The Fronius TransPuls Synergic 4000 is a digital inverter MIG/MAG power source with a pulsing arc and synergic lines, run from a 3 x 400 V supply. You set the current from 3 to 400 A, at a 50% duty cycle the machine gives 400 A, at 60% it gives 365 A, and in continuous work 280 A. The source weighs about 35.6 kg and works with a separate wire feeder and an FK 4000 liquid cooling module.
What this machine is for
This is a unit for series production and for robot cells. A signal processor watches the course of the short circuits and doses the melting energy, so the joints come out repeatable, and the arc reacts to disturbances in the welding zone at once. The basis of the work are the synergic curves: you point to the wire, the gas and the current, and the machine picks the rest of the settings. In pulse mode digital packets of current detach the drops without mechanical contact with the pool, so there is little spatter, and the heat put into stainless steel or galvanised sheet stays lower than with a spray arc. The pulsing transfer itself is louder than a plain arc, which is worth saying to an operator moving over from a simpler machine. An inverter construction also limits power losses compared with a transformer source of similar current, which in multi shift work shows in the energy use.
Besides MIG/MAG the machine handles TIG DC with a contact start and a covered electrode. In TIG there is the Comfort Stop function, which detects the torch being moved away and starts the fade with a falling current, so the crater closes itself. In MMA mode you have HotStart, which lifts the voltage when you scratch the electrode on the sheet, and Anti-Stick, which cuts the current when the tip sticks. On top of that there is a spot cycle with a timer, where the machine ends the arc after a set time whatever the trigger is doing, which evens out the size and the strength of the tack welds.
The maker pointed this model to automated lines in the automotive trade, to heavy load bearing structures on girders, to large tanks and masts, to reclamation of mining equipment with thick alloy wires, to the shipbuilding industry and to pulse welding of aluminium sections in rail vehicles and of acid resistant assemblies. The machine is prepared to work with robots: it has a programmable two stroke mode for manipulators, and it runs the communication with the master controller through digital modules and factory network cards. The robot then gets information about striking, voltage and faults, so the arm reacts to what is really happening in the joint, and not to a rigidly programmed time.
Features and equipment
- Signal processor control: the circuit corrects the arc characteristic as it goes and evens out disturbances in the welding zone.
- Current range from 3 to 400 A with duty cycles of 400 A at 50%, 365 A at 60% and 280 A at 100%: from thin sheet to long work at a high current.
- Synergic lines and pulse mode: you pick the wire, the gas and the current, and the machine counts the rest of the settings.
- Spatter-Free Ignition: before the full strike the machine steers the base current and the wire feed, so the start does not spread spatter around the nozzle.
- Job Mode memory: you store a full set of settings under a number, which shortens changeovers and puts quality in order in the plant.
- Arc break control: on a sudden loss of the arc the circuit cuts the current in milliseconds and stops the carriage on a mechanised bay.
- Ignition Time-Out protection: when the wire does not touch the earth within a set time, the machine cuts off the feed and the gas flow.
- Interface for industrial robots: a programmable two stroke mode and exchange of data about striking, voltage and faults.
- TIG DC with a contact start and the Comfort Stop function: the arc fades with a falling current after the torch is moved away.
- MMA with HotStart and Anti-Stick: a sure start on thicker cores and protection of the electrode when it sticks.
- Spot welding cycle with a timer: a repeatable size and energy of every tack weld.
- Four roll wire drive in a separate VR 4000 or VR 1500 feeder, with a brushless motor that corrects the feed whatever the resistance of the torch liner.
- FK 4000 liquid cooling module: a forced coolant circuit takes heat off the torch neck at currents close to 400 A and protects the contact tips against fast wear.
- Separation of the source and the wire drive: the power unit stays in one place, and the light feeder goes after the welder over a large three dimensional structure.
- Brushless motor in the drive: the feed is even also with soft alloys, for example with aluminium wire, where a snatch shows in the weld at once.
- Open circuit voltage about 70 V: a sure strike also on dirty material.
Technical data
| Brand | Fronius |
|---|---|
| Type | digital inverter MIG/MAG power source |
| Processes | MIG/MAG, pulse, TIG DC, MMA |
| Supply voltage | 3 x 400 V |
| Welding current range | from 3 to 400 A |
| Current at 50% duty cycle | 400 A |
| Current at 60% duty cycle | 365 A |
| Current at 100% duty cycle | 280 A |
| Open circuit voltage | about 70 V |
| Protection class | IP23 |
| Weight of the source | about 35.6 kg |
| Dimensions (l x w x h) | about 625 x 290 x 475 mm |
| Torch cooling | liquid, FK 4000 module |
What to watch out for
The supply is 3 x 400 V, the protection class is IP23. The source itself weighs about 35.6 kg at dimensions of 625 x 290 x 475 mm, but that is only the power unit: for work you need a feeder, a cooler and a package of interconnection cables, so a complete bay is much heavier and dearer than the box alone. When you buy, settle which parts of this layout you get, because the feeder and the cable package are separate items. Work with a robot needs network cards and communication cables for the given model of manipulator on top of that.
Densely packed electronics do not take conductive dust, which is why in a dusty shop the machine has to be blown out from time to time. The cooling system needs the filters, the fluid level and the tightness of the couplings to be checked, and with a liquid cooled torch an empty circuit means damage in a few seconds. A contact start in TIG does not suit jobs in which tungsten inclusions are not allowed. The arc break control can be sensitive on parts with an anti corrosion coating of changing thickness, where the short circuits last longer and can look like a loss of the arc. The ignition time protection works properly only with a clean contact of the earth clamp, so it pays to keep the place where the earth is connected tidy.
This unit is sold
This machine has already gone to a customer. Similar units are listed below, and if you want the same model, leave your contact details in the form and we will let you know when the next one arrives.