder
⁄⁄⁄⁄
Motor
MotorMotor
Motor----plate
plateplate
plate
Gas Connection (
Gas Connection (Gas Connection (
Gas Connection (
bottle
⁄
⁄ ⁄
⁄
----
PAP System Only
----
Wire Inch Button
Wire Inch ButtonWire Inch Button
Wire Inch Button
Gas Connection (
Gas Connection (Gas Connection (
Gas Connection (
bottle
⁄
⁄ ⁄
⁄
----
Standard System Only
----
LocalNet Connection (
LocalNet Connection (LocalNet Connection (
LocalNet Connection (
welder
⁄
⁄ ⁄
⁄
Standard System Only -
Wire Inlet (
Wire Inlet (Wire Inlet (
Wire Inlet (
drum or spool
⁄⁄⁄⁄
Wire Feeder
Connections & Controls – VR 5000 Rob
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LocalNet Connection (
LocalNet Connection (LocalNet Connection (
LocalNet Connection (
welder
⁄⁄⁄⁄
Gas Connection (
Gas Connection (Gas Connection (
Gas Connection (
bottle
⁄⁄⁄⁄
Current/Gas Connection (
Current/Gas Connection (Current/Gas Connection (
Current/Gas Connection (
torch
⁄⁄⁄⁄
Spool Holder
Spool HolderSpool Holder
Spool Holder
Current Connection (
Current Connection (Current Connection (
Current Connection (
welder
⁄⁄⁄⁄
Motor
MotorMotor
Motor----plate
plateplate
plate
Spool Window
Spool WindowSpool Window
Spool Window
Handle
HandleHandle
Handle
Weld Control
Weld Control Weld Control
Weld Control
Panel
PanelPanel
Panel
Synergic Selection
Synergic Selection Synergic Selection
Synergic Selection
----
Synergic version only
----
Coolant Feed
Coolant Feed Coolant Feed
Coolant Feed ---- cold (
cold (cold (
cold (
torch
⁄
⁄ ⁄
⁄
----
optional add on
----
Coolant Feed
Coolant Feed Coolant Feed
Coolant Feed ---- hot (
hot (hot (
hot (
torch
⁄
⁄ ⁄
⁄
----
optional add on
----
Coolant Feed
Coolant Feed Coolant Feed
Coolant Feed ---- hot (
hot (hot (
hot (
welder
⁄
⁄ ⁄
⁄ ----
optional add on
----
Coolant Feed
Coolant Feed Coolant Feed
Coolant Feed ---- cold (
cold (cold (
cold (
welder
⁄
⁄ ⁄
⁄
----
optional add on
----
Wire Feeder
Connections & Controls – VR 5000 Manual
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Manual Torches
Manual TorchesManual Torches
Manual Torches
Trigger to start/stop the arc.
Water-cooled or Air-cooled
Several control options
None
Up/Down (U/D⁄
Jobmaster (JM⁄
Several wire feeder connections
Fronius (F/F++⁄
Fronius System Connector (FSC⁄
Euro (E⁄
Tweeko (Z⁄
Robotic Torches
Robotic TorchesRobotic Torches
Robotic Torches
Robotic/Automated control of the arc
Water-cooled or Air-cooled
No parameter control options.
Wire feed and gas control
Only on drive-based torches.
Several wire feeder connections
Fronius (F/F++⁄
Fronius System Connector (FSC⁄
Euro (E⁄
Tweeko (Z⁄
Will have Robacta in the description
BAAN/Price
BAAN/PriceBAAN/Price
BAAN/Price----book Description Examples
book Description Examplesbook Description Examples
book Description Examples
AL 4000 G/E/UD/4.5m/14.5ft - AL 4000
AL 4000AL 4000
AL 4000 (torch type-manual⁄ GGGG (gas-cooled⁄ EEEE (Euro connector⁄ UD
UDUD
UD (up/down control⁄
Robacta Drive Ext. W/F++/1.75m/5.7ft - Robacta Drive Ext
Robacta Drive ExtRobacta Drive Ext
Robacta Drive Ext (torch type-robotic⁄ WWWW (water-cooled⁄ F++
F++F++
F++ (Fronius connector⁄
PullMig CMT W/F/6m/19.7ft - PullMig CMT
PullMig CMTPullMig CMT
PullMig CMT (torch type-manual⁄ WWWW (water-cooled⁄ FFFF (Fronius connector⁄
Welding Torch
Models
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Cooling Units
Cooling UnitsCooling Units
Cooling Units
Standard Features
Standard FeaturesStandard Features
Standard Features
Integrated system linked directly to power source for power and control.
Fuse protection against potential over-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 5000FK 4000 / FK 5000
FK 4000 / FK 5000
Standard water cooler for most MIG and TIG packages
Internal reservoir that allows for a completely closed system.
FK 9000
FK 9000FK 9000
FK 9000
High volume water cooler for specialized system that require a larger
coolant capability.
Two separate units with integral components divided between them.
Cooler
Models
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Weld Process
Overview
Shielded Metal Arc Welding (SMAW)
An arc welding process that produces coalescence of metals by heating them with an arc between a covered metal electrode and the workpiece(s).
Shielding is obtained from decomposition of the electrode covering. Pressure is not used, and filler metal is obtained from the electrode.
– Stick Welding
– Performed with a basic constant current (CC) power source that is equipped with an electrode holder and a ground clamp
– Manual
Gas Tungsten Arc Welding (GTAW)
An arc welding process that produces coalescence of metals by heating them with an arc between a tungsten electrode (non-consumable) and the
workpiece(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 that supplies current through a tungsten electrode
and ground clamp
– GTAW requires an inert gas such as Argon (most commonly used) or Helium (or a mixture of the two) to support the arc
– Manual, Mechanized, and Automated
Gas Metal Arc Welding (GWAW)
An arc welding process that produces coalescence of metals by heating them with an arc between a continuous filler metal electrode and the
workpiece(s). Shielding is obtained entirely from an externally supplied gas.
– MIG/MAG welding
– Performed with a constant voltage (CV) power supply equipped with a wire feeder to supply welding wire through a GMA welding torch to the
workpiece(s) and with a ground clamp to complete the electrical circuit
– Semi–auto process (manual), Mechanized, and Automated
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Weld Process
Overview
Synergic Welding
– Computer control of the welding arc based on a single user-defined characteristic (wire-
feed speed, material thickness, amps, etc.)
– Changing the wire-feed speed will automatically adjust the voltage necessary for the
filler metal and gas being used. This is done through the use of a digital signal
processor and a synergic line
– Provides an extremely high level of repeatability and precision
– The synergic line can be modified slightly to account for environmental 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 metal, wire diameter, shielding gas, and
operating mode
– This line is created through a complex set of measurements taken while welding with
the specified settings
– A standard line can be chosen/programmed in a matter of seconds with the simple
selection of a few base parameters
TransSynergic and TransPulseSynergic
– Standard MIG power sources available from Fronius
– Both have the ability to do standard (conventional “2 dial”) welding and synergic welding
(one dial)
– The TransPulse Synergic power source has the added ability to perform pulse-synergic
welding
WIRE-FEED SPEED (current)
VOLTAGE
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