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CMT 4000 Advanced
Fronius CMT 4000 Advanced User Manual
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Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044
1
3
Table of Contents
Default Chapter
2
Parameters for Operating Power Sources in Parallel in the Setup Menu Level
2
Parameters for Timetwin Digital in the Setup Menu Level
2
Parameters for TIG Welding in the Setup Menu Level
2
Parameters for Rod Electrode (MMA) Welding in the Setup Menu Level
2
Table of Contents
3
Safety Rules
9
Explanation of Safety Notices
9
General
9
Proper Use
9
Environmental Conditions
10
Obligations of the Operator
10
Obligations of Personnel
10
Mains Connection
10
Protecting Yourself and Others
11
Noise Emission Values
11
Danger from Toxic Gases and Vapours
12
Danger from Flying Sparks
12
Risks from Mains Current and Welding Current
13
Meandering Welding Currents
14
EMC Device Classifications
14
EMC Measures
14
EMF Measures
15
Specific Hazards
15
Requirement for the Shielding Gas
16
Danger from Shielding Gas Cylinders
16
Danger from Escaping Shielding Gas
17
Safety Measures at the Installation Location and During Transport
17
Safety Measures in Normal Operation
17
Commissioning, Maintenance and Repair
18
Safety Inspection
18
Disposal
19
Safety Symbols
19
Data Protection
19
Copyright
19
General Information
21
General
23
Device Concept
23
Functional Principle
23
Application Areas
23
Warning Notices on the Device
24
Description of Warning Notices on the Device
25
Special Versions
27
General
27
Alu Edition
27
Crni Edition
27
CMT Variants
27
CMT 4000 Advanced
28
TIME 5000 Digital
28
Yard Edition
28
Steel Edition
28
System Components
29
General
29
Overview
29
Control Elements and Connections
31
Description of the Control Panels
33
General
33
Safety
33
Overview
33
Standard Control Panel
34
General
34
Key Combinations - Special Functions
36
Displaying the Feeder Inching Speed
36
Displaying the Gas Pre-Flow and Gas Post-Flow Time
36
Displaying the Software Version
37
Comfort / Crni / Steel Control Panel
38
Difference between Comfort, Crni and Steel Control Panels
38
Comfort Control Panel
38
Key Combinations - Special Functions
42
Displaying the Feeder Inching Speed
42
Displaying the Gas Pre-Flow and Gas Post-Flow Time
43
Displaying the Software Version
43
US Control Panel
44
Key Combinations - Special Functions
47
Displaying the Feeder Inching Speed
47
Displaying the Gas Pre-Flow and Gas Post-Flow Time
48
Displaying the Software Version
48
TIME 5000 Digital Control Panel
49
Key Combinations - Special Functions
52
Displaying the Feeder Inching Speed
53
Displaying the Gas Pre-Flow and Gas Post-Flow Time
53
Displaying the Software Version
53
CMT Control Panel
54
Key Combinations - Special Functions
57
Displaying the Feeder Inching Speed
57
Displaying the Gas Pre-Flow and Gas Post-Flow Time
57
Displaying the Software Version
58
Yard Control Panel
59
Key Combinations - Special Functions
62
Displaying the Feeder Inching Speed
62
Displaying the Gas Pre-Flow and Gas Post-Flow Time
63
Displaying the Software Version
63
Remote" Control Panel
64
General
64
CMT Remote Control Panel
65
General
65
CMT Remote and CMT Advanced Control Panel
65
Connections, Switches and Mechanical Components
66
TPS 2700 Power Source
66
TPS 2700 CMT Power Source
67
TS 4000 / 5000, TPS 3200 / 4000 / 5000, TIME 5000 Digital Power Sources
68
CMT 4000 Advanced Power Source
69
Installation and Commissioning
71
Minimum Equipment Needed for Welding Task
73
General
73
MIG/MAG Gas-Cooled Welding
73
MIG/MAG Water-Cooled Welding
73
MIG/MAG Automated Welding
73
CMT Manual Welding
73
CMT Automated Welding
74
CMT Advanced Welding
74
TIG DC Welding
74
Manual Metal Arc Welding
74
Before Installation and Commissioning
75
Safety
75
Proper Use
75
Setup Regulations
75
Mains Connection
75
Connecting up the Mains Cable on US Power Sources
77
General
77
Stipulated Mains Cables and Strain-Relief Devices
77
Safety
77
Connecting the Mains Cable
77
Replacing the Strain-Relief Device
79
Start-Up
80
Safety
80
Remarks on the Cooling Unit
80
Information on System Components
80
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
84
Inserting the Wirespool
84
Inserting the Basket-Type Spool
85
Feeding in the Wire Electrode
86
Setting the Contact Pressure
87
Adjusting the Brake
87
Design of the Brake
88
Commissioning the TS 4000 / 5000, TPS 3200 / 4000 / 5000, TIME 5000 Digital
89
General
89
Fitting the System Components (Overview)
89
Fixing the Strain-Relief Device in Place
90
Connecting the Interconnecting Hosepack
90
Connecting the Gas Cylinder
91
Establishing a Ground (Earth) Connection
92
Connecting the Welding Torch
92
Other Tasks
92
Commissioning the CMT4000 Advanced
93
Fitting the System Components (Overview)
93
Connecting the Interconnecting Hosepack, CMT Welding Torch and Wire Buffer
93
Other Tasks
94
Preparing the Wire-Feed Unit
94
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
103
Remarks on the Standard Control Panel
103
MIG/MAG Standard Manual Welding
104
General
104
Available Parameters
104
Corrections During Welding
105
Adjusting Parameters for Correction
106
CMT Welding
107
General
107
Corrections During Welding
108
Adjusting Parameters for Correction
110
Special Functions and Options
111
Arc Break Watchdog Function
111
Ignition Time-Out Function
111
Spatter-Free Ignition Option
111
Synchropulse Option
112
Robot Welding
114
Prerequisite
114
General
114
Special 2-Step Mode for Robot Interface
114
Wire-Stick Control Function
115
Changing the Welding Process During CMT Advanced Welding
115
TIG Welding
116
Safety
116
Prerequisite
116
Preparation
116
TIG Welding
117
Igniting the Arc
117
Finishing Welding
118
TIG Comfort Stop Option
118
TIG Welding with TIG Comfort Stop
119
MMA Welding
121
Safety
121
Prerequisite
121
Preparation
121
Manual Metal Arc Welding
122
Corrections During Welding
122
Adjusting Parameters for Correction
123
Hotstart Function
123
Softstart Function
123
Anti-Stick Function
124
Job Mode
125
General
125
Prerequisites
125
Restrictions
125
Job Mode Displays on the Left-Hand Digital Display
125
Selecting Job Mode as the Process
125
Creating a Job
126
Retrieving a Job
127
Copying/Overwriting a Job
128
Deleting a Job
129
Setup Settings
131
Job Correction
133
General
133
Opening the Job Correction Menu
133
Changing Welding Parameters
133
Exiting the Job Correction Menu
133
Parameters in the Job Correction Menu
134
Permanently Settable Parameters
134
Parameters that Can be Corrected at a Later Time
137
Shielding Gas Setup Menu
139
General
139
Protective Gas Shield Setup Menu for the Standard Control Panel
139
Protective Gas Shield Setup Menu for the Comfort, US, TIME 5000 Digital and CMT Control Panels
139
Welding Parameters in the Protective Gas Shield Setup Menu
139
Setup Menu for the Standard Control Panel
141
General
141
Parameters in the Setup Menu for the Standard Control Panel
141
Process Setup Menu
144
General
144
Process Setup Menu for the Comfort, US, TIME 5000 Digital and CMT Control Panels
144
Parameters for MIG/MAG Welding in the Process Setup Menu
144
Parameters for TIG Welding in the Process Setup Menu
147
Parameters for MMA Welding in the Process Setup Menu
147
Mode Setup Menu
149
General
149
Mode Setup Menu for the Comfort, US, TIME 5000 Digital and CMT Control Panels
149
Welding Parameters for "Special 2-Step Mode" in the Mode Setup Menu
149
Welding Parameters for "Special 4-Step Mode" in the Mode Setup Menu
150
Parameters for Spot Welding in the Mode Setup Menu
151
Setup Menu - Level 2
152
General
152
Setup Menulevel 2 for the Standard Control Panel
152
Setup Menu Level 2 for the Comfort, US, TIME 5000 Digital and CMT Control Panels
153
Parameters for MIG/MAG Welding in the Setup Menu Level
153
Notes on the Use of the FAC Parameter
161
Calibrating Push-Pull Unit
162
General
162
Calibrating the Push-Pull Unit - Overview
162
Calibrating the Push-Pull Unit
163
Service Codes for Push-Pull Calibration
167
Safety
167
Service Codes When the Drive Units Are Disengaged ("Open-Circuit" Calibration)
167
Service Codes When the Drive Units Are Engaged ("Engaged" Calibration)
168
Measuring Welding Circuit Resistance R
170
General
170
Displaying Welding Circuit Inductivity L
172
General
172
Arranging the Interconnecting Hosepack Correctly
172
Troubleshooting and Maintenance
173
Troubleshooting
175
General
175
Safety
175
Displayed Service Codes
175
Power Source - Troubleshooting
183
Care, Maintenance and Disposal
187
General
187
Safety
187
At Every Start-Up
187
Every 2 Months
187
Every 6 Months
187
Disposal
187
Appendix
189
Technical Data
191
Special Voltages
191
Tps 2700
191
Tps 2700 MV
192
Tps 3200
193
Tps 3200 MV
194
Tps 3200 460 V Ac
195
Ts/Tps 4000
196
Ts/Tps 4000 MV
197
Ts/Tps 5000
198
Ts/Tps 5000 MV
199
Technical Data - US Devices
200
Technical Data - Alu Edition, Crni Edition, Yard Edition and CMT Variants
200
TIME 5000 Digital
200
CMT 4000 Advanced
201
CMT 4000 Advanced MV
202
Welding Program Databases
204
Explanation of Symbols
204
Setting up a Welding Program Database - Example
204
Terms and Abbreviations Used
205
General
205
Terms and Abbreviations a - C
205
Terms and Abbreviations D - F
205
Terms and Abbreviations G - I
206
Terms and Abbreviations J - R
207
Terms and Abbreviations S
207
Terms and Abbreviations T - 2Nd
208
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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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