Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this device and all system components.
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
Danger from electric current due to defective system components and incorrect operation.
This can result in serious personal injury and damage to property.
All cables, leads and hosepacks must always be securely connected, undamaged and correctly insulated.
Only use adequately dimensioned cables, leads and hosepacks.
Risk of coolant escaping.
This can result in serious personal injury and damage to property.
When disconnecting a welding torch from the cooling unit or other system components, always seal the coolant hoses using the plastic seal attached to the torch.
Danger due to hot system components and/or equipment.
Can result in serious burns or scalding.
Before starting work, allow all hot system components and/or equipment to cool to +25°C/+77°F (e.g., coolant, water-cooled system components, wirefeeder drive motor, etc.)
Wear suitable protective equipment (e.g., heat-resistant gloves, safety goggles, etc.) if cooling down is not possible.
Danger from contact with toxic welding fumes.
This can result in serious personal injuries.
Always extract welding fumes.
Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least 20 m³ (169070.1 US gi) per hour at all times.
If in doubt, a safety engineer should be commissioned to check the pollution level in the workplace.
Danger from operation without coolant.
This can result in damage to property.
Never operate water-cooled welding torches without coolant.
During welding, ensure that the coolant is circulating correctly – this will be the case for Fronius cooling units if a regular return flow of coolant can be seen in the coolant container of the cooling unit.
The manufacturer will not be liable for any damages due to non-observance of the above mentioned points. All claims against the warranty are void.
Danger of burns from hot surface.
Serious personal injuries may result.
When the ambient temperature in operation is at its maximum of 40°C, the surface temperature of the Robacta Drive CMT can rise as high as 90°C. This is a normal operating temperature and does not endanger the Robacta Drive CMT.
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this device and all system components.
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
Danger from electric current due to defective system components and incorrect operation.
This can result in serious personal injury and damage to property.
All cables, leads and hosepacks must always be securely connected, undamaged and correctly insulated.
Only use adequately dimensioned cables, leads and hosepacks.
Risk of coolant escaping.
This can result in serious personal injury and damage to property.
When disconnecting a welding torch from the cooling unit or other system components, always seal the coolant hoses using the plastic seal attached to the torch.
Danger due to hot system components and/or equipment.
Can result in serious burns or scalding.
Before starting work, allow all hot system components and/or equipment to cool to +25°C/+77°F (e.g., coolant, water-cooled system components, wirefeeder drive motor, etc.)
Wear suitable protective equipment (e.g., heat-resistant gloves, safety goggles, etc.) if cooling down is not possible.
Danger from contact with toxic welding fumes.
This can result in serious personal injuries.
Always extract welding fumes.
Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least 20 m³ (169070.1 US gi) per hour at all times.
If in doubt, a safety engineer should be commissioned to check the pollution level in the workplace.
Danger from operation without coolant.
This can result in damage to property.
Never operate water-cooled welding torches without coolant.
During welding, ensure that the coolant is circulating correctly – this will be the case for Fronius cooling units if a regular return flow of coolant can be seen in the coolant container of the cooling unit.
The manufacturer will not be liable for any damages due to non-observance of the above mentioned points. All claims against the warranty are void.
Danger of burns from hot surface.
Serious personal injuries may result.
When the ambient temperature in operation is at its maximum of 40°C, the surface temperature of the Robacta Drive CMT can rise as high as 90°C. This is a normal operating temperature and does not endanger the Robacta Drive CMT.
The Robacta Drive CMT robot welding torch consists of atorch neck, drive unit with fixing bracket and hosepack.
In combination with the wire buffer on the hosepack, the integral wire drive motor can quickly reverse the welding wire. The external wirefeed means that all wirefeed components can be replaced quickly. Many different torch neck designs facilitate easy access to the weld.
The Robacta Drive CMT robot welding torch consists of atorch neck, drive unit with fixing bracket and hosepack.
In combination with the wire buffer on the hosepack, the integral wire drive motor can quickly reverse the welding wire. The external wirefeed means that all wirefeed components can be replaced quickly. Many different torch neck designs facilitate easy access to the weld.
a) Graphite with end piece | |
b) Graphite | |
c) Bronze | |
d) Steel |
* „Spanner for union nut“ (optional) |
* Blade terminal on housing | |
** Gas nozzle positioning kit incl. - 290 mm sensor cable - 430 mm sensor cable (depending on length and bend in the torch neck) |
(1) | Robacta 2801) : 22° |
(2) | Robacta 3001) : 22°, 36° |
(3) | Robacta 4001) : 22°, 36° |
(4) | Robacta 5002) : 22°, 36° |
(5) | Robacta 7002) : 22°, 36° |
(6) | Robacta 50002) : 22°, 36° |
Contact tubes required:
1) M8 CB contact tube (with centre hole) | |
2) M10 CB contact tube (with centre hole) |
The following assembly steps are explained using a Robacta 300 / 500 as the example. Assembly with other torch necks is carried out in a similar manner.
IMPORTANT! Use only contact tubes with centre holes.
* If a Robacta 280 45° torch body is being used, the wire guide 44,0350,1806 can only be fitted and removed from the front. |
IMPORTANT! When cutting the wire guide insert to length, make sure that
Use the power tong (item no. 42,0435,0009) to shorten the steel wire guide.
IMPORTANT! Take care to ensure the following when attaching the torch neck to the Robacta Drive CMT coupling point: the wire guide insert must slide into the outlet section on the Robacta Drive CMT coupling point without kinking.
Risk of coolant escaping.
This can result in damage to property.
Ensure union nut fits tightly when assembling torch neck.
IMPORTANT! Use only the locking tool supplied with the system to undo and tighten the drive rollers.
IMPORTANT! When fitting the hosepack, lay the connection cable in the recess (Fig. 5). Be sure to connect the plug connectors correctly.
* Torques: 3.0 Nm | |
** Torques: 1,5 Nm |
IMPORTANT! When fitting the hosepack, lay the connection cable in the recess (Fig. 5). Be sure to connect the plug connectors correctly.
* Torques: 3,0 Nm | |
** Torques: 3,0 Nm |
IMPORTANT! The wirefeeding hose must not be pulled out of the hosepack. Refitting can only be performed by Fronius.
IMPORTANT! Do not subject the wirefeeding hose between the wire buffer and the Robacta Drive CMT to tensile stress.
* For detailed information on fitting the hosepack to the respective robot types, please refer to the „Fitting the CMT hosepack with wire buffer to the robot“ leaflet (42,0410,1518). |
IMPORTANT! Do not subject the wirefeeding hose between the wire buffer and the Robacta Drive CMT-PAP W to tensile stress.
IMPORTANT! When connecting the torch check that
* Control cable for wire buffer | |
** Torch blow-through option |
IMPORTANT! Ensure the blowthrough line is tightly sealed if the torch blow-through option is not being used.
Risk of damage to dangling wirefeed hose.
This can result in damage to property.
Fasten the wirefeed hose to the hosepack in such a way that it cannot dangle close to surrounding machines or components (Fig. 3 + 6).
Figures 4 + 5 do not apply to robot welding torches (PAP)
To attain optimum wirefeed, observe the following when laying the hose pack:
To attain optimum wirefeed, observe the following when laying the hose pack:
Danger from welding wire emerging at speed.
This can result in serious personal injuries.
Hold the torch so that it points away from your face and body.
IMPORTANT! Deburr welding wire before feeding in. Open clamping lever when feeding in soft welding wire (AlSi 5, Al, and AlMg).
* LED illuminated | |
- green: ready for use - red: no control signal connection |
IMPORTANT! If LED is not illuminated: Check power supply to drive unit.
Danger of injury due to rotating feed rolls.
This can result in serious personal injuries.
Do not touch the feed rolls.
IMPORTANT! The adjuster screw can only be adjusted when the welding wire has been fed in. The values stated are applicable when the adjuster screw is closed.
IMPORTANT! When fitting the Robacta Drive CMT flex (22° / 36°) fixing bracket, ensure that the installation marker for the desired angle matches the installation marker on the Robacta Drive CMT (TCP in 6th robot axis).
* Torque: 2,4 Nm |
Risk of scalding due to hot coolant.
This can result in serious personal injuries.
Turn mains switch on power source to - O - position prior to removing torch neck.
IMPORTANT! Do not allow coolant to leak out. Pay attention to the following points when removing the pipe bend from the Robacta Drive coupling point:
Danger of burns from hot torch neck
This can result in serious personal injuries.
Allow the torch neck to cool down before changing the gas nozzle positioning kit.
Switch the power source mains switch to the „O“ position.
IMPORTANT! The union nut (*) must be by the torch neck before the gas nozzle positioning kit is installed.
* Union nut |
Position cable correctly:
** Gas nozzle side | |
*** Drive unit side |
Regular and preventive maintenance of the CMT robot welding torch is essential for problem-free operation. The welding torch is subjected to high temperatures and heavy soiling. The welding torch therefore requires more frequent maintenance than other components in the welding system.
IMPORTANT! When removing welding spatter, avoid scoring or scratching the torch. Future welding spatter may become firmly lodged in score or scratch marks.
Regular and preventive maintenance of the CMT robot welding torch is essential for problem-free operation. The welding torch is subjected to high temperatures and heavy soiling. The welding torch therefore requires more frequent maintenance than other components in the welding system.
IMPORTANT! When removing welding spatter, avoid scoring or scratching the torch. Future welding spatter may become firmly lodged in score or scratch marks.
* Check spatter guard and insulation for damage |
Waste electrical and electronic equipment must be collected separately and recycled in an environmentally-friendly way, in accordance with the European Directive and national legislation. Used equipment must be returned to the distributor or disposed of via an approved local collection and disposal facility. Correct disposal of used equipment promotes the sustainable recycling of material resources. Failing to dispose of used equipment correctly can lead to adverse health and/or environmental impacts.
Packaging materials
Separate collection according to material. Check your local authority regulations. Crush containers to reduce size.
The Robacta Drive CMT robot welding torch is designed for automated applications in conjunction with a collision box and at normal welding speeds.
Fronius International GmbH accepts no liability for any other use.
Undoing sealed screws can damage the drive unit. Fronius International GmbH accepts no liability if sealed screws are undone.
Cause: | Incorrect earth (ground) connection |
Remedy: | Check the earth (ground) connection and clamp for correct polarity |
Cause: | There is a break in the current cable in the Robacta Drive CMT hosepack |
Remedy: | Contact After-Sales Service |
Cause: | Loose connection on hosepack |
Remedy: | Check that hosepack is firmly in place |
Cause: | Control plug or motor plug not plugged in |
Remedy: | Plug in the control plug or motor plug |
Cause: | The control line or motor lead is defective |
Remedy: | Contact After-Sales Service |
Cause: | Drive unit is faulty |
Remedy: | Contact After-Sales Service |
Cause: | The interconnecting hosepack is faulty or not connected properly |
Remedy: | Check the interconnecting hosepack and connection |
Cause: | The gas cylinder is empty |
Remedy: | Change the gas cylinder |
Cause: | Gas pressure regulator is faulty |
Remedy: | Change the gas pressure regulator |
Cause: | The gas hose is not connected, or is damaged or kinked |
Remedy: | Fit gas hose, lay out straight or change |
Cause: | Welding torch is faulty |
Remedy: | Exchange the welding torch |
Cause: | Gas solenoid valve in the CMT feeder is faulty |
Remedy: | Exchange the gas solenoid valve in the CMT feeder |
Cause: | Incorrect welding parameters |
Remedy: | Check the settings |
Cause: | Poor connection to earth (ground) |
Remedy: | Ensure good contact to workpiece |
Cause: | Not enough shielding gas, or none at all |
Remedy: | Check the pressure regulator, gas hose, gas solenoid valve and torch gas connection. On gas-cooled welding torches, inspect the gas seals, use a suitable inner liner. |
Cause: | Connections leaking |
Remedy: | Tighten connections |
Cause: | Contact tube does not fit or is damaged |
Remedy: | Change the contact tube |
Cause: | Wrong wire alloy or wrong wire diameter |
Remedy: | Check the wirespool that has been inserted, check the weldability of the base metal |
Cause: | The shielding gas is not suitable for this wire alloy |
Remedy: | Use the correct shielding gas |
Cause: | Unfavourable welding conditions: shielding gas is contaminated (by moisture, air), inadequate gas shielding (weld pool „boiling“, draughts), contaminants in the workpiece (rust, paint, grease) |
Remedy: | Optimise the welding conditions |
Cause: | Gas nozzle soiled |
Remedy: | Remove welding spatter |
Cause: | Turbulence caused by too high a rate of shielding gas flow |
Remedy: | Reduce amount of shielding gas, recommended: shielding gas quantity (l/min) = wire diameter (mm) x 10 (e.g. 16 l/min for 1.6 mm welding wire) |
Cause: | Too large a distance between the contact tube and the workpiece. |
Remedy: | Reduce the distance between the contact tube and the workpiece (approx. 10-15 mm) |
Cause: | Tilt angle of the welding torch is too great |
Remedy: | Reduce the tilt angle of the welding torch |
Cause: | The wirefeed components do not match the welding wire diameter |
Remedy: | Use the correct wirefeed components |
Cause: | Loss of gas or extraneous air |
Remedy: | Check leak-tightness of blow-through line and blow-through valve. Check closure seal of blowthrough line (push-on nipple) |
Cause: | Wire does not fit |
Remedy: | Check the position of the wire inlet nozzle relative to the feed rollers, and correct as necessary |
Cause: | Brake force on the CMT wirefeeder set too high |
Remedy: | Set the brake on the CMT wirefeeder to a looser setting |
Cause: | Hole in contact tube constricted due to deposits |
Remedy: | Change the contact tube |
Cause: | The wire feed inner liner or wire feed insert is defective |
Remedy: | Check the wire feed inner liner and wire feed insert for kinks, dirt, etc. ; change the faulty liner or wire feed insert |
Cause: | The wirefeed rollers are not suitable for the wire electrode being used |
Remedy: | Use suitable wire feed rollers |
Cause: | The wirefeed rollers are exerting the wrong contact pressure |
Remedy: | Check the contact pressure, adjust if necessary |
Cause: | The wirefeed rollers are soiled or damaged |
Remedy: | Clean the wirefeed rollers or exchange them for new ones |
Cause: | Inner line was kinked while being inserted |
Remedy: | When inserting the inner liner, only handle it around the infeed tube |
Cause: | The inner liner has been cut too short |
Remedy: | Replace the inner liner and cut it to the correct length |
Cause: | Welding wire worn due to heavy contact pressure at the feed rollers |
Remedy: | Reduce contact pressure at the feed rollers |
Cause: | Welding wire contains impurities or is corroded |
Remedy: | Use high-quality welding wire with no impurities |
Cause: | Union nut on torch neck connection loose |
Remedy: | Tighten the union nut |
Cause: | The welding torch has been operated beyond its maximum duty cycle. |
Remedy: | Lower the welding power or use a higher-capacity torch; observe the duty cycle and loading limits |
Cause: | Coolant flow rate too low |
Remedy: | Check coolant level, coolant through-flow, cleanliness of coolant, arrangement of hosepack, etc. |
Cause: | Welding wire worn due to heavy contact pressure at the feed rollers |
Remedy: | Reduce contact pressure at the feed rollers |
Cause: | Wrong dimension of contact tube |
Remedy: | Use a contact tube of the correct dimension |
Cause: | Duty cycle of welding torch has been exceeded |
Remedy: | Shorten the ON times or use a higher-capacity torch |
Cause: | Contact tube has overheated. No thermal dissipation, as the contact tube is fitted too loosely |
Cause: | Tighten the contact tube |
NOTE!When using CrNi, the contact tube may be subject to a higher degree of wear due to the nature of the surface of CrNi welding wire. |
Cause: | Plug-in connections of „control line/power source“ faulty |
Remedy: | Check plug connection / Contact After-Sales Service |
Cause: | Control line is faulty |
Remedy: | Replace control line / Contact After-Sales Service |
Cause: | Soiled gas nozzle, causing inadequate gas-shielding of the weld seam |
Remedy: | Remove welding spatter |
Cause: | Either the shielding gas hose has holes in it, or the hose is not connected properly |
Remedy: | Change the shielding gas hose, ensure the hose is connected properly |
Cause: | The O-ring seals on the connection points are faulty |
Remedy: | Change the O-ring seals |
Cause: | Moisture/condensation in the shielding gas hose |
Remedy: | Dry the shielding gas hose |
Cause: | Shielding gas flow is either too high or too low |
Remedy: | Correct the shielding gas flow |
Cause: | Insufficient shielding-gas flow at the beginning or end of welding |
Remedy: | Increase gas pre-flow or gas post-flow |
Cause: | Rusty or poor quality welding wire |
Remedy: | Use high-quality welding wire with no impurities |
Cause: | Too much parting agent applied |
Remedy: | Wipe off excess parting agent / apply less parting agent |
Explanation of symbols
Water cooling | |
Length of the hosepack | |
X | Duty cycle in % |
Imax | max. welding current in A |
Electrode diameter | |
* | Lowest cooling power as per IEC 60974-2 |
This product conforms to the requirements of IEC 60974-7.
|
| Robacta 300 | Robacta 500 | Robacta 700 | |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | |
[mm] | 0,8 - 1,2 | 0,8 - 1,6 | 1,0 - 1,6 |
|
| Robacta 5000 | Robacta 7000 | Robacta Twin Compact PRO | |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | |
[mm] | 0,8 - 1,6 | 1,0 - 1,6 | 1,0 - 1,6 |
|
| Robacta Drive CMT/PAP | Robacta Drive CMT Twin | ||
X / I max (10 min / 40°C) | [%] / [A] | 40 / 500 | - | ||
X / I max (10 min / 40°C) | [%] / [A] | 40 / 500 | - | ||
[mm] | 0,8 - 1,2 (Alu 1,6) | 0,8 - 1,2 (Alu 1,6) | |||
Pmin* |
| [m] ([W]) | 4,25 (800) / 6,25 (1100) / 8,25 (1400) | 4,25 (1950) / 6,25 (2500) / 8,25 (3100) | |
Qmin | [L/min] | 1 | 1 | ||
Pmin | [bar] | 3 | 3 | ||
Qmin | [bar] | 5,5 | 5,5 | ||
[V] DC | 55 | 55 | |||
[A] | 2,5 | 2,5 | |||
[min] | 0,5 - 22 | 0,5 - 22 |
Explanation of symbols
Water cooling | |
Length of the hosepack | |
X | Duty cycle in % |
Imax | max. welding current in A |
Electrode diameter | |
* | Lowest cooling power as per IEC 60974-2 |
This product conforms to the requirements of IEC 60974-7.
|
| Robacta 300 | Robacta 500 | Robacta 700 | |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | |
[mm] | 0,8 - 1,2 | 0,8 - 1,6 | 1,0 - 1,6 |
|
| Robacta 5000 | Robacta 7000 | Robacta Twin Compact PRO | |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | |
X / I max (10 min / 40°C) | [%] / [A] | - | - | - | |
[mm] | 0,8 - 1,6 | 1,0 - 1,6 | 1,0 - 1,6 |
|
| Robacta Drive CMT/PAP | Robacta Drive CMT Twin | ||
X / I max (10 min / 40°C) | [%] / [A] | 40 / 500 | - | ||
X / I max (10 min / 40°C) | [%] / [A] | 40 / 500 | - | ||
[mm] | 0,8 - 1,2 (Alu 1,6) | 0,8 - 1,2 (Alu 1,6) | |||
Pmin* |
| [m] ([W]) | 4,25 (800) / 6,25 (1100) / 8,25 (1400) | 4,25 (1950) / 6,25 (2500) / 8,25 (3100) | |
Qmin | [L/min] | 1 | 1 | ||
Pmin | [bar] | 3 | 3 | ||
Qmin | [bar] | 5,5 | 5,5 | ||
[V] DC | 55 | 55 | |||
[A] | 2,5 | 2,5 | |||
[min] | 0,5 - 22 | 0,5 - 22 |