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CMT 4000 Advanced
Fronius CMT 4000 Advanced Operating Instructions & Spare Parts
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/ Battery Charging Systems /
Welding Technology
/ Solar Electronics
42,0426,0001,EN
006-04092012
TransSynergic 4000/5000
TransPuls Synergic 2700
TransPuls Synergic 3200/4000/5000
TIME 5000 Digital
CMT 4000 Advanced
Operating Instructions
Spare parts list
MIG/MAG Power source
EN
2
Table of Contents
Default Chapter
5
Table of Contents
5
Safety Rules
11
Explanation of Safety Symbols
11
General
11
Intended Purpose
12
Environmental Conditions
12
Obligations of the Operator
12
Obligations of Personnel
13
Mains Connection
13
Protecting Yourself and Others
13
Noise Emission Values
14
Danger from Toxic Gases and Vapours
14
Danger from Flying Sparks
15
Risks from Mains Current and Welding Current
15
Meandering Welding Currents
17
EMC Device Classifications
17
EMC Measures
17
EMF Measures
18
Specific Hazards
18
Danger from Shielding Gas Cylinders
20
Safety Measures at the Installation Location and During Transport
20
Safety Measures in Normal Operation
21
Maintenance and Repair
22
Safety Inspection
22
Disposal
22
Safety Symbols
22
Data Protection
23
Copyright
23
General Information
25
General
27
Device Concept
27
Functional Principle
27
Application Areas
27
Warning Notices on the Device
27
Special Versions
29
General
29
Alu Edition
29
Crni Edition
29
CMT Variants
29
CMT 4000 Advanced
29
TIME 5000 Digital
30
Yard Edition
30
Steel Edition
30
System Components
31
General
31
Overview
31
Control Elements and Connections
33
Description of the Control Panels
35
General
35
Safety
35
Overview
35
Standard Control Panel
36
General
36
Key Combinations - Special Functions
38
Displaying the Feeder Inching Speed
38
Displaying the Gas Pre-Flow and Gas Post-Flow Time
38
Displaying the Software Version
38
Comfort / Crni / Steel Control Panel
40
Difference between Comfort, Crni and Steel Control Panels
40
Comfort Control Panel
40
Key Combinations - Special Functions
43
Displaying the Feeder Inching Speed
43
Displaying the Gas Pre-Flow and Gas Post-Flow Time
44
Displaying the Software Version
44
US Control Panel
45
Key Combinations - Special Functions
48
Displaying the Feeder Inching Speed
48
Displaying the Gas Pre-Flow and Gas Post-Flow Time
48
Displaying the Software Version
49
TIME 5000 Digital Control Panel
50
Key Combinations - Special Functions
53
Displaying the Feeder Inching Speed
53
Displaying the Gas Pre-Flow and Gas Post-Flow Time
54
Displaying the Software Version
54
CMT Control Panel
55
Key Combinations - Special Functions
58
Displaying the Feeder Inching Speed
58
Displaying the Gas Pre-Flow and Gas Post-Flow Time
58
Displaying the Software Version
58
Yard Control Panel
60
Key Combinations - Special Functions
63
Displaying the Feeder Inching Speed
63
Displaying the Gas Pre-Flow and Gas Post-Flow Time
63
Displaying the Software Version
64
Remote" Control Panel
65
General
65
CMT Remote Control Panel
66
General
66
CMT Remote and CMT Advanced Control Panel
66
Connections, Switches and Mechanical Components
67
TPS 2700 Power Source
67
TPS 2700 CMT Power Source
68
TS 4000 / 5000, TPS 3200 / 4000 / 5000, TIME 5000 Digital Power Sources
69
CMT 4000 Advanced Power Source
70
Installation and Commissioning
73
Minimum Equipment Needed for Welding Task
75
General
75
MIG/MAG Gas-Cooled Welding
75
MIG/MAG Water-Cooled Welding
75
MIG/MAG Automated Welding
75
CMT Manual Welding
75
CMT Automated Welding
76
CMT Advanced Welding
76
TIG DC Welding
76
Manual Metal Arc Welding
76
Before Installation and Commissioning
77
Safety
77
Proper Use
77
Setup Regulations
77
Mains Connection
77
Connecting up the Mains Cable on US Power Sources
78
General
78
Stipulated Mains Cables and Strain-Relief Devices
78
Safety
78
Connecting the Mains Cable
78
Replacing the Strain-Relief Device
79
Start-Up
81
Safety
81
Remarks on the Cooling Unit
81
Information on System Components
81
Overview
81
Commissioning the TPS 2700
82
General
82
Recommendation for Water-Cooled Applications
82
Connecting the Gas Cylinder
82
Establishing a Ground (Earth) Connection
83
Connecting the Welding Torch
83
Inserting/Replacing Feed Rollers
83
Inserting the Wirespool
84
Inserting the Basket-Type Spool
84
Feeding in the Wire Electrode
85
Setting the Contact Pressure
86
Adjusting the Brake
86
Design of the Brake
87
Commissioning the TS 4000 / 5000, TPS 3200 / 4000 / 5000, TIME 5000 Digital
88
General
88
Fitting the System Components (Overview)
88
Fixing the Strain-Relief Device in Place
89
Connecting the Interconnecting Hosepack
89
Connecting the Gas Cylinder
90
Establishing a Ground (Earth) Connection
91
Connecting the Welding Torch
91
Other Tasks
91
Commissioning the CMT4000 Advanced
92
Fitting the System Components (Overview)
92
Connecting the Interconnecting Hosepack, CMT Welding Torch and Wire Buffer
92
Other Tasks
92
Preparing the Wire-Feed Unit
93
Welding
95
MIG/MAG Modes
97
General
97
Symbols and Their Explanations
97
2-Step Mode
98
Special 4-Step Mode
99
Spot Welding
99
MIG/MAG Welding
100
Safety
100
General Tasks before MIG/MAG Welding
100
Overview
100
MIG/MAG Synergic Welding
101
General
101
Corrections During Welding
102
Adjusting Parameters for Correction
102
Remarks on the Standard Control Panel
102
MIG/MAG Standard Manual Welding
103
General
103
Available Parameters
103
Corrections During Welding
104
Adjusting Parameters for Correction
104
CMT Welding
105
General
105
Corrections During Welding
106
Adjusting Parameters for Correction
108
Special Functions and Options
109
Arc Break Watchdog Function
109
Ignition Time-Out Function
109
Spatter-Free Ignition Option
109
Synchropulse Option
110
Robot Welding
112
Prerequisite
112
General
112
Special 2-Step Mode for Robot Interface
112
Wire-Stick Control Function
113
Changing the Welding Process During CMT Advanced Welding
113
TIG Welding
114
Safety
114
Prerequisite
114
Preparation
114
Igniting the Arc
115
Finishing Welding
116
TIG Comfort Stop Option
116
TIG Welding with TIG Comfort Stop
118
MMA Welding
119
Safety
119
Prerequisite
119
Preparation
119
Manual Metal Arc Welding
119
Corrections During Welding
120
Adjusting Parameters for Correction
120
Hotstart Function
120
Softstart Function
121
Anti-Stick Function
121
Job Mode
122
General
122
Prerequisites
122
Restrictions
122
Job Mode Displays on the Left-Hand Digital Display
122
Selecting Job Mode as the Process
122
Creating a Job
122
Retrieving a Job
123
Copying/Overwriting a Job
124
Deleting a Job
125
Setup Settings
127
Job Correction
129
General
129
Opening the Job Correction Menu
129
Changing Welding Parameters
129
Exiting the Job Correction Menu
129
Parameters in the Job Correction Menu
130
Permanently Settable Parameters
130
Parameters that Can be Corrected at a Later Time
132
Shielding Gas Setup Menu
135
General
135
Protective Gas Shield Setup Menu for the Standard Control Panel
135
Protective Gas Shield Setup Menu for the Comfort, US, TIME 5000 Digital and CMT Control Panels
135
Welding Parameters in the Protective Gas Shield Setup Menu
135
Setup Menu for the Standard Control Panel
137
General
137
Parameters in the Setup Menu for the Standard Control Panel
137
Process Setup Menu
140
General
140
Process Setup Menu for the Comfort, US, TIME 5000 Digital and CMT Control Panels
140
Parameters for MIG/MAG Welding in the Process Setup Menu
140
Parameters for TIG Welding in the Process Setup Menu
143
Parameters for MMA Welding in the Process Setup Menu
143
Mode Setup Menu
144
General
144
Mode Setup Menu for the Comfort, US, TIME 5000 Digital and CMT Control Panels
144
Welding Parameters for "Special 2-Step Mode" in the Mode Setup Menu
144
Welding Parameters for "Special 4-Step Mode" in the Mode Setup Menu
145
Parameters for Spot Welding in the Mode Setup Menu
145
Setup Menu - Level 2
146
General
146
Setup Menulevel 2 for the Standard Control Panel
146
Setup Menu Level 2 for the Comfort, US, TIME 5000 Digital and CMT Control Panels
147
Parameters for MIG/MAG Welding in the Setup Menu Level 2
147
Parameters for Operating Power Sources in Parallel in the Setup Menu Level2
150
Parameters for Timetwin Digital in the Setup Menu Level2
150
Parameters for TIG Welding in the Setup Menu Level2
150
Parameters for Rod Electrode (MMA) Welding in the Setup Menu Level 2
152
Notes on the Use of the FAC Parameter
154
Calibrating Push-Pull Unit
155
General
155
Calibrating the Push-Pull Unit - Overview
155
Calibrating the Push-Pull Unit
155
Service Codes for Push-Pull Calibration
159
Safety
159
Service Codes When the Drive Units Are Disengaged ("Open-Circuit" Calibration)
159
Service Codes When the Drive Units Are Engaged ("Engaged" Calibration)
160
Measuring Welding Circuit Resistance R
162
General
162
Displaying Welding Circuit Inductivity L
164
General
164
Arranging the Interconnecting Hosepack Correctly
164
Troubleshooting and Maintenance
165
Troubleshooting
167
General
167
Safety
167
Displayed Service Codes
167
Power Source - Troubleshooting
175
Care, Maintenance and Disposal
179
General
179
Safety
179
At Every Start-Up
179
Every 2 Months
179
Every 6 Months
179
Disposal
179
Appendix
181
Technical Data
183
Special Voltages
183
Tps 2700
183
Tps 2700 MV
184
Tps 3200
185
Tps 3200 MV
186
Tps 3200 460Vac
187
Ts/Tps 4000
188
Ts/Tps 4000 MV
189
Ts/Tps 5000
189
Ts/Tps 5000 MV
190
Technical Data - US Devices
191
Technical Data - Alu Edition, Crni Edition, Yard Edition and CMT Variants
191
TIME 5000 Digital
191
CMT 4000 Advanced
192
CMT 4000 Advanced MV
193
Welding Program Databases
195
Explanation of Symbols
195
Setting up a Welding Program Database - Example
195
Terms and Abbreviations Used
196
General
196
Terms and Abbreviations a - C
196
Terms and Abbreviations D - F
196
Terms and Abbreviations G - I
197
Terms and Abbreviations J - R
197
Terms and Abbreviations S
198
Terms and Abbreviations T - 2Nd
198
Spare Parts List
201
Spare Parts List: Transpuls Synergic 2700
202
Spare Parts List: TS/TPS 3200/4000/5000, TIME 5000
205
Spare Parts List: CMT 4000 Advanced
208
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Operating Instructions
212 pages
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Fronius CMT 4000 Advanced Specifications
General
Brand
Fronius
Model
CMT 4000 Advanced
Category
AC Power Distribution
Language
English
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