Wire buffer test box
Safety
WARNING!
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.
WARNING!
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.
After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.
Safety
WARNING!
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.
WARNING!
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.
After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.
General remarks
If you have any questions about the tests, a team of experts is on hand.
E-Mail: welding.techsupport@fronius.com
Device concept
The wire buffer test box is used for checking output signals from the wire buffer. The wire buffer’s communication can also be checked with the power source to which it is connected.
Controls and connections
| (1) | Torch control connecting cable for connecting to a power source or a wire-feed unit |
| (2) | Wire buffer connecting cable for connecting to a power source or a wire-feed unit |
| (3) | BNC socket for measuring the output signals using a BNC plug |
| (4) | Minus potential connection for measuring the output signals using a digital multimeter |
| (5) | Plus potential connection for measuring the output signals using a digital multimeter |
| (6) | Wire buffer connection for connecting a wire buffer |
| (7) | Guntrigger switch for triggering welding start-up using the test box |
Measuring and testing equipment
- CMT power source + CMT wire-feed unit or
- CMT test power source (adapted TPS 2700)
- Digital multimeter
Checking the wire buffer on a Robacta Drive CMT hosepack
Preparations
1Turn power source mains switch to the „O“ position
2Disconnect the power source from the mains
3Feed the wire electrode out of the hosepack
4Disconnect the welding torch from all other system components
5Connect the wire buffer test box to the power source or wire-feed unit using the wire buffer connecting cable (1) and the torch control connecting cable (2)
6Connect wire buffer to wire buffer test box (3)
7Prepare the digital multimeter for measuring DC voltage
8Connect a digital multimeter to the wire buffer test box (4)
Preparations
1Turn power source mains switch to the „O“ position
2Disconnect the power source from the mains
3Feed the wire electrode out of the hosepack
4Disconnect the welding torch from all other system components
5Connect the wire buffer test box to the power source or wire-feed unit using the wire buffer connecting cable (1) and the torch control connecting cable (2)
6Connect wire buffer to wire buffer test box (3)
7Prepare the digital multimeter for measuring DC voltage
8Connect a digital multimeter to the wire buffer test box (4)
Checking the wire buffer
WARNING!
Risk of electric shock, if the power source is ON.
This can result in serious personal injury and damage to property.
During all work: ensure that no welding operation is started,
do not touch the central connection of the power source
Wire buffer lever upper stop
1Connect the power source to the mains
2Turn the power source mains switch to the „I“ position
3Push up the wire buffer lever (1) as far as its upper stop in order to simulate wire buffer full
„Wire buffer full“ set value: 2.34 - 2.46 volts
Wire buffer lever lower stop
4Push down the wire buffer lever (2) as far as its lower stop in order to simulate „wire buffer empty“
„Wire buffer empty“ set value: 0.42 - 0.54 volts
5Once the test has been completed, restore the wire buffer to its original state
Checking the wire buffer on a PullMig CMT hosepack
General remarks
To enable the wire buffer’s output signals to be tested in conjunction with a PullMig CMT hosepack, the wire buffer’s control line must be changed.
IMPORTANT! The wire buffer control line, item no. 43,0004,2803, is not included in the scope of supply of the wire buffer test box.
Symbols used | |
Torch side | |
Feed side | |
General remarks
To enable the wire buffer’s output signals to be tested in conjunction with a PullMig CMT hosepack, the wire buffer’s control line must be changed.
IMPORTANT! The wire buffer control line, item no. 43,0004,2803, is not included in the scope of supply of the wire buffer test box.
Symbols used | |
Torch side | |
Feed side | |
Preparations
1Turn power source mains switch to the „O“ position
2Disconnect the power source from the mains
3Feed the wire electrode out of the hosepack
4Disconnect the welding torch from all other system components
5Remove cover from the control line
6Unplug the wire buffer’s existing control line
7Temporarily connect the wire buffer control line, item no. 43,0004,2803, to the wire buffer
8Connect the wire buffer test box to the power source or wire-feed unit using the wire buffer connecting cable (1) and the torch control connecting cable (2)
9DConnect wire buffer to wire buffer test box (3)
10Prepare the digital multimeter for measuring DC voltage
11Connect a digital multimeter to the wire buffer test box (4)
Checking the wire buffer
WARNING!
Risk of electric shock, if the power source is ON.
This can result in serious personal injury and damage to property.
During all work: ensure that no welding operation is started,
do not touch the central connection of the power source
Wire buffer lever upper stop
1Connect the power source to the mains
2Turn the power source mains switch to the „I“ position
3Push up the wire buffer lever (1) as far as its upper stop in order to simulate wire buffer full
„Wire buffer full“ set value: 2.34 - 2.46 volts
Wire buffer lever lower stop
4Push down the wire buffer lever (2) as far as its lower stop in order to simulate „wire buffer empty“
„Wire buffer empty“ set value: 0.42 - 0.54 volts
5Once the test has been completed, restore the wire buffer to its original state
Checking error messages
Safety
WARNING!
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.
Only qualified technicians, who have attended the appropriate Fronius training course, are permitted to commission and operate the device.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this device and all system components.
WARNING!
Danger due to welding processes starting unintentionally.
This can result in serious personal injury and damage to property.
The following steps should only be carried out when there is no wire being fed in the welding system.
Safety
WARNING!
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.
Only qualified technicians, who have attended the appropriate Fronius training course, are permitted to commission and operate the device.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this device and all system components.
WARNING!
Danger due to welding processes starting unintentionally.
This can result in serious personal injury and damage to property.
The following steps should only be carried out when there is no wire being fed in the welding system.
Preparations
1Turn power source mains switch to the „O“ position
2Disconnect the power source from the mains
3Feed the wire electrode out of the hosepack
4Disconnect the welding torch from all other system components
Checking error messages
In welding systems that have an external welding start-up facility (robot applications) it is possible to trigger welding start-up using the Guntrigger switch on the wire buffer test box. This enables error messages to be checked easily at the power source’s indicators. To check error messages, proceed as follows:
1Connect the wire buffer test box to the power source or wire-feed unit using the wire buffer connecting cable (1) and the torch control connecting cable (2)
2Connect wire buffer to wire buffer test box (3)
3Connect the power source to the mains
4Turn the power source mains switch to the „I“ position
5Push up the wire buffer lever as far as its upper stop and hold it in this position
6At the same time, move the Guntrigger switch to the ON position
- The power source indicators should be indicating the error message Efd I 15.2 wire buffer full
7Push down the wire buffer lever as far as its lower stop and hold it in this position
8At the same time, move the Guntrigger switch to the ON position
- The power source indicators should be indicating the error message Efd I 15.1 wire buffer empty