Fronius TransPulsSynergic 4000 CMT is an inverter MIG/MAG power source with the Cold Metal Transfer process, an RCU 5000i panel and a Profinet module. The duty cycle is 400 A at 50% and 320 A at 100%, the supply 3 x 400 V with a 35 A fuse. Liquid cooling is built into the source.
What this machine is for
This is a source for heavy industry, the motor industry and robot stations. The Profinet module plugs it into robot controllers, for example Fanuc, Kuka or ABB, but the RCU 5000i panel also lets you work by hand, like a high class semi automatic machine. A reserve of 400 A at a 50% duty cycle and 320 A in continuous work is enough for thicker joints in series production.
The CMT process solves the problem of excess heat and spatter. The wire retracts mechanically at the moment of the short circuit, so the droplet detaches at a current close to zero and the arc looks almost static. The heat put into the material is small, so you weld sheet thinner than 1 mm without burn through and without distortion. The same process handles braze welding of galvanised sheet, where the zinc layer next to the weld is to stay intact, and the joining of dissimilar materials.
The Synchropuls software changes the arc energy cyclically, so the face lays in a regular ripple close to a TIG bead, at a speed typical for MIG/MAG. That matters on aluminium and on stainless steel, where the look of the weld is part of accepting the product. Spatter Free Ignition watches over a clean arc start, so parts going to painting need no cleaning after tacking.
A classic short arc in MIG/MAG tears the droplet off with current, hence the spatter and the heat spikes. CMT reverses that order: it is the wire drive, not the current, that ends the short circuit, so the energy needed to move the droplet is much lower. For the station that means less cleaning after welding, smaller distortion of thin parts and the option to join pairs of materials that a normal arc cannot join without burning one side through.
Features and equipment
- The CMT process, that is Cold Metal Transfer: the wire movement is linked digitally to the arc, the wire retracts at the short circuit, and the droplet passes into the pool at a very low current.
- Spatter Free Ignition: the system damps spatter already in the ignition phase, which tidies the look of parts meant for painting.
- Welding of sheet thinner than 1 mm: a small amount of heat put in protects against burn through and distortion.
- Braze welding of galvanised sheet: the zinc layer next to the weld is not destroyed.
- Synchropuls: a cyclic change of arc energy lays a regular ripple on aluminium and on stainless steel.
- RCU 5000i remote control panel: you switch synergic curves and correct the arc length without walking up to the source, and you see the parameters while working.
- Profinet module, Robot Interface: communication with the robot controller and transfer of process data.
- Built in liquid cooling: the circuit takes heat from the torch during long work at high current.
Technical data
| Brand | Fronius |
|---|---|
| Type | inverter MIG/MAG power source with the CMT process |
| Supply | 3 x 400 V |
| Fuse | 35 A |
| Duty cycle 50% | 400 A |
| Duty cycle 100% | 320 A |
| Digital communication | Profinet module, Robot Interface |
| Control panel | RCU 5000i |
| Software | CMT, Synchropuls, Spatter Free Ignition |
| Thinnest material given by the maker | under 1 mm in the CMT process |
| Cooling | liquid, built in system |
What you get
- Fronius TPS 4000 CMT liquid cooled power source
- RCU 5000i control panel
- Robot Interface Profinet communication module
- Synchropuls and Spatter Free Ignition software
What to watch out for
The supply is 3 x 400 V with a 35 A fuse, check the connection before installation. A 50% duty cycle at 400 A gives five minutes of welding in a ten minute window, work without a limit starts at 320 A. Liquid cooling is built in, so after delivery you check the fluid level and the tightness of the circuit.
The machines were taken off robot stations, so setting up Profinet communication for your controller needs the work of an automation engineer. The product card lists neither a wire feeder nor a torch nor interconnection cables, and without them the source does not run, so ask about the equipment before you buy. For the CMT process you need a torch with a wire retracting drive, and a normal MIG torch will not replace it.
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.
