Fronius TransPuls Synergic 5000 CMT is a digital, inverter MIG/MAG power source with a current from 3 to 500 A, sold with an external VR 7000 CMT feeder and an RCU 5000i panel. At a 40% duty cycle the machine gives 500 A, and in continuous work 320 A. The supply is 3 x 400 V with a 35 A fuse, the cooling is run by a liquid system.
What this machine is for
The base of this set is the Cold Metal Transfer process. The wire is drawn back mechanically at the moment of the short circuit, at a frequency from 50 to 170 Hz, which breaks the arc and transfers the drop at the lowest possible current. The result is practically no spatter, an even ripple and a very small amount of heat put into the material, so you join sheet a fraction of a millimetre thick without distortion. The station for grinding off spatter disappears with it, and in series production that can cost more than the welding itself. This is a completely different logic than in a classic short circuit arc: instead of putting out the effects of the short circuit with current, the machine physically pulls the wire back and transfers the drop at a current close to zero.
Beyond CMT itself the machine has three more modes. CMT-Pulse combines CMT cycles with high current pulse phases, so you fuse deeper into thicker walls, aluminium alloys and CrNi steels without overheating the material. MIG/MAG Puls Synergic tears off a single drop per impulse, without a short circuit, and the system picks the relation of the base current to the peak impulse against the wire speed itself. On top of that comes braze welding with the CuSi 3 and CuAl 9 programs, with which you join galvanised steel without melting the base sheet, keeping the anti corrosion coating, and curves for the aluminium alloys AlMg 5 and AlSi 5.
The manufacturer aimed this system at welding shops introducing CMT, at sheet metal shops and the automotive sector joining galvanised sheet, at makers of aluminium structures that need control over heat and at plants that carry high costs of mechanical removal of spatter. The uses listed are robotised large series production on thin steels, neat joining of acid resistant CrNi 18 8 and CrNi 19 9 steels, braze welding of thin galvanised sheet in ventilation structures and repairs of difficult aluminium alloys. The set is prepared for manual operation and for a mechanised station, because the power source has a library of digital programs, and the feeder is tied to it by a bus and controlled straight from the panel.
Features and equipment
- MIG/MAG current range from 3 to 500 A with a duty cycle of 500 A at 40% and 320 A at 100%: a reserve for thick welds and a high current in continuous work.
- Cold Metal Transfer process: mechanical retraction of the wire at the short circuit at a frequency from 50 to 170 Hz, without spatter and with minimal heat put in.
- CMT-Pulse: CMT cycles interleaved with pulse phases give deeper fusion in thicker walls, aluminium alloys and CrNi steels without overheating the base.
- MIG/MAG Puls Synergic: one drop per impulse, without a short circuit, with automatic choice of the base and peak current for the wire feed speed.
- Braze welding CuSi 3 and CuAl 9: joining of galvanised steel without melting the base sheet, keeping the anti corrosion coating.
- Curves for the aluminium alloys AlMg 5 and AlSi 5: a lowered current at the start protects cold material, and the fade out takes the high thermal conductivity of the alloy into account.
- Wire diameters handled 0.8, 0.9, 1.0 and 1.2 mm: the full range for thin sheet and thicker joints.
- External VR 7000 CMT feeder with a four roll drive, liquid cooled: it synchronises with the reversing drive in the torch and compensates the wire tension, also with soft aluminium alloys.
- RCU 5000i panel: digital displays and a large selection indicator, navigation through the processes, the lists of characteristics, the Job functions and the pulse programs, and corrections straight from the panel.
- Special 4-Step: an extended four step sequence with a start current, stabilisation of the main phase and slow fading of the crater, useful on long stretches and on aluminium.
- JOB mode with a save button: the engineer sets the dynamics, the currents and the gas program, and the operator calls up a ready set, which shortens changeovers.
- Corrections of the dynamics and of the arc length: control of the arc stiffness in short circuit mode and Droplet Detachment, which controls the release of the drop in CMT.
- Burn-Back: burn back of the wire at the end of a weld, so the tip is ready for the next strike and does not stick into the pool.
- Inch Forward and Purge buttons: calm feeding of soft wire without current and a gas purge to set the flow meter without using up filler.
- Open circuit voltage 70 V and protection rating IP23: a sure strike and a housing prepared for hall conditions.
- Manual and robotised work from one power source: a rich library of digital programs handles both modes of production.
Technical data
| Brand | Fronius |
|---|---|
| Model | TransPuls Synergic 5000 CMT |
| Supply | 3 x 400 V |
| Mains fuse | 35 A |
| MIG/MAG current range | from 3 to 500 A |
| Duty cycle 40% | 500 A |
| Duty cycle 100% | 320 A |
| Open circuit voltage | 70 V |
| Wire retraction frequency in CMT | from 50 to 170 Hz |
| Protection rating | IP23 |
| Wire diameters handled | 0.8, 0.9, 1.0 and 1.2 mm |
| Wire feeder | VR 7000 CMT, 4 roll, liquid cooled |
| Torch cooling | liquid |
What you get
- Fronius TransPuls Synergic 5000 CMT power source
- VR 7000 CMT wire feeder, four roll, liquid cooled
- RCU 5000i control panel
What to watch out for
The supply is 3 x 400 V with a 35 A fuse, so the station needs a proper power connection. The duty cycle is 500 A at 40% and 320 A at 100%, the open circuit voltage is 70 V, and the housing has protection rating IP23. The most important thing with this set is the torch: the CMT process needs a torch with a buffer and mechanical retraction of the wire, and the description does not list it in the set, so confirm the configuration before you buy, because without that part CMT will not run.
Liquid cooling covers the feeder as well, so before the start you check the coolant level, the flow in the circuit and the tightness of the quick couplings. The set with the power source, the feeder and the panel is heavy and elaborate, plan a fixed station for it and interconnection cables of the right length. The RCU 5000i panel gives many functions, so it is worth starting the training by going through the program lists and saving your own tasks. The feeder talks to the power source digitally, and you make corrections of the feed speed and of the arc length from the panel, not on the feeder itself.
How we sell used machines
This unit was checked in our service workshop in Krotoszyn with measurements to PN-EN 60974-4 and a load test. The price includes the first year of the basic service package: an inspection with cleaning of the machine and a validation measurement. Further years can be added. We ship across the European Union, collection in person by appointment.
