FRO­NIUS CMT Twin Operation manual

/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0138,EN 003-28082017
CMT Twin
Process description and
commissioning
User information
System extension
EN

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Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.

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Contents
General 7
General ...................................................................................................................................................... 9
System concept .................................................................................................................................... 9
Functional principle ............................................................................................................................... 9
Configurations....................................................................................................................................... 9
Dimensioning of the robot ..................................................................................................................... 10
Measures to increase system availability.............................................................................................. 10
Note for TimeTwin welding using a CMT Twin system ......................................................................... 10
System components required .................................................................................................................... 11
System components required ............................................................................................................... 11
Application example................................................................................................................................... 14
Application example.............................................................................................................................. 14
Installation and commissioning 15
Safety......................................................................................................................................................... 17
Safety.................................................................................................................................................... 17
Notes regarding the installation of Fronius system components ............................................................... 18
Installation and commissioning of Fronius system components ........................................................... 18
Setup regulations for the power sources .............................................................................................. 18
Fitting wearing parts to the torch neck ....................................................................................................... 19
Fitting wearing parts to the torch neck .................................................................................................. 19
Fitting the mounting bracket and torch neck .............................................................................................. 20
Fitting the mounting bracket to the robot .............................................................................................. 20
Screw the torch neck and drive units to the mounting bracket ............................................................. 20
Earth connection ........................................................................................................................................ 22
Earth connection ................................................................................................................................... 22
Recommendation to minimise arc blow ................................................................................................ 23
Connecting the LHSB-HUB with the power sources and wire-feed units .................................................. 24
Connecting the LHSB-HUB with the power sources and wire-feed units ............................................. 24
Connecting to the robot control.................................................................................................................. 25
Connecting to the robot control............................................................................................................. 25
Robot interfaces for CMT Twin ............................................................................................................. 25
Standard robot interfaces...................................................................................................................... 25
Twin fieldbus systems .......................................................................................................................... 26
Standard fieldbus systems.................................................................................................................... 27
Description of signal statuses .............................................................................................................. 28
Check compatibility of power sources and remote controls....................................................................... 29
Safety.................................................................................................................................................... 29
Checking power source compatibility.................................................................................................... 29
Checking the RCU 5000i database version .......................................................................................... 29
Checking the characteristics version ......................................................................................................... 31
Safety.................................................................................................................................................... 31
Checking the characteristics version .................................................................................................... 31
L/R alignment - aligning welding circuit inductivity and welding circuit resistance..................................... 33
Safety.................................................................................................................................................... 33
L/R alignment using RCU 5000i............................................................................................................ 33
Welding start-up......................................................................................................................................... 36
Welding start-up sequence ................................................................................................................... 36
Safety.................................................................................................................................................... 36
Welding start-up settings ...................................................................................................................... 36
Start delay parameter correction........................................................................................................... 37
Pulse/CMT welding .................................................................................................................................... 38
Process description pulse/CMT welding ............................................................................................... 38
CMT/CMT welding ..................................................................................................................................... 39
Process description CMT/CMT welding................................................................................................ 39
Single-wire welding .................................................................................................................................... 40
Special features and advantages.......................................................................................................... 40

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Material transfer .................................................................................................................................... 40
Applying the 'HD' ('Heavy Duty') configuration........................................................................................... 42
Available characteristics ....................................................................................................................... 42
Description of characteristics ................................................................................................................ 42
Configuring the system ......................................................................................................................... 42
Stick out ................................................................................................................................................ 44
Use 'Speed' configuration .......................................................................................................................... 45
Available characteristics ....................................................................................................................... 45
Description of characteristics ................................................................................................................ 45
Configuring the system ......................................................................................................................... 46
Stick out ................................................................................................................................................ 48
Use 'Root' configuration ............................................................................................................................. 49
Available characteristics ....................................................................................................................... 49
Description of characteristics ................................................................................................................ 49
Configuring the system ......................................................................................................................... 49
Standard welding parameter values for fillet welds.................................................................................... 51
Standard welding parameter values for fillet welds............................................................................... 51
Alignment of welding torch relative to the workpiece ............................................................................52
Standard welding parameter values for lap joints ...................................................................................... 53
Standard welding parameter values for lap joints ................................................................................. 53
Alignment of welding torch relative to the workpiece ............................................................................53
Prerequisities for welding........................................................................................................................... 55
Safety.................................................................................................................................................... 55
Prerequisities for welding...................................................................................................................... 55

General

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EN
General
System concept CMT Twin is a high performance welding process that combines the advantages of CMT
welding and Twin welding. In addition to numerous other benefits, it offers a very high weld-
ing speed and simple control of the process.
Functional princi-
ple
- The wire is fed by two separate wire-feed units and Robacta Drive CMT drive units
- The wire-feed units and drive units are supplied by two independent power sources
- The wire electrodes are brought together in the torch neck in such a way that two in-
dependent welding potentials are created
No. Explanation
(1) Wire-feed unit 1 and 2
(2) Wire electrode 1 and 2
(3) LHSB-HUB
(4) Power source 1 and 2
(5) Separate welding potential
Configurations CMT Twin can be used in a variety of configurations depending on requirements. The
available configurations comprise:
- wearing parts optimised for CMT Twin
- dedicated characteristics on the RCU 5000i
Refer to the "Installation and commissioning" section for more information about the indi-
vidual configurations.
(1)
(1)
(4)
(5)
(4)
(5)
(2) (3) (2)

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Dimensioning of
the robot
Dimension the robot so that it is able to accommodate the Robacta Twin Compact Pro
torch neck and associated mounting bracket plus 2 Robacta Drive CMT drive units and 1
metre of the relevant hosepacks.
Measures to in-
crease system
availability
To increase system availability, we recommend the following welding torch cleaning devic-
es:
Note for
TimeTwin weld-
ing using a CMT
Twin system
NOTE! The total weight of these components is 7.5 kg (16.53 Ib.).
Robacta Reamer Twin
Mechanical welding torch cleaner, suitable for all base materials, such as steel, alumini-
um, CrNi steels, copper, etc.
Robacta Reamer V Twin
Mechanical welding torch cleaner, suitable for all base materials, such as steel, alumini-
um, CrNi steels, copper, etc.
Robacta TC 1000 Twin
Electromagnetic welding torch cleaner for ferromagnetic base materials
NOTE! When welding the TimeTwin process using a CMT Twin system, the
"TimeTwin Digital" software needs to be enabled on both power sources.
NOTE! Pulse synchronous welding can only be performed using TimeTwin char-
acteristics.
It is not possible with CMT Twin characteristics.

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System components required
System compo-
nents required
- 2 TPS 5000 CMT
- with DSP software version
5.01.063 or higher
- 2 RCU 5000i
- with database version 908 or hig-
her
Use 2 FK 4000 R or 1 FK 9000 for:
- hosepack lengths of up to 4.25 m
(14.76ft.)
- 100 % duty cycle (10min/40°C) at 360
A
Use 2 FK 9000 for:
- hosepack lengths from 4.25 m - 8.25 m
(14.76 ft. - 27.07 ft.)
- 100 % duty cycle (10min/40°C) at 360
A
FK 4000 R
FK 9000 R

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- 2 VR 7000 CMT or 2 VR 1550
- 2 Robacta Drive CMT drive units with
wire buffer and hosepacks
- 1 LHSB-HUB
VR 1550
VR 7000 CMT

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- 1 Robacta Twin Compact Pro torch
neck and mounting bracket
(1) 2 inner liners
(2) 1 wrench for nozzle fitting and con-
tact tip
(3) 2 nozzle fittings
(4) 2 spatter guards
(5) 2 contact tips
(6) 1 gas nozzle
(7) 2 TCP tips
(8) 1 wrench for union nut on drive
units
- Robot interface for connecting power source to the robot control
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)

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Application example
Application ex-
ample
(1) Connection to robot control (12) Robot
(2) Robot interface (13) Drum coil
(3) Connection to robot interface (14) Drum coil
(4) Interconnecting hosepack (15) FK 9000 R or FK 4000 R cooling
unit
(5) VR 7000 CMT or VR 1550 (16) TPS 5000 CMT power source
(6) VR 7000 CMT or VR 1550 (17) LHSB-HUB
(7) Wire buffer (18) FK 9000 R or FK 4000 R cooling
unit
(8) Wire buffer (19) TPS 5000 CMT power source
(9) Robacta Drive CMT drive unit (20) RCU 5000i
(10) Robacta Drive CMT drive unit (21) RCU 5000i
(11) Robacta Twin Compact Pro torch
neck
(22) Robot control
(1)
(11)
(12)
(22)
(2) (3) (4)
(17)
(6)
(9)
(10)
(20)
(21)
(18)
(19)
(15)
(16) (14) (13)
(5)
(8)
(7)

Installation and commissioning

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Safety
Safety Observe the following safety instructions for all work described in these operating instruc-
tions.
WARNING! Work that is carried out incorrectly can cause serious injury or dam-
age. All the work described below must only be carried out by trained and quali-
fied personnel. Do not carry out any of the work described below until you have
fully read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe-
ty rules
WARNING! Machines that start up automatically can cause serious injury and
damage. In addition to these operating instructions, the safety rules issued by the
manufacturers of the robot and welding systems must also be observed. For your
personal safety, ensure that all protective measures have been taken and will re-
main in place while you are in the working area of the robot.
WARNING! Work that is carried out incorrectly can cause serious injury or dam-
age. Before starting the work listed below:
- turn the mains switch of both power sources to the "O" position
- disconnect both power sources from the mains
- put up an easy-to-understand warning sign to stop anybody inadvertently
switching it back on again
WARNING! Risk of serious injury and damage from articles being dropped. All
the screw connections described below:
- must be checked after fitting to ensure they are tight
- must be checked after unusual events (e.g. a crash) to ensure they are tight
- must be checked regularly to ensure they are tight

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Notes regarding the installation of Fronius system
components
Installation and
commissioningof
Fronius system
components
Setup regulations
for the power
sources
NOTE! Install and commission Fronius system components (power source, wire-
feed unit, cooling unit, hosepack, RCU 5000i, LHSB-HUB, etc.) according to the
operating instructions of the relevant device.
NOTE! If the power sources are used with two FK 4000 R, ensure a minimum gap
of 1000 mm (39.07 in.) between the power sources in order to guarantee a suffi-
cient supply of fresh air to the cooling units.
NOTE! If the power sources are used with two FK 9000 R, ensure a minimum gap
of 1000 mm (39.07 in.) between the power sources in order to guarantee a suffi-
cient supply of fresh air to the cooling units.
1000 mm
(39.37 in.)

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Fitting wearing parts to the torch neck
Fitting wearing
parts to the torch
neck
1 2
3
12
3

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Fitting the mounting bracket and torch neck
Fitting the mount-
ing bracket to the
robot
1
Screw the torch
neck and drive
units to the
mounting bracket
1 2
3
1
1
2
1
3x M6x12
2x
M6x12
3
8Nm
2
3