Katalog Gb

Product catalogue 2008 /2009Sales division welding technology

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8485868686

Manual power sourcesRobot power sourcesOptionsWelding torches

Manual power sources MagicCleanerRobot power sourcesOptionsWelding torches

Manual power sources

Plasma weldingSoftPlasmaPlasma keyhole welding at robotPlasma welding torches

LaserHybridLaser Coldwire, Laser Hotwire

DeltaSpot

TransCut 300

Standard componentsOrbital

International welding accessoriesTeachware SetWelding samplesFronius CollectionCalibration system

MIG/MAG

TIG

MMA welding rectifer

Plasma

Laser

Resistance welding

Plasma Cutting

Automation components

Miscellaneous

4

Wire feed unitWire Ø inch 0.03 – 0.06

mm 0,8 – 1,6Wire feed speed ipm 0 – 708.66

m/min 0 – 18

VarioStar 1500 / 2500 / 3100

Recommended base metalsConstructional steelsFerritic / austenitic CrNi steelsDuplex steelsAluminium materials

Standard equipment2-roller driveWire-inching without gas or currentS-mark, CE-mark Overtemperature protection2-step mode, 4-step modeIntermittent weldingManual modeSpot-welding

Recommended areas of useMaintenance and repairMetal & portal construction, fitters’s shopsand smithies

OptionsGas pre-heating socket 42 V / 230 VRubber matPolarity reversalHolding device for gas bottles, widePlastic handle for VSTCurrent rush limiterThermostat-controlled fanIsolation wire coil, adapter wire coil

ProcessesMIG/MAG welding

Wire coil mounting D 200, D 300Large dimensioned wheels

Power source VST 1500 VST 2500 VST 3100Mains voltage +/–10 % 50/60 Hz 230 V 3 x 230 V / 400 V 3 x 230 V / 400 VCos phi 0,89 0,95 0,95Welding current range 30 – 140 A 25 – 250 A 20 – 310 AWelding current at 10 min / 40° C 18 % d.c. 140 A 27 % d.c. 250 A 30 % d.c. 310 A

10 min / 40° C 60 % d.c. 70 A 60 % d.c. 160 A 60 % d.c. 190 A10 min / 40° C 100 % d.c. 55 A 100 % d.c. 130 A 100 % d.c. 140 A

Switch steps 6 10 15Open-circuit voltage 34 V 38 V 46 VOperating voltage 15,5 – 21 V 15,3 – 26,5 V 15 – 29,5 VProtection class IP 21 IP 21 IP 21Dimension l x w x h inch 31.50 x 14.96 x 26.77 31.50 x 14.96 x 26.77 31.50 x 14.96 x 26.77

mm 800 x 380 x 680 800 x 380 x 680 800 x 380 x 680Weight lbs. / kg 133.38 / 60,5 163.14 / 74 202.83 / 92

The wirefeeder is included in the power source

5

Wire feed unit VR 3000 VR 3300Wire Ø inch 0.03 – 0.06 0.03 – 0.06

mm 0,8 – 1,6 0,8 – 1,6Wire feed speed ipm 0 – 708,66 0 – 708,66

m/min 0 – 18 0 – 18Dimension l x w x h inch 24.41 x 11.42 x 16.54 23.62 x 10.24 x 17.32

mm 620 x 290 x 420 600 x 260 x 440Weight lbs. / kg 35.27 / 16 28.99 / 13Only for VS 3400-2, VS 4000-2 and VS 5000-2

Cooling unit FK 3000 RCooling capacity (25° C) Q = 1l/min 505 WThroughput gal/min / l/min 0.79 / 3,0Coolant volume gal. / l 1.45 / 5,5Protection class IP 23Dimension l x w x h inch 8.46 x 9.45 x 18.90

mm 215 x 240 x 480Weight (without coolant) lbs. / kg 24.24 / 11

VarioSynergic 3400 / 3400-2 / 4000 /4000-2 / 5000 / 5000-2


Standard equipment4-roller driveAutomatic cooling-unit cut-outSoft-startWire-inching without gas or currentAutomatic burn-back controlGas-test buttonGenerator-compatibleProgram modeSynergic modeS-mark, CE-mark Thermostat-controlled fanOvertemperature protection

Recommended areas of useConstruction of plant, containers, machinery,structural steelAutomobile and allied vendor industriesConstruction of special vehicles and construction machineryConstruction of rail vehicles & rolling stockShipbuilding and offshore engineering

ProcessesMIG/MAG welding

2-step mode, 4-step modeIntermittent weldingManual modeSpot-weldingWire coil adapterVolt- / AmperemeterLarge dimensioned wheelsWire coil mounting D200, D300

OptionsGas pre-heating socket 230 V / 42 VRubber matCrane-hoisting lugsPullMig modeHosepack holderCurrent regulation+stop+revolutions control(automatic mode)Intermediate wirefeederDouble headRotary table or VR-mountingHuman mountingPolarity reversalCalibrationdocument

Power source VS 3400 / 3400-2 VS 4000 / 4000-2 VS 5000 / 5000-2 Mains voltage clampable +/–10 % 50 / 60 Hz 3 x 230 V / 400 V 3 x 230 V / 400 V 3 x 230 V / 400 VCos phi (340 A) 0,95 (400 A) 0,94 (500 A) 0,95Welding current range 10 – 340 A 30 – 400 A 35 – 500 AWelding current at 10 min/40° C 30 % d.c. – – 500 A

10 min/40° C 35 % d.c. 340 A 400 A –10 min/40° C 40 % d.c. 300 A – –10 min/40° C 60 % d.c. 260 A 290 A 360 A10 min/40° C 100 % d.c. 200 A 220 A 280 A

Open-circuit voltage 45 V 51 V 54 VOperating voltage 14,5 – 31,0 V 15,5 – 34,0 V 15,8 – 39,0 VWelding-programm locations 2 x 7 3 x 7 4 x 7Protection class IP 23 IP 23 IP 23Dimension l x w x h inch 35.04 x 18.11 x 37.20 35.04 x 18.11 x 37.20 35.04 x 18.11 x 37.20

mm 890 x 460 x 945 890 x 460 x 945 890 x 460 x 945Weight lbs. / kg 306.44 / 139 325.18 / 147,5 343.92 / 156

6

TransSynergic 4000 / 4000 C / 5000 / 5000 C

Wire feed unit VR 2000 VR 4000 VR 7000Wire Ø inch 0.03 – 0.06 0.03 – 0.06 0.03 – 0.06

mm 0,8 – 1,6 0,8 – 1,6 0,8 – 1,6Wire feed speed ipm 19.69 – 866.14 19.69 – 866.14 19.69 – 866.14

m/min 0,5 – 22 0,5 – 22 0,5 – 22Weight lbs. / kg 19.84 / 9 35.27 / 16 39.68 / 18Dimension l x w x h inch 20.47 x 12.60 x 8.46 25.59 x 11.42 x 16.14 25.20 x 10.24 x 16.93

mm 520 x 320 x 215 650 x 290 x 410 640 x 260 x 430

Cooling unit FK 4000* FK 4000 R (FC)Cooling capacity (25° C) Q = 1l/min 1120 W 1360 WMax. throughput gal./min / l/min 0.42 / 1,6 0.92 / 3,5Coolant volume gal. / l 1.45 / 5,5 1.45 / 5,5Weight (without coolant) lbs. / kg 31.09 / 14,1 35.94 / 16,3Protection class IP 23 IP 23Dimension l x w x h inch 27.56 x 11.42 x 9.84 27.56 x 11.42 x 9.84

mm 700 x 290 x 250 700 x 290 x 250

* recommended to max. 5m connection hose pack and with low duty circle.

TS 4000 C TS 4000 MV C TS 5000 C TS 5000 MV CPower source TS 4000 TS 4000 MV TS 5000 TS 5000 MVMains voltage +/–10 % 50/60 Hz 3 x 200 – 240 V 3 x 200 – 240 V

+/–10 % 50/60 Hz 3 x 380 – 460 V 3 x 380 – 460 V+/–15 % 50/60 Hz 3 x 400 V 3 x 400 V

Cos phi 0,99 (400 A) 0,99 (400 A) 0,99 (500 A) 0,99 (500 A)Welding current range 3 – 400 A 3 – 400 A 3 – 500 A 3 – 500 AWelding current at10 min/40° C 35 % d.c. 400 A 500 A

10 min/40° C 40 % d.c. 500 A10 min/40° C 60 % (75 %) d.c. 365 A (400 A) 365 A 450 A (500 A) 450 A10 min/40° C 100 % d.c. 320 A 300 A 360 A 320 A10 min/25° C 100 % d.c. 365 A 365 A 420 A 420 A

Open-circuit voltage 70 V 68 – 78 V 68 V 68 – 78 VOperating voltage 14,2 – 34,0 V 14,2 – 34,0 V 14,2 – 39,0 V 14,2 – 39,0 VProtection class IP 23 IP 23 IP 23 IP 23Dimension l x w x h inch 24.61 x 11.42 x 18.70 24.61 x 11.42 x 18.70 24.61 x 11.42 x 18.70 24.61 x 11.42 x 18.70

mm 625 x 290 x 475 625 x 290 x 475 625 x 290 x 475 625 x 290 x 475Weight lbs. / kg 77.60 / 35,2 77.60 / 35,2 78.48 / 35,6 78.48 / 35,6

Recommended areas of useAutomobile and allied vendor industriesConstruction of special vehicles and construction machineryConstruction of plant, containers, machinery,structural steelRobot weldingConstruction of rail vehicles & rolling stockShipbuilding and offshore engineering

OptionsRemote control unitUser-defined function buttonTouch-down ignitionPullMig modeRobot interface“Human” hosepack boomKeylock switch (C-version)Welding programs from databankSpatter-free ignition SFIRate-of-flow watchdog for torch coolingSynchroPulseJobExplorer / WIN RCUWeld Process DataCalibrationdocumentSpecial step mode

ProcessesMIG/MAG weldingMIG brazingTIG-DC (C-version)Manual electrode (MMA) welding (C-version)Arc-air gouging (TS 5000 C)

Recommended base metalsConstructional steelsCoated constructional steelsFerritic / austenitic CrNi steelsDuplex steelsNickel-based materialsAluminium materials

Standard equipment2-/4-roller driveAutomatic cooling-unit cut-outWire-inching without gas or currentEarth leakage monitoringAutomatic burn-back controlGas-test buttonJob mode (C-version)Manual-welding (C-version)Synergic mode

S-mark, CE-mark Thermostat-controlled fanUpDown control from torch Overtemperature protection2-step mode, 4-step modeSpot-weldingAluminium welding start-up Digital DisplayWire coil adapter

7

The wirefeeder is included in the power source

TransPulsSynergic 2700 / 2700 TIG /2700 Duo / 2700 Duo TIG

OptionsRemote control unitPullMig modeKeylock switchWelding programs from databankSpatter-free ignition SFIRate-of-flow watchdog for torch coolingSynchroPulseJobExplorer / WIN RCUSpecial step modeCalibrationdocument

Recommended areas of useAutomobile and allied vendor industriesMaintenance and repairConstruction of plant, containers, machinery,structural steelConstruction of rail vehicles & rolling stock

ProcessesMIG/MAG weldingMIG/MAG pulsed arc weldingMIG brazingTIG-DCManual electrode (MMA) welding

Recommended base metalsConstructional steelsCoated constructional steelsFerritic / austenitic CrNi steelsDuplex steelsNickel-based materialsAluminium materialsSpecial materials

Standard equipment4-roller driveAutomatic cooling-unit cut-outUser-defined function buttonWire-inching without gas or currentEarth leakage monitoringAutomatic burn-back controlGas-test buttonJob modeSynergic mode

S-mark, CE-mark Thermostat-controlled fanUpDown control from torch Overtemperature protection2-step mode, 4-step modeManual-/Spot-weldingAluminium welding start-upDigital displayWire coil adapter

Power source TPS 2700 TPS 2700 MVMains voltage 50/60 Hz +/–15 % 3 x 400 V +/–10 % 3 x 200 – 240 V/3 x 380 – 460 VCos phi 270 A 0,99 0,99Welding current range 3 – 270 A 3 – 270 AWelding current at 10 min/40° C 40 % d.c. 270 A 270 A

10 min/40° C (25°) 60 % d.c. 210 A 210 A (270 A)10 min/40° C (25°) 100 % d.c. 170 A 170 A (210 A)

Open-circuit voltage 50 V 50 VOperating voltage 14,2 – 27,5 V 14,2 – 27,5 VProtection class IP 23 IP 23Dimension l x w x h inch 24.61 x 11.42 x 18.90 24.61 x 11.42 x 18.90

mm 625 x 290 x 480 625 x 290 x 480Weight lbs. / kg 60.63 / 27,5 60.63 / 27,5

Cooling unit FK 4000* FK 4000 R (FC)Cooling capacity (25° C) Q = 1l/min 1120 W 1360 WMax. throughput gal/min / l/min 0.42 / 1,6 0.92 / 3,5 Coolant volume gal. / l 1.45 / 5,5 1.45 / 5,5Weight (without coolant) lbs. / kg 31.09 / 14,1 35.94 / 16,3Protection class IP 23 IP 23Dimension l x w x h inch 27.56 x 11.42 x 9.84 27.56 x 11.42 x 9.84

mm 700 x 290 x 250 700 x 290 x 250


Wire feed unitWire Ø inch 0.03 – 0.06

mm 0,8 – 1,6Wire feed speed ipm 19.69 – 866.14

m/min 0,5 – 22

8

TransPulsSynergic 3200 / 4000 / 5000

Power source TPS 3200 TPS 3200 MV TPS 4000 TPS 4000 MV TPS 5000 TPS 5000 MVMains voltage +/–10 % 50/60 Hz 3 x 200 – 240 V 3 x 200 – 240 V 3 x 200 – 240 V

+/–10 % 50/60 Hz 3 x 380 – 460 V 3 x 380 – 460 V 3 x 380 – 460 V+/–15 % 50/60 Hz 3 x 400 V 3 x 400 V 3 x 400 V

Cos phi 0,99 (320 A) 0,99 (320 A) 0,99 (400 A) 0,99 (400 A) 0,99 (500 A) 0,99 (500 A)Welding current range 3 – 320 A 3 – 320 A 3-400 A 3-400 A 3-500 A 3-500 AWelding 10 min/40° C 40 % d.c. 320 A 320 A 400 A 500 A 500 Acurrent 10 min/40° C 50 % d.c. 400 Aat 10 min/40° C 60 % d.c. 365 A 365 A 450 A 450 A

10 min/40° C 100 % d.c. 210 A 190 A 320 A 300 A 360 A 320 A10 min/25° C 100 % d.c. 365 A 450 A

Open-circuit voltage 70 V 70 V 68 – 78 V 68 – 78 V 68 – 78 V 68 – 78 VOperating voltage 14,2 – 30,0 V 14,2 – 30 V 14,2 – 34,0 V 14,2 – 34,0 V 14,2 – 39,0 V 14,2 – 39,0 VProtection class IP 23 IP 23 IP 23 IP 23 IP 23 IP 23Weight lbs. / kg 76.28 / 34,6 76.28 / 34,6 77.61 / 35,2 77.61 / 35,2 78.48 / 35,6 78.48 / 35,6Dimension l x w x h inch 24.61 x 11.42 x 18.70 24.61 x 11.42 x 18.70 24.61 x 11.42 x 18.70 24.61 x 11.42 x 18.70 24.61 x 11.42 x 18.70 24.61 x 11.42 x 18.70

mm 625 x 290 x 475 625 x 290 x 475 625 x 290 x 475 625 x 290 x 475 625 x 290 x 475 625 x 290 x 475

Wire feed unit VR 2000 VR 4000 VR 4000 Yard VR 7000Wire Ø inch 0.03 – 0.06 0.03 – 0.06 0.03 – 0.06 0.03 – 0.06

mm 0,8 – 1,6 0,8 – 1,6 0,8 – 1,6 0,8 – 1,6Wire feed speed ipm 19.69 – 866.14 19.69 – 866.14 19.69 – 866.14 19.69 – 866.14

m/min 0,5 – 22 0,5 – 22 0,5 – 22 0,5 – 22Weight lbs. / kg 19.84 / 9 35.27 / 16 24.69 / 11,2 38.58 / 17,5Dimension l x w x h inch 20.47 x 12.60 x 8.46 25.59 x 11.42 x 16.14 24.02 x 8.72 x 15.75 25.20 x 10.24 x 16.93

mm 520 x 320 x 215 650 x 290 x 410 610 x 210 x 400 640 x 260 x 430

Cooling unit FK 4000* FK 4000 RCooling capacity (25° C) Q = 1l/min 1120 W 1360 WMax. throughput gal./min / l/min 0.42 / 1,6 0.92 / 3,5Coolant volume gal. / l 1.45 / 5,5 1.45 / 5,5Weight (without coolant) lbs. / kg 31.09 / 14,1 35.94 / 16,3Protection class IP 23 IP 23Dimension l x w x h inch 27.56 x 11.42 x 9.84 27.56 x 11.42 x 9.84

mm 700 x 290 x 250 700 x 290 x 250


OptionsRemote controlPullMig modeRobot interface“Human” hosepack boomKeylock switchWelding programs from databankSpatter-free ignition SFISynchroPulseJobExplorer / WIN RCU Weld Process DataSpecial step modeCalibrationdocument

Recommended areas of useAutomobile and allied vendor industriesConstruction of special vehicles and construction machineryMaintenance and repairConstruction of plant, containers, machinery,structural steelRobot weldingIndustry plant & pipeline construction,site-erection firmsConstruction of rail vehicles & rolling stockShipbuilding and offshore engineering

ProcessesMIG weldingMIG/MAG pulsed arc weldingMIG brazingTIG-DCManual electrode (MMA) weldingArc-air gouging (TPS 5000)

Standard equipment2-/4-roller driveAutomatic cooling-unit cut-outWire-inching without gas or currentEarth leakage monitoringAutomatic burn-back controlGas-test buttonJob modeManual weldingSynergic modeS-mark, CE-mark Thermostat-controlled fan

UpDown control from torch Overtemperature protection2-step mode, 4-step modeManual-/Spot-weldingAluminium welding start-upDigital displayWire coil adapter

Recommended base metalsConstructional steelsCoated constructional steelsFerritic / austenitic CrNi steelsDuplex steelsNickel-based materialsAluminium materialsSpecial materialsCopper materials (TPS 5000)Special materials (TPS 5000)

9

Power source Time 5000 DigitalMains voltage +/–10 % 50/60 Hz 3 x 400 – 460 VCos phi 0,99 (500 A)Welding current range HL / MIG/MAG 4 – 400 A / 3 – 500 AWelding current at 10 min/40° C 40 % d.c. 500 A

10 min/40° C 60 % d.c. 450 A10 min/40° C 100 % d.c. 360 A10 min/25° C 100 % d.c. 400 A

Open-circuit voltage 70 VOperating voltage 28 – 48 VProtection class IP 23Dimension l x w x h inch 24.61 x 11.42 x 18.90

mm 625 x 290 x 480Weight lbs. / kg 79.37 / 36

Wire feed units VR 4000-30 TimeWire Ø inch 0.03 – 0.06

mm 0,8 – 1,6Wire feed speed ipm 20 – 1180

m/min 0,5 – 30Dimension l x w x h inch 25.59 x 11.42 x 16.14

mm 650 x 290 x 410

Cooling unit FK 4000 ROBCooling capacity (25° C) Q = 1l/min 1360 WMax. throughput gal./min / l/min 0.92 / 3,5Coolant volume gal. / l 1.45 / 5,5Weight (without coolant) lbs. / kg 35.94 / 16,3Protection class IP 23Dimension l x w x h inch 27.56 x 11.42 x 9.84

mm 700 x 290 x 250

OptionsRemote controlPullMig modeKeylock switchWelding programs from databankSpatter-free ignition SFIRate-of-flow watchdog for torch coolingSynchroPulseDocumentation of dataSpecial step modeCalibration document

ProcessesMIG/MAG weldingMIG/MAG pulsed arc weldingMAG high performance weldingMIG brazingTIG-DCManual electrode (MMA) welding, arc-air gouging

Recommended base metalsConstructional steelsCoated constructional steelsFerritic / austenitic CrNi steelsDuplex steelsNickel-based materialsAluminium materialsSpecial materials

Standard equipment4-roller driveAutomatic cooling-unit cut-outFunction buttonsWire-inching without gas or currentEarth leakage monitoringAutomatic burn-back controlGas-test buttonSynergic modeS-mark, CE-mark

Time 5000 Digital

Thermostat-controlled fanOvertemperature protection2-step mode, 4-step modeManual-/Spot-weldingDigital displayWire coil adapterSpecial welding programs

Recommended areas of useAutomobile and allied vendor industriesConstruction of plant, containers, machinery,structural steelConstruction of rail vehicles & rolling stockConstruction machineryPipeline constructionShipbuilding and offshore engineering

10

Human 4000The mounting for hose pack HUMAN 4000 compensates with its gas pressurecylinder the weight of the torch hose pack.Therefore the torch seems to be nearly weightless, damages of the hose packcan be avoided extensively.

Hose pack Human 4000Weight 28.88 lbs. / 13,1 kgRange of action in 6 steps adjustable min. 72.83 inch / 1,85 m

max. 102.36 inch / 2,60 mSlope range from horizontal + 75 °

– 45 °

Checklisteno additional wider carriage necessaryload reduction fine adjustablecan be adapted to the torch lengthintegrated torch mountingrange of action can be adjustedfourfold adjustablealso suitable for Pull-Mig torchesprotection of hose pack by means of bend protection chain

Technical Data, standard equipment and options of the power source see page 7+8TransPuls Synergic 2700/3200/4000/5000

TransPuls Synergic 2700 CMT /3200 CMT / 4000 CMT / 5000 CMT

Recommended areas of useAutomobile and allied vendor industriesConstruction of special vehicles and construction machineryConstruction of plant, containers, machinery,structural steelConstruction of rail vehicles & rolling stock

ProcessesCMT-brazingCMT-weldingMIG/MAG weldingMIG/MAG pulsed arc welding

Nickel-based materialsAluminium materialsSpecial materials

Recommended base metalsConstructional steelsCoated constructional steelsCrNi steels

OptionsRemote controlWelding programmes from databaseSpatter free ignition SFISynchroPulsJobExplorer/WIN RCUSpecial step modeCalibration document

Standard equipment4-roller driveAutomatic cooling unit cut-outUser defined function buttonWire inching without gas or currentEarth current leakageAutomatic burn-back controlGas test buttonJob-modeSynergic-modeS-mark, CE-mark

Thermostat-controlled fanUp/down control from torchOvertemperature protection2-step mode, 4-step modeManual spot weldingWelding start AluminiumDigital displayKorbspulenadapterPullMig mode

Magnesium materialsCopper materials

11

RobotControl

ROB 4000

I/O

1

2

3

6

97a

7b

7c

8

104

11

5

12

13

RobotControl

1

2

3

4

67

8

9a 11

10

9b

13

12

RCU 5000i

5

14

15

Synergic modeS-mark, CE-markThermostat-controlled fanOvertemperature protection

Standard equipment4-roller driveBurn-back impulse (perfectly formed wire-tip, optimum re-ignition)Digital welding process controlSoft-startWire-inching without gas or currentEnergy-saving inverter technologyEarth leakage monitoringRemote-controllableAutomatic burn-back controlGas test buttonExternal robot interface for synergic modeHosepack holder (pull relief)VR-display for motor-currentSpecial 2-step modeWelding programs from databankCurrent-flow signal

Recommended areas of useAutomobile and allied vendor industriesAerospace industryConstruction of plant, containers, machinery,structural steelConstruction of rail vehicles & rolling stockShipbuilding and offshore engineering

OptionsTwin-head controlUpgrades by add-on modulesSynchro PulseKeylock switch Spatter free ignition (Robacta Drive)Intermediate drive (Master/Slave) External displaysWeld Process DataJobExplorer / WIN RCUCalibrationdocument

ProcessesMIG/MAG weldingMIG/MAG pulsed arc weldingMIG brazing

TPS 3200 /Rob 4000 Set / Push / CleanerBasic equipment with standard I/O Interface (Rob 4000) for Synergic modefor TS/TPS 3200/4000/5000.

Equipped for ø 1,2 mm wire.

Recommended base metalsConstructional steelsCoated constructional steelsFerritic / austenitic CrNi steelsDuplex steels Nickel-based materials

ProcessesMIG/MAG weldingMIG/MAG pulsed arc weldingMIG/MAG high-performance weldingMIG brazing

TPS 5000 Remote /Fieldbus Set / Push / CleanerBasic equipment with fieldbus interface (Interbus D-sub) for Synergic and Jobmode forTS/TPS 4000/5000 Remote.


12

RobotControl

2

3

5

7

10

1

6

8

9

11

12

13

16

4

14

15

Synergic- / Job- / Manual modeS-mark, CE-markThermostat-controlled fanOvertemperature protectionTouch sense mode (with welding wire)External program- / job selection

Standard equipment4-roller driveBurn-back impulse (perfectly formed wire-tip, optimum re-ignition)Automatic cooling-unit cut-outUser-defined function buttonDigital welding process controlSoft-startWire-inching without gas our currentEnergy-saving inverter technologyEarth leakage monitoringRemote-controllableAutomatic burn-back controlGas test buttonRobot interface fieldbusHosepack holder (pull relief)Special 2-step modeWelding programs from databankCurrent-flow signal

Recommended areas of useAutomobile and allied vendor industriesConstruction of special vehicles and construction machinery Aerospace industryConstruction of plant, containers, machinery,structural steelConstruction of rail vehicles & rolling stock

OptionsTwin-head controlUpgrades by add-on modulesRate-of-flow watchdog for torch coolingKeylock switch Synchro PulseIntermediate drive (Master/Slave) Weld Process DataJobExplorer / WIN RCUCalibrationdocument


TPS 5000 /Fieldbus Set /PushPull / ReamerHigh End equipment with fieldbus interface (Interbus D-sub) for TS/TPS 4000/5000.


Recommended base metalsConstructional steelsCoated constructional steelsFerritic / austenitic CrNi steelsDuplex steels Nickel-based materialsAluminium materialsMagnesium materials (TPS 5000)Copper materials (TPS 5000)Special materials

Synergic- / Job- / Manual modeS-mark, CE-markThermostat-controlled fanOvertemperature protectionTouch sense mode (with welding wire)External program- / job selectionRemote / Error-quit functionsReal- and command value (display function)External user convenience

Standard equipment4-roller driveBurn-back impulse (perfectly formed wire-tip, optimum re-ignition)Automatic cooling-unit cut-outUser-defined function buttonDigital welding process controlSoft-startWire-inching without gas our currentEnergy-saving inverter technologyEarth leakage monitoringRemote-controllableAutomatic burn-back controlGas test buttonExternal robot interface for synergic-and job modeHosepack holder (pull relief)VR-display for motor-currentSpecial 2-step modeWelding programs from databankCurrent-flow signal

Recommended areas of useAutomobile and allied vendor industriesConstruction of special vehicles and construction machinery Aerospace industryConstruction of plant, containers, machinery,structural steelConstruction of rail vehicles & rolling stock

OptionsTwin-head controlUpgrades by add-on modulesKeylock switch Synchro PulseIntermediate drive (Master/Slave) Weld Process DataJobExplorer / WIN RCUCalibrationdocument

Recommended base metalsConstructional steelsCoated constructional steelsFerritic / austenitic CrNi steelsDuplex steels Nickel-based materialsAluminium materialsMagnesium materials (TPS 5000)Copper materials (TPS 5000)Special materials

TPS 5000 Remote / Fieldbus Set / Push / CleanerBasic equipment with fieldbus interface (Interbus D-sub) for Synergic and Jobmode for TS/TPS 4000/5000 Remote.Equipped for ø 1,2 mm wire.

13

RobotControl

ROB 5000

I/O

1

2

3

69

7b

7c

8

104

11

5

12

13

7d

7a

RobotControl

ROB 5000

I/O

1

2

4

89

7b

7c

10

11

5 126

13

14

7a

3

Welding programs from data bankCurrent flow signalSynergic / Job / manual modeS-mark/ CE-markThermostat controlled fan.Overemperature protection

Standard equipment4-roller driveBurn-back impulse (perfectly formed wire-tip,optimum re-ignition)Digital welding process controlSoft-startWire-inching without gas or currentEnergy-saving inverter technologyEarth leaking monitoringRemote controllableAutomatic burn-back controlGas-test buttonExternal robot interface for Synergic modeSynergic / Rob / manuell ModeHose pack holder (pull relief)VR-display for motor currentSpecial 2-step mode

Recommended areas of useAutomobile and allied vendor industriesAerospace industryConstruction of plant, containers, machinery,structural steel

OptionsUpgrades by add-on modulesSynchro PulsKeylock switchExternal displayWeld Process DataJobExplorer /WIN RCUCalibration document

ProcessesMIG/MAG weldingMIG/MAG pulsed arc welding

TPS 3200 / Rob 5000 /PushSet / CleanerEA 1400 N / 1900 NGascooled construction with Standard I/OInter face (Rob 5000) for Synergic and Job -mode for TS/TPS 3200/4000/5000 possible.


Recommended base metalsConstructional steelsCoated constructional steelsFerritic/austenitic CrNi steelsDuplex steelsNickel based materials

Welding programs from data bankCurrent flow signalSynergic / Job / manual modeS-mark/ CE-markThermostat controlled fan.Overemperature protection

Standard equipment4-roller driveBurn-back impulse (perfectly formed wire-tip,optimum re-ignition)Digital welding process controlSoft-startWire-inching without gas or currentEnergy-saving inverter technologyEarth leaking monitoringRemote controllableAutomatic burn-back controlGas-test buttonExternal robot interface for Synergic modeExtensive robot interface signal rangeSynergic / Rob / manuell ModeHose pack holder (pull relief)VR-display for motor currentSpecial 2-step mode

Recommended areas of useAutomobile and allied vendor industriesAerospace industryConstruction of plant, containers, machinery,structural steel

OptionsUpgrades by add-on modulesSynchro PulsKeylock switchExternal displayWeld Process DataJobExplorer /WIN RCUCalibration document

ProcessesMIG/MAG weldingMIG/MAG pulsed arc welding

TPS 5000 / Rob 5000 /PushSet / CleanerEA 1900 N SetWatercooled construction with Standard I/OInterface (Rob 5000) for Synergic andJobmode for TS/TPS 3200/4000/5000.


Recommended base metalsConstructional steelsCoated constructional steelsFerritic/austenitic CrNi steelsDuplex steelsNickel based materials

14

RobotControl

ROB 5000

I/O

RCU 5000i

1

3

4

5

6

7 8

2

9

11

12

10

RobotControl

ROB 5000

I/O

RCU 5000i

14

78

2

3

6

1213

10

11

15

1

4

1

59

Technical data, standard equipment andoptions of the power source see page 8TransPulsSynergic 3200 / 4000 / 5000.


TPS 3200 CMT

Recommended areas of useAutomobile and allied vendor industriesConstruction of special vehicles and construction machineryConstruction of plant, containers, machinery,structural steelRobot weldingConstruction of rail vehicles & rolling stock

ProcessesCMT-brazingCMT-weldingMIG/MAG weldingMIG/MAG pulsed arc weldingMIG brazing

Aluminium materialsSpecial materialsMagnesium materialsCopper materials

Recommended base metalsConstructional steelsCoated constructional steelsFerritic / austenitic CrNi steelsDuplex steelsNickel-based materials

OptionsRemote controlPullMig modeRobot interface fieldbusGas sensorKeylock switchWelding programs from databankSpatter-free ignition SFISynchroPulseWeld Process DataJobExplorer / WIN RCUWire coil adapterService modulIntermediate wirefeederTwin-head controlUpgrades by add-on modulesFlat wire equipmentCalibrationdocument

Recommended areas of usefor automatical applications• Construction of plant, containers, machinery,• structural steel• Automobile and allied vendor industries• Construction of special vehicles and • construction machinery• Maintenance and repair• Pipeline construction• Construction of rail vehicles & rolling stock• Shipbuilding and offshore engineering

ProcessesMIG/MAG impulse high performance weldingMIG/MAG standard high performance weldingMIG/MAG high performance welding for filled wire up to 3,2mmMIG/MAG high performance welding for flatwire

Standard equipment2-/4-roller driveWire-inching without gas or currentEarth leakage monitoringAutomatic burn-back controlGas-test buttonJob mode (depending on Interface)Manual mode (depending on Interface)Synergic modeRate-of-flow watchdog for torch cooling (FK 9000)Thermostat for torch cooling (FK 9000)S-mark, CE-mark Thermostat-controlled fanOvertemperature protection2-step mode, special 2-step modeSpot-weldingAluminium welding start-upDigital displayCurrent-flow signal

TransPulsSynergic7200 / 9000TransSynergic7200 / 9000

Touch Sense Mode (with welding wire)External program- / job selection

Recommended base metalsConstructional steelsCoated constructional steelsFerritic / austenitic CrNi steelsDuplex steelsNickel-based materialsSpecial materialsMagnesium materials Copper materials

15

TransPulsSynergic 7200 / 9000TransSynergic 7200 / 9000

Power source TPS 7200 TPS 7200 MV TPS 9000 TPS 9000 MVMains voltage +/–15 % (400 V) 50/60 Hz 2 Zul. 3 x 400 V 2 Zul. 3 x 230/400/460 V 2 Zul. 3 x 400 V 2 Zul. 3 x 230/400/460 VMains fuse (200 – 240 V) 2 x 63 A (200 – 240 V) 2 x 63 Aslow 2 x 35 A (380 – 460 V) 2 x 35 A 2 x 35 A (380 – 460 V) 2 x 35 ACos phi 0,99 0,99 0,99 0,99Welding current range 6 – 720 A 6 – 720 A 6 – 900 A 6 – 900 AWelding current at 10 min 40° C 60 % d.c. 720 A 720 A 900 A 900 A

10 min/(25° C) 40° C 100 % d.c. (720 A) 640 A (720 A) 640 A (900 A) 720 A (900 A) 720 AOpen-circuit voltage 70 – 80 V 70 – 80 V 70 – 80 V 70 – 80 VOperating voltage (MIG/MAG) 2 x 14,2 – 34,0 V 2 x 14,2 – 34,0 V 2 x 14,2 – 39,0 V 2 x 14,2 – 39,0 VProtection class IP 23 IP 23 IP 23 IP 23Weight lbs. / kg 156.52 / 71 156.52 / 71 158.73 / 72 158.73 / 72Dimension l x w x h inch 2 x (24.63 x 11.43 x 18.72) 2 x (24.63 x 11.43 x 18.72) 2 x (24.63 x 11.43 x 18.72) 2 x (24.63 x 11.43 x 18.72)

mm 2 x (625 x 290 x 480) 2 x (625 x 290 x 480) 2 x (625 x 290 x 480) 2 x (625 x 290 x 480)

Wire feed unit VR 1500-11 VR 1500-12 VR 1500-30 VR 1500-22De-reeler device VR 1530-11 VR 1530-12 VR 1530-30 VR 1530-22Wire-Ø inch .030 – 1/8 .030 – 1/8 .030 – 1/16 .030 – 1/16

mm 0,8 – 3,2 0,8 – 3,2 0,8 – 1,6 0,8 – 1,6Wire feed ipm 20 – 433 20 – 472 20 – 1180 20 – 866speed m/min 0,5 – 11 0,5 – 12 0,5 – 30 0,5 – 22Torque Nm 11 21,6 3,7 4Weight lbs. / kg 17.6 / 8 22 / 10 17.6 / 8 15.4 / 7Dimension l x w x h inch 15.3 x 8.0 x 10.2 15.3 x 8.0 x 10.2 15.3 x 8.0 x 10.2 15.3 x 8.1 x 8.0

mm 390 x 205 x 260 390 x 205 x 260 390 x 205 x 260 390 x 208 x 205

Wire feed unit VR 7000-11 VR 7000-22 VR 7000-30Wire-Ø inch .030 – 1/8 .030 – 1/16 .030 – 1/16

mm 0,8 – 3,2 0,8 – 1,6 0,8 – 1,6Wire feed speed ipm 20 – 433 20 – 866 20 – 1180

m/min 0,5 – 11 0,5 – 22 0,5 – 30Torque Nm 11 4 3,7Weight lbs. / kg 39.6 / 18 38.5 / 17,5 39.6 / 18Dimension l x w x h inch 25.1 x 10.2 x 16.9 25.1 x 10.2 x 16.9 25.1 x 10.2 x 16.9

mm 640 x 260 x 430 640 x 260 x 430 640 x 260 x 430

Cooling unit FK 6000 FK 9000-RCooling capacity (25° C) Q = 1l/min 1770 W 1700 WMax. Throughput l/min 3,5 5Coolant volume gal. / l 2.3 / 9 2.3 / 9Weight (without coolant) lbs. / kg 48.5 / 22 61.7 / 28Protection class IP 23 IP 23Dimension l x w x h inch 27.55 x 11.41 x 18.70 27.55 x 11.41 x 18.70

mm 700 x 290 x 475 700 x 290 x 475

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Time Twin Time Twin Time Twin Time TwinPower source Digital 4000 Digital 5000 Digital 7200 Digital 9000Mains voltage +/–15 % (400 V) 50/60 Hz 2 cables 3 x 400 V 2 cables 3 x 400 V 4 cables 3 x 400 V 4 cables 3 x 400 VMains fuseslow 2 x 35 A 2 x 35 A 2 x 35 A 2 x 35 ACos phi 0,99 0,99 0,99 0,99Welding current range 2 x 400 A 2 x 500 A 2 x 720 A 2 x 900 AWelding current at 10 min/40° C 40 % d.c. – 2 x 500 A – –

10 min/40° C 50 % d.c. 2 x 400 A – – –10 min/40° C 60 % d.c. 2 x 365 A 2 x 450 A 2 x 720 A 2 x 900 A

10 min/(25° C) 40° C 100 % d.c. (2 x 400 A) 2 x 320 A (2 x 450 A) 2 x 360 A 2 x 640 A 2 x 720 AOpen-circuit voltage 2 x 70 – 80 V 2 x 70 – 80 V 2 x 70 – 80 V 2 x 70 – 80 VOperating voltage (MIG/MAG) 2 x 14,2 – 34,0 V 2 x 14,2 – 44,0 V 4 x 14,2 – 34,0 V 4 x 14,2 – 44,0 VProtection class IP 23 IP 23 IP 23 IP 23Weight lbs. / kg 2 x 77.6 / 2 x 35,2 2 x 78.4 / 2 x 35,6 4 x 77.6 / 4 x 35,2 4 x 78.4 / 4 x 35,6Dimension l x w x h inch 2 x (24.63 x 11.43 x 18.72) 2 x (24.63 x 11.43 x 18.72) 4 x (24.63 x 11.43 x 18.72) 4 x (24.63 x 11.43 x 18.72)

mm 2 x (625 x 290 x 480) 2 x (625 x 290 x 480) 4 x (625 x 290 x 480) 4 x (625 x 290 x 480)

Wire feed unit VR 1500-30 VR 1500-22 VR 7000-30Wire-Ø .030 – 1/16” .030 – 1/16” .030 – 1/16”

mm 0,8 – 1,6 0,8 – 1,6 0,8 – 1,6Wire feed ipm 20 – 1180 20 – 472 20 – 1180speed m/min 0,5 – 30 0,5 – 22 0,5 – 30Torque Nm 3,7 4,0 3,7Weight lbs. / kg 17.6 / 8 15.4 / 7 39.6 / 18Dimension l x w x h inch 15.3 x 8.0 x 10.2 15.3 x 8.1 x 8.0 25.1 x 10.2 x 16.9

mm 390 x 205 x 260 390 x 208 x 205 640 x 260 x 430

Cooling unit FK 6000 FK 9000-RCooling capacity at Q = 1l/min 1150 W 1100 WMax. Throughput gal/min / l/min 0.92 / 3,5 1.32 / 5,0Coolant volume gal / l 2.3 / 9 2.3 / 9Weight (without coolant) lbs. / kg 48.50 / 22 61.73 / 28Protection class IP 23 IP 23Dimension l x w x h inch 27.55 x 11.41 x 18.70 27.55 x 11.41 x 18.70

mm 700 x 290 x 475 700 x 290 x 475

Recommended areas of usefor automatical applications• Construction of plant, containers, machinery,• structural steel• Automobile and allied vendor industries• Construction of special vehicles and • construction machinery• Maintenance and repair• Pipeline construction• Construction of rail vehicles & rolling stock• Shipbuilding and offshore engineering

ProcessesMIG/MAGtandem impulse high performance weldingMIG/MAGtandem-standard high performance weldingMIG/MAG tandem impulse weldingMIG/MAG tandem standard weldingMIG/MAG standard brazing

Standard equipment2-/4-roller driveWire-inching without gas or currentEarth leakage monitoringAutomatic burn-back controlGas-test buttonRate-of-flow watchdog for torch cooling (FK 9000)Thermostat for torch cooling (FK 9000)S-mark, CE-mark Thermostat-controlled fanOvertemperature protection2-step mode, special 2-step modeSpot-weldingAluminium welding start-upDigital displayCurrent-flow signalSynergic- / Job- / Manual modeTouch Sense ModeExternal program- / job selection

TimeTwin Digital4000 / 5000 /7200 / 9000

OptionsRemote controlPullMig modeRobot interface fieldbusGas sensorKeylock switchWelding programs from databankSpatter-free ignition SFISynchroPulsWeld Process DataJobExplorer / WIN RCUWire coil adapterService moduleIntermediate wirefeederTwin-head controlUpgrades by add-on modulesSolutions for robot-systemsCalibrationdocument

Recommended base metalsConstructional steelsCoated constructional steelsFerritic / austenitic CrNi steelsDuplex steelsNickel-based materialsSpecial materials

17

FK 3000 R FK 4000FK 4000-RFK 4000-R FCFK 4000 ROB

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VarioSynergic 3400 / 3400-2 / 4000 / 4000-2 / 5000 / 5000-2TS 4000 / 4000 C / 4000 RemoteTS 4000 C (UL-/CSA) / 4000 Remote (UL-/CSA)TS 5000 / 5000 C / 5000 RemoteTS 5000 C (UL-/CSA) / 5000 Remote (UL-/CSA)TPS 2700/2700 Alu/2700 TIG/2700 Duo/2700 Duo TIG/2700 CrNiTPS 2700 (UL-/CSA)TPS 3200 / 3200 Remote / 3200CrNi TPS 3200 PipeTPS 3200 (UL-/CSA) / 3200 Remote (UL-/CSA)TPS 4000 / 4000 Remote / 4000 CrNiTPS 4000 (UL-/CSA) / 4000 Remote (UL-/CSA)TPS 5000 / 5000 RemoteTPS 5000 (UL-/CSA) / Remote (UL-/CSA)TPS 3200 CMT / 3200 CMT MVTPS 3200 CMT MV Remote (UL-/CSA)TPS 4000 CMT / 4000 CMT MVTPS 4000 CMT MV Remote (UL-/CSA)TPS 5000 CMT / 5000 CMT MVTPS 5000 CMT MV Remote (UL-/CSA)TIME 5000 DigitalOptionsI-Kit Autotrafo FK4000-R 50/60Hz 200V-230V-400V-440V-460V I-Kit Autotrafo FK9000-R 50/60Hz 200V-230V-400V-440V-460V (for MV) attention only factory installationI-kit flow meter FK 4000 R (at FK4000 up to max. 5m connection hose pack)I-kit thermal guard FK 4000 attention: only factory-installationI-kit cooling unit FK4000-Duo I-Kit water flow control FK6000 Pipe EquipmentThermal guardWater flow controlFlow sensorWater filterMultivoltage (Autotrafo) Rotation pumpMagnetic connected rotation pump50/60 Hz - capable5l torch cooling liquid

S = Standard equipmentO = Option

Cooling units MIG/MAG

18

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Power sourcesTS 4000 / 4000 C / 4000 RemoteTS 5000 / 5000 C / 5000 RemoteTPS 2700 TPS 3200 / 3200 Remote / 3200 CrNi / 3200 Pipe / 3200 CMTTPS 4000 / 4000 Remote / 4000 CrNi / 4000 Pipe / 4000 CMTTPS 5000 / 5000 Remote / 5000 CMTTIME 5000 DigitalWire feederVR 4000VR 7000VR 3000/ VR 3300OptionsTransport handles Pickup

Bottle mounting plate Duo Crane-transport PickUp I-kit wheel-brake PickUp I-kit PickUp strengthening (for TPS2700)I-Kit turning pintle mounting VR4000 Extension for Trabant holderI-Kit turning pintle mounting podium for VR4000/7000I-Kit turning pintle mounting central for 2 podiums I-kit wheel-brake podium I-Kit gas cylinder holder PickUp Pickup I-kit crane-hoisting for double-podium

S = Standard equipmentO = Option

Carriages for MIG/MAG

Carriage Everywhere

Set podium digital machines

Carriage PickUp

VR carriage Caddy

CarriageTrabant

Carriage Trabantwith 4 swivel rollers

Wire feed unit VR 1500-22Wire-Ø inch / mm 0.03 – 0.06 / 0,8 – 1,6Wire feed speed ipm / m/min 19.69 – 866.14 / 0,5 – 22Protection class IP 21Dimension l x w x h inch 15.94 x 8.19 x 8.07

mm 405 x 208 x 205Weight (without options) lbs. / kg 15.43 / 7

Robot wire feed unit VR 1500-22

Picture: VR 1500-22 incl. option cover (4,100,257) and incl. VR-mounting (4,100,295)

19

Technical Data acc. to EN 60974-7 Welding current at Duty cycle Standard equipment Wire WeightGascooled CO2 ArCO2 Ø inch/mm Ø inch/mm lbs./kgAL2300 230 A 200 A 40 % 0.03 / 0,8 0.02 – 0.04 / 0,6 – 1,0 2.09 / 0,950AL3000 300 A 250 A 40 % 0.04 / 1,0 0.03 – 0.05 / 0,8 – 1,2 2.43 / 1,100AL4000 400 A 350 A 40 % 0.05 / 1,2 0.04 – 0.06 / 1,0 – 1,6 2.98 / 1,350AL5000 500 A 400 A 40 % 0.05 / 1,2 0.04 – 0.06 / 1,0 – 1,6 3.97 / 1,800AL2300 JobMaster 230 A 200 A 40 % 0.03 / 0,8 0.02 – 0.04 / 0,6 – 1,0 2.31 / 1,050AL3000 JobMaster 300 A 250 A 40 % 0.04 / 1,0 0.03 – 0.05 / 0,8 – 1,2 2.65 / 1,200AL4000 JobMaster 400 A 350 A 40 % 0.05 / 1,2 0.04 – 0.06 / 1,0 – 1,6 3.20 / 1,450

Standard equipment - Jobmaster onlyIntegrated remote controlFrequency parameter recall

Parameter correction modeRecall function for operating points and jobs

Digital parameter display

Recommended areas of useAutomobile and allied vendor industriesConstruction of chemical plantsMaintenance and repair

ProcessesMIG/MAG weldingMIG brazing

Recommended base metalsConstructional steelsCoated constructional steelsFerritic / austenitic CrNi steelsAluminium materialsMagnesium materials

Standard equipmentSteel inner liner for steel wireTorch-neck 45°Spatter protection, with high thermal stabilityContact tube, CuCrZr alloy

Coaxial cableRubber anti-kink feature at machine and torch end

AL2300 / 3000 / 4000 / 5000Standard, Up/Down, JobMaster

OptionsCombination inner liner for Al and CrNi wiresContact tubes with centre bore for Al wireTop-mounted torch triggerSpecial lengths of hose pack 1,5 – 6,0 m (with 35 mm2 power cable if more than 4,5m)Customer-specific torch body lengthCustomer-specific torch body bend





Recommended base metalsConstructional steelsCoated constructional steelsFerritic / austenitic CrNi steelsDuplex steelsNickel-based materialsAluminium materialsMagnesium materialsCopper materials

Standard equipmentSteel inner liner for steel wireTorch-neck 45°Spatter protection, with high thermal stabilityContact tube, CuCrZr alloyForced contacting arrangement for welding-wire

Swirl-free gas-flow – no loss of gasSwivel-mounted protective hoseRubber anti-kink feature at machine and torch end

AW2500 / 4000 / 5000 / 7000Standard, Up/Down, JobMaster

Recommended areas of useConstruction of plant, containers, machinery,structural steelAutomobile and allied vendor industriesConstruction of special vehicles and construction machineryConstruction of chemical plantsMaintenance and repairConstruction of rail vehicles & rolling stockShipbuilding and offshore engineering

OptionsCombination inner liner for Al and CrNi wiresContact tubes with centre bore for Al wireTop-mounted torch triggerSpecial lengths of hose pack 1,5 – 6,0 m Customer-specific torch body lengthCustomer-specific torch body bend

20

Technical Data acc. to EN 60974-7 Welding current at Duty cycle Standard equipment Wire WeightWatercooled CO2 ArCO2 Ø inch/mm Ø inch/mm lbs./kgAW2500 250 A 220 A 100 % 0.04 / 1,0 0.02 – 0.05 / 0,6 – 1,2 2.43 / 1,100AW4000 400 A 350 A 100 % 0.05 / 1,2 0.03 – 0.05 / 0,8 – 1,2 2.65 / 1,200AW5000 500 A 400 A 100 % 0.05 / 1,2 0.04 – 0.06 / 1,0 – 1,6 3.09 / 1,400AW7000 700 A 550 A 100 % 0.05 / 1,2 0.04 – 0.06 / 1,0 – 1,6 3.64 / 1,650AW2500 JobMaster 250 A 220 A 100 % 0.04 / 1,0 0.02 – 0.05 / 0,6 – 1,2 2.53 / 1,150AW4000 JobMaster 400 A 350 A 100 % 0.05 / 1,2 0.03 – 0.05 / 0,8 – 1,2 2.75 / 1,250AW5000 JobMaster 500 A 400 A 100 % 0.05 / 1,2 0.04 – 0.06 / 1,0 – 1,6 3.19 / 1,450AW7000 JobMaster 700 A 550 A 100 % 0.05 / 1,2 0.04 – 0.06 / 1,0 – 1,6 3.74 / 1,700

AW2500 / 4000 / 5000 / 7000Standard, Up/Down, JobMaster

Technical Data acc. to EN 60974-7 Welding current at Duty cycle Standard equipment Wire WeightGascooled CO2 ArCO2 Ø inch/mm Ø inch/mm lbs./kgAL2300 230 A 200 A 40 % – 0.02 – 0.04 / 0,6 – 1,0 0.65 / 0,295AL2400 240 A 200 A 40 % – 0.02 – 0.04 / 0,6 – 1,0 0.97 / 0,440AL3000 300 A 250 A 40 % – 0.03 – 0.05 / 0,8 – 1,2 0.77 / 0,350AL4000 400 A 350 A 40 % – 0.04 – 0.06 / 1,0 – 1,6 0.96 / 0,435Hosepack 400 A 350 A 40 % 0.05 / 1,2 0.02 – 0.06 / 0,6 – 1,6 2.31 / 1,050*WatercooledAW2500 250 A 220 A 100 % – 0.02 – 0.05 / 0,6 – 1,2 0.65 / 0,295AW4000 400 A 350 A 100 % – 0.03 – 0.05 / 0,8 – 1,2 0.77 / 0,350AW5000 500 A 400 A 100 % – 0.04 – 0.06 / 1,0 – 1,6 0.96 / 0,435AW7000 700 A 550 A 100 % – 0.04 – 0.06 / 1,0 – 1,6 0.86 / 0,390AW332 250 A 200 A 60 % – 0.03 – 0.05 / 0,8 – 1,2 0.57 / 0,260AW335 250 A 200 A 60 % – 0.03 – 0.05 / 0,8 – 1,2 0.86 / 0,390Hosepack 500 A 400 A 100 % 0.05 / 1,2 0.02 – 0.06 / 0,6 – 1,6 2.65 / 1,200*

* (without torch body)

OptionsTorch bodyContact tubes with centre bore for Al wireContact tube, CuCrZr alloySpecial torch body bendSpecial lengths up to max. 1200 mm,for more than 500 mm a support is necessary!Hose pack Combi inner liner for Al and CrNi wiresTop-mounted torch trigger at standard hose packSpecial lengths 1,5 – 6,0 m gascooled: with 35 mm2 power cable if more than 4,5 m

Standard equipmentTorch bodySpatter protection, with high thermal stabilityForced contacting arrangement for welding-wireTorch neck rotates through 360°Hose packSteel inner liner for steel wireSwivel-mounted protective hoseCoaxial cable at gascooled welding torchRubber anti-kink feature at machine and torch end


ProcessesMIG/MAG weldingMIG/MAG pulsed arc welding with watercooledtorchesMIG brazing

Multilock-System

Recommended base metalsConstructional steelsCoated constructional steelsFerritic / austenitic CrNi steelsDuplex steels Nickel-based materials Aluminium materialsMagnesium materialsCopper materials

21

Technical Data acc. to EN 60974-7 Welding current at Duty cycle Standard equipment Wire WeightWatercooled CO2 ArCO2 Ø inch/mm Ø inch/mm lbs./kgTime manual welding torch 700 A 100 % 0.04 / 1,0 0.04 – 0.06 / 1,0 – 1,6 3.97 / 1,800Time Multilock 700 A 100 % 0.04 / 1,0 0.04 – 0.06 / 1,0 – 1,6 –Time 701 700 A 100 % 0.04 / 1,0 0.04 – 0.06 / 1,0 – 1,6 –AW5000 Z Time manual welding torch 400 A 100 % 0.05 / 1,2 0.04 – 0.06 / 1,0 – 1,6 3.31 / 1,500AW7000 Z Time manual welding torch 700 A 100 % 0.04 / 1,0 0.04 – 0.06 / 1,0 – 1,6 3.75 / 1,700



Recommended base metalsConstructional steelsCoated constructional steelFerritic / austenitic CrNi steelsDuplex steelsNickel-based materialsAluminium materials

Standard equipmentSteel inner liner for steel wireTorch-neck 45° (exceptautomatic welding torch 30°)Spatter protection, with high thermal stabilityContact tube, CuCrZr alloy(AW5000 Time, AW7000 Time, AW7000 K4 Time)

Time / Time Multilock /AW5000 Time / AW7000 Time

Forced contacting arrangement for weldingwire (AW5000 Time, AW7000 Time, AW7000 K4 Time)Swivel-mounted protective hoseRubber anti-kink feature at machine and torch end

OptionsCombination inner liner for Al and CrNi wiresContact tubes with centre bore for Al wireTop-mounted torch trigger at standard torchSpecial length of hose pack 1,5 – 6,0 m


ProcessesMIG/MAG weldingMIG/MAG pulsed arc welding with watercooled torchesMIG brazing

Recommended base metalsConstructional steelsCoated constructional steelFerritic / austenitic CrNi steelsDuplex steels Nickel-based materialsAluminium materialsMagnesium materialsCopper materials

Standard equipmentSteel inner liner for steel wireAirflow regulator with single-hand controlTorch-neck 45°Spatter protection, with high thermal stabilityContact tube, CuCrZr alloyExtraction nozzleSwivel-mounted extractor torch

K4 smoke extractor torches

Gascooled welding torch: Fabric protectivehose 1,3 mCoaxial cableRubber anti-kink feature at machine endSwivel-mounted protective hoseWatercooled welding torch: Swirl-free gas-flow –no loss of gas Leather protective hose at torch endForced contacting arrangement for welding-wire

OptionsCombination inner liner for Al and CrNi wiresContact tubes with centre bore for Al wireUp/Down-, JobMaster functionTop-mounted torch trigger atstandard hose packSpecial length of hose pack 1,5 – 6,0 m, gascooled: with 35 mm2 power cable if morethan 4,5 mLeather protective hose

22

Technical Data acc. to EN 60974-7 Welding current at Duty cycle Standard equipment Wire WeightGascooled CO2 ArCO2 Ø inch/mm Ø inch/mm lbs./kgAL2300 K4 230 A 200 A 40 % 0.03 / 0,8 0.02 – 0.04 / 0,6 – 1,0 3.31 / 1,500 AL3000 K4 300 A 250 A 40 % 0.04 / 1,0 0.03 – 0.05 / 0,8 – 1,2 4.19 / 1,900AL4000 K4 400 A 350 A 40 % 0.05 / 1,2 0.04 – 0.06 / 1,0 – 1,6 4.63 / 2,100WatercooledAW2500 K4 250 A 220 A 100 % 0.04 / 1,0 0.02 – 0.05 / 0,6 – 1,2 3.53 /1,600AW4000 K4 400 A 330 A 100 % 0.05 / 1,2 0.03 – 0.05 / 0,8 – 1,2 4.41 / 2,000AW5000 K4 500 A 400 A 100 % 0.05 / 1,2 0.04 – 0.06 / 1,0 – 1,6 4.85 / 2,200AW7000 K4 Time – 700 A 100 % 0.05 / 1,2 0.04 – 0.06 / 1,0 – 1,6 –Time 701 K4 – 700 A 100 % 0.04 / 1,0 0.04 – 0.06 / 1,0 – 1,6 –Aspirated air volume 50 – 100m3/h at 5.000 – 20.000 Pa low pressure

K4 smoke extractor torches

Technical Data acc. to EN 60974-7 Welding current at Duty cycle Standard equipment Wire WeightWatercooled CO2 ArCO2 Ø inch/mm Ø inch/mm lbs./kgAW4000 400 A 350 A 100 % – 0.03 – 0.05 / 0,8 – 1,2 0.77 / 0,350AW5000 500 A 400 A 100 % – 0.04 – 0.06 / 1,0 – 1,6 0.96 / 0,435AW7000 700 A 550 A 100 % – 0.04 – 0.06 / 1,0 – 1,6 0.86 / 0,390Hosepack 360 A 360 A 100 % Basic kit 0.03 – 0.06 / 0,8 – 1,6 4.41 / 2,000*


Recommended base metalsConstructional steelsCoated constructional steelsFerritic / austenitic CrNi steelsDuplex steelsNickel-based materialsAluminium materialsSpecial materialsMagnesium materialsCopper materials

ProcessesCMT-brazingCMT weldingMIG/MAG-welding

Recommended areas of useAutomobile and allied vendor industriesConstruction of special vehicles and construc-tion machineryConstruction of plant, containers, machinery,structural steelPipeline constructionConstruction of rail vehicles & rolling stock

Standard equipmentTorch bodySpatter protection, with high thermal stabilityForced contacting arrangement for weldingwire360° rotatable

Hose packAC direct drive for highdynamic wire feedingSignal LED for status displayForming pressure stepless adjustablePower stepless adjustable

Rotatable stored protection hoseRubber anti-kink feature at machine and torchend

PullMIG CMT hose pack

23

Technical Data acc. to EN 60974-7 Welding current at Duty cycle Standard equipment Wire WeightGascooled CO2 ArCO2 Ø inch/mm Ø inch/mm lbs./kgAL2300 230 A 200 A 40 % – 0.03 – 0.04 / 0,8 – 1,0 0.65 / 0,295AL3000 300 A 250 A 40 % – 0.03 – 0.05 / 0,8 – 1,2 0.77 / 0,350AL4000 400 A 350 A 40 % – 0.04 – 0.06 / 1,0 – 1,6 0.96 / 0,435Hose pack 330 A 280 A 40 % 0.03 – 0.05 / 0,8 – 1,2 0.03 – 0.06 / 0,8 – 1,6 4.96 / 2,250*Hose pack JobMaster 330 A 280 A 40 % 0.03 – 0.05 / 0,8 – 1,2 0.03 – 0.06 / 0,8 – 1,6 4.96 / 2,250*WatercooledAW2500 250 A 220 A 100 % – 0.03 – 0.05 / 0,8 – 1,2 0.65 / 0,295AW4000 400 A 350 A 100 % – 0.03 – 0.05 / 0,8 – 1,2 0.77 / 0,350AW5000 500 A 400 A 100 % – 0.04 – 0.06 / 1,0 – 1,6 0.96 / 0,435AW7000 700 A 550 A 100 % – 0.04 – 0.06 / 1,0 – 1,6 0.86 / 0,390AW332 250 A 200 A 60 % – 0.03 – 0.05 / 0,8 – 1,2 0.57 / 0,260AW335 250 A 200 A 60 % – 0.03 – 0.05 / 0,8 – 1,2 0.86 / 0,390Time 701 – 700 A 100 % – 0.04 – 0.06 / 1,0 – 1,6 –Hose pack 500 A 400 A 100 % 0.03 – 0.05 / 0,8 – 1,2 0.03 – 0.06 / 0,8 – 1,6 4.74 / 2,150*Hose pack JobMaster 500 A 400 A 100 % 0.03 – 0.05 / 0,8 – 1,2 0.03 – 0.06 / 0,8 – 1,6 4.74 / 2,150*





PullMig hose packsPullMig JobMaster hose packs


ProcessesMIG/MAG weldingMIG/MAG pulsed arc welding with watercooled torchesMIG brazing

Recommended base metalsConstructional steelsCoated constructional steelFerritic / austenitic CrNi steelsDuplex steels Nickel-based materialsAluminium materialsMagnesium materialsCopper materials

Standard equipmentTorch bodySpatter protection, with high thermal stabilityForced contacting arrangement for welding-wireTorch neck rotates through 360°Hose packGraphit innerliner ø 2,5 mmContinuously adjustable powerPowerfull gear-motor unit

Toothed drive and pressure rollers ø 0,8 – 1,2 mmBronze innerliner diameter 2,0 mm for Multilock torch bodySwivel-mounted protective hoseCoaxial cable at gascooled welding torchRubber anti-kink feature at machine and torch end

OptionsTorch bodyContact tubes with centre bore for Al wireContact tube, CuCrZr alloySpecial torch body bend Special lengths up to max. 1200 mm,for more than 500 mm a support is necessary!Hose pack Steel inner liner for steel wireToothed drive and pressure rollers 1,6 mmSpecial lengths gascooled: 3,5 – 10 m watercooled: 3,5 – 16 m

24

Technical Data acc. to EN 60974-7 Welding current at Duty cycle Standard equipment Wire WeightGascooled CO2 ArCO2 Ø inch/mm Ø inch/mm lbs./kgAL2300 230 A 200 A 40 % – 0.02 – 0.04 / 0,6 – 1,0 0.65 / 0,295AL3000 300 A 250 A 40 % – 0.03 – 0.05 / 0,8 – 1,2 0.77 / 0,350AL4000 400 A 350 A 40 % – 0.04 – 0.06 / 1,0 – 1,6 0.96 / 0,435PT Drive hose pack 330 A 280 A 40 % Basic kit 0.03 – 0.06 / 0,8 – 1,6 3.75 / 1,700WatercooledAW2500 250 A 220 A 100 % – 0.02 – 0.05 / 0,6 – 1,2 0.65 / 0,295AW4000 400 A 350 A 100 % – 0.03 – 0.05 / 0,8 – 1,2 0.77 / 0,350AW5000 500 A 400 A 100 % – 0.04 – 0.06 / 1,0 – 1,6 0.96 / 0,435AW7000 700 A 550 A 100 % – 0.04 – 0.06 / 1,0 – 1,6 0.86 / 0,390AW332 250 A 200 A 60 % – 0.03 – 0.05 / 0,8 – 1,2 0.57 / 0,260AW335 250 A 200 A 60 % – 0.03 – 0.05 / 0,8 – 1,2 0.96 / 0,390AW701 – 700 A 100 % – 0.04 – 0.06 / 1,0 – 1,6 –PT Drive hose pack 500 A 400 A 100 % Basic kit 0.03 – 0.06 / 0,8 – 1,6 3.53 / 1,600

Hose pack Steel inner liner for steel wireSpecial lengths 3,5 – 8,0 m Basic kits

OptionsTorch bodyContact tubes with centre bore for Al wireContact tube, CuCrZr alloySpecial torch body bend Special lengths up to max. 1200 mm,for more than 500 mm a support is necessary!


ProcessesMIG/MAG weldingMIG/MAG pulsed arc welding MIG brazing

Recommended base metalsConstructional steelsCoated constructional steelFerritic / austenitic CrNi steelsDuplex steelsNickel-based materialsAluminium materialsMagnesium materialsCopper materials

Standard equipmentTorch bodySpatter protection, with high thermal stabilityForced contacting arrangement for welding-wireTorch neck rotates through 360°Hose packGraphit innerliner ø 2,5 mm for Al- and CrNi-wirePlanetary drive for wire Ø 0,8 – 1,6 mmContinuously adjustable powerBronze innerliner diameter 2,0 mm for Multilock torch body

PT Drive

25

Technical Data acc. to EN 60974-7 Welding current at Duty cycle Standard equipment Wire WeightMultilock robot hose packs CO2 ArCO2 Ø inch/mm Ø inch/mm lbs./kgGascooled 400 A 350 A 40 % 0.045 / 1,2 0.03 – 0.06 / 0,8 – 1,6 3.86 / 1,750*Watercooled 500 A 400 A 100 % 0.045 / 1,2 0.03 – 0.06 / 0,8 – 1,6 3.64 / 1,650*Robacta

Welding current Duty cycleStandard equipment Wire Weight

Robot hose packs Ø inch/mm Ø inch/mm lbs./kgWatercooled 700 A 100 % 0.045 / 1,2 0.03 – 0.06 / 0,8 – 1,6 3.75 / 1,700*Time Robot hose packsWatercooled 700 A 100 % 0.04 / 1,0 0.04 – 0.06 / 1,0 – 1,6 5.29 / 2,400

* (without torch body)Technical data Multilock torch bodies page 20, Robacta torch bodies page 26.


ProcessesMIG/MAG pulsed arc welding with watercooled torchesMIG brazing

Recommended base metalsConstructional steelsCoated constructional steelFerritic / austenitic CrNi steelsDuplex steels Nickel-based materialsAluminium materialsCopper materials

Standard equipmentMultilock torch bodySpatter protection, with high thermal stabilityForced contacting arrangement for welding-wireTorch neck rotates through 360°Multilock robot hose packAutomatic tube diameter 44 mm at F and F++ connectionAutomatic tube diameter 38 mm at Euro connectionSteel inner liner for steel wireCoaxial cable at gascooled welding torchRubber anti-kink feature at machine endRobacta torch bodyInsulation sleeve at watercooled welding torchInsulated gas nozzle at gascooled welding torchContact tube, CuCrZr alloy

Forced contacting arrangement for welding-wireTorch body bend 0°, 22°, 36°, 45°Robacta robot hose packAutomatic tube diameter 38 mmSteel inner liner for steel wireWirefeed FWD buttonSeparate gas and blow-out linesSwirl-free gas-flow – no loss of gasUV, temp. and ozone-resistant rubber fabric hosesRubber anti-kink feature at machine end

Multilock automatic hose packsRobacta automatic hose packs /Time robot welding torches

OptionsMultilock torch bodyContact tubes with centre bore for Al wireContact tube, CuCrZr alloySpecial torch body bendspecial lengths up to max. 1200 mm,for more than 500 mm a support is necessary!Multilock robot hose pack Combi inner liner for Al and CrNi wiresSpecial lengths 1,0 – 6,0 m (gascooled: with 35 mm2 power cable if more than 4,5 m)Blow-out lineRobacta torch bodyContact tubes with centre bore for Al wireSpecial torch body bendSpecial lengths up to max. 500 mmRobacta robot hose packCombi inner liner for Al and CrNi wiresSpecial lengths 1,0 – 6,0 m Holding- and adjusting clamp (only with reducing sleeve)Reducing sleeveBlow-out line

26

Technical Data acc. to EN 60974-7 Welding current at Duty cycle Standard equipment Wire WeightGascooled CO2 ArCO2 Ø inch/mm Ø inch/mm lbs./kgRobacta MTG 2500 250 A 200 A 60 % 0.04 / 1,0 0.03 – 0.05 / 0,8 – 1,2 1.10 / 0,500Robacta MTG 3200 320 A 260 A 60 % 0.04 / 1,0 0.03 – 0.05 / 0,8 – 1,2 1.21 / 0,550Robacta MTG 4000 400 A 320 A 60 % 0.05 / 1,2 0.03 – 0.05 / 0,8 – 1,2 1.32 / 0,600Hose pack 400 A 320 A 60 % 0.05 / 1,2 0.03 – 0.05 / 0,8 – 1,2 3.97 / 1,800Hose pack EA 1400 / 1900 400 A 320 A 60 % 0.04 / 1,0 0.03 – 0.06 / 0,8 – 1,6 3.52 / 1,600

Robacta MTG 2500 / MTG 3200 / MTG 4000 torch bodies

OptionsTorch bodyContact tubes with centre bore for Al wireSpecial lengths up to max. 500 mmExamination- and correction deviceSeam-tracking lineHose pack Combi inner liner for Al and CrNi wiresHolding- and adjusting clampExtractor setSpecial lengths 1,0 – 4,5 m


ProcessesMIG/MAG weldingMIG brazing

Recommended base metalsConstructional steelsCoated constructional steelFerritic / austenitic CrNi steelsDuplex steelsNickel-based materialsCopper materials

Standard equipmentMultilock Torch bodyInsulated gas nozzle at gascooled welding torchContact tube, CuCrZr alloyPrecision TCP ± 0,5 mm

Hose packSteel inner liner for steel wireWirefeed FWD button (watercooled torches)Separate gas and blow-out linesSwirl-free gas-flow – no loss of gasUV, temp. and ozone-resistant rubber fabric hosesSeam-tracking line in the hose pack (only at the gascooled hose pack)

Robacta 2500 / 280 / 300 / 400 / 500 /5000 / 700 / 700 Time / 7000 torch bodies

OptionsTorch bodyContact tubes with centre bore for Al wireSpecial lengths up to max. 500 mmExamination- and correction deviceSeam-tracking lineHose pack Combi inner liner for Al and CrNi wiresHolding- and adjusting clampExtractor setSeam-tracking line in the hose pack (only at the watercooled hose pack)Special lengths 1,0 – 4,5 mCorrugated hose


ProcessesMIG/MAG weldingMIG/MAG pulsed arc weldingwith watercooled torchesMIG/MAG high-performance weldingMIG brazing

Recommended base metalsConstructional steelsCoated constructional steelFerritic / austenitic CrNi steelsDuplex steelsNickel-based materialsCopper materials

Standard equipmentMultilock Torch bodyInsulation sleeve at watercooled welding torchContact tube, CuCrZr alloyForced contacting arrangement for welding-wire (watercooled torches)Precision TCP ± 0,5 mm

Hose packSteel inner liner for steel wireWirefeed FWD button (watercooled torches)Separate gas and blow-out linesSwirl-free gas-flow – no loss of gasUV, temp. and ozone-resistant rubber fabric hosesRubber anti-kink feature at machine and torch end (watercooled torches)

27

Robacta 2500 / 280 / 300 / 400 / 500 /5000 / 700 / 700 Time / 7000 torch bodies

Technical Data acc. to EN 60974-7 Welding Duty cycle Standard equipment Wire WeightTorch body, watercooled current Ø inch/mm Ø inch/mm lbs./kgRobacta2500 250 A 100 % - 0.02 – 0.05 / 0,6 – 1,2 1.13 / 0,515Robacta280 280 A 100 % 0.04 / 1,0 0.03 – 0.05 / 0,8 – 1,2 1.15 / 0,520Robacta300 350 A 100 % 0.04 / 1,0 0.03 – 0.05 / 0,8 – 1,2 1.14 / 0,515Robacta400 400 A 100 % 0.04 / 1,0 0.03 – 0.05 / 0,8 – 1,2 1.11 / 0,505Robacta500 500 A 100 % 0.04 / 1,2 0.03 – 0.06 / 0,8 – 1,6 1.29 / 0,585Robacta5000 500 A 100 % 0.05 / 1,2 0.03 – 0.06 / 0,8 – 1,6 1.29 / 0,585Robacta700 700 A 100 % 0.05 / 1,2 0.04 – 0.06 / 1,0 – 1,6 1.27 / 0,575Robacta700 Time 700 A 100 % 0.05 / 1,2 0.04 – 0.06 / 1,0 – 1,6 1.31 / 0,595Robacta7000 700 A 100 % 0.06 / 1,6 0.04 – 0.06 / 1,0 – 1,6 1.27 / 0,575Hose pack 700 A 100 % 0.05 / 1,2 0.03 – 0.06 / 0,8 – 1,6 4.19 / 1,900*Hose pack EA 1400 / 1900 360 A 100 % 0.05 / 1,2 0.03 – 0.06 / 0,8 – 1,6 3.52 / 1,600


Recommended areas of use

Automobile and allied vendor industriesConstruction of special vehicles and construction machineryConstruction of plant, containers, machinery,structural steelConstruction of chemical plantsConstruction of rail vehicles and rolling stockShipbuilding / Offshore

Processes

CMT weldingCMT Pulsmix weldingCMT brazingMIG/MAG weldingMIG/MAG pulsed arc welding

Recommended base metals

Constructional steelsCoated constructional steelsFerritic / austenitic CrNi steelsAluminium materialsSpecial materialsCopper materials

OptionsWire buffer set (1,2m, 1,6m)Wire buffer connections (Universal , ABB)Holding angle (=°, 22°, 36°, FLEX)

Torch bodyRobacta torch bodies recommendedRA300/500/5000 (0°, 22°, 36°)Customer specific lengths up to 500mm)Examination and testing device

Torch bodyContact tube with centre boreForced contacting arrangementPrecision TCP 0,5mm

Driving unitAC direct drive for highdynamic wire feedingExternal wire feed hose onlyWirefeed FWD/BACK buttonGas test button

Standard equipment

Robacta Drive CMT

Self centering pressure rollDisplay for press-on force adjustmentSignal LED for status display

Hose packDemountable hose packSeparate gas and blow out lineSwirl free gas flow - no loss of gasUV, temp and ozone resistant rubber fabric hosesRubber hoses

Technical Data acc. to EN 60974-7 Welding Duty cycle Standard equipment Wire WeightRobacta Drive current Ø inch/mm Ø inch/mm lbs./kgRobacta Drive CMT 360 A 100% Basic kit 0.03 – 0.06 / 0,8 – 1,6 4.85 / 2,200*


28

Recommended base metals

Construcional steelsCoated and galvanised steelsFerritic/austenitic CrNi steelsDuplex steelsAluminium materialsMagnesium materialsCopper materials

Torch bodyContact tube CuCrZrForced contacting arrangementPrecision TCP 0,5mmDriving unitWirefeed FWD/BACK buttonGas test buttonDisplay for press-on force-adjustment

Standard equipment Robacta DriveDC-servomotor with digital encoderToothed drive and pressure rollersHose packGraphit inner liner 2,5mmSeparate gas and blow out linesSwirl free gas flow - no loss of gasUV, temp and ozone resistant rubber fabric hoses

OptionsTorch bodySpecial lengths up to 500mmForced contacting arrangement for welding-wireSeam tracking line

Hose pack - Robacta DriveSteel inner liner for steel wireCustomer specific lenghts 1,0 to 10mwithout driving unitExtraction setSeam tracking lineHolding and adjusting clampAdaptor for Dinse boxBasic kit

Recommended areas of use

Construction of plant, containers, machinery,structural steelAutomobile and allied vendor industryConstruction of special vehicles and construction machineryConstruction of chemical plantsConstruction of rail vehicles & rolling stockShipbuilding / Offshore

ProcessesCMT standard weldingMIG/MAG pulsed arc weldingMIG/MAG brazingLaser hotwire

Robacta Drive / Robacta Drive withexternal wire feed hose / Laser hotwire

Technical Data acc. to EN 60974-7 Welding Duty cycle Standard equipment Wire WeightRobacta Drive current Ø inch/mm Ø inch/mm lbs./kgRobacta Drive 500 A 100% Basic kit 0.03 – 0.07 / 0,8 – 2,0 5.07 / 2,300*


Technical Data acc. to EN 60974-7 Welding Duty cycle Standard equipment Wire WeightWatercooled current Ø inch/mm Ø inch/mm lbs./kgRobacta Twin 900 900 A 100 % 0.05 / 1,2 0.05 – 0.06 / 1,2 – 1,6 3.31 / 1,500Hose pack 900 A 100 % 0.05 / 1,2 0.05 – 0.06 / 1,2 – 1,6 8.82 / 4,000Robacta Twin Compact 900 A 100 % 0.05 / 1,2 0.05 / 1,2 3.75 / 1,700Hose pack Twin Compact 900 A 100 % 0.05 / 1,2 0.05 / 1,2 3.31 / 1,500

Standard equipmentTorch bodyContact tube "industrial" with centre bore atRobacta Twin 900Contact tube "industrial" at Robacta TwinCompactWire electrodes insulated from one anotherSpatter protection, with high thermal stabilityForced contacting arrangement for weldingwire Precision TCP ± 0,5mmSeam tracking line at Robacta Twin CompactIntegrated blow out line

Hose packSteel inner liner for steel wireWirefeed FWD button at Robacta Twin 900Separate gas and blow-out linesSwirl-free gas-flow - no loss of gasUV, temp and ozone-resistant rubber fabrichosesRubber anti-kink feature at machine and torchendHolding clamp mountedSeam tracking line at Robacta Twin Compact

OptionsTorch bodyTorque spanner for RA Twin Compact

Hose packCombi inner liner for Al and CrNi wiresSpecial lengths 1,1-4,5m



Recommended base metalsDuplex steels

Robacta Twin 900 / Compact /Compact Complete

29

Technical Data acc. to EN 60974-7 Welding Duty cycle Standard equipment Wire WeightWatercooled current Ø inch/mm Ø inch/mm lbs./kgRobacta Twin900 900 A 100 % 0.05 / 1,2 0.05 / 1,2 3.31 / 1,500Hose pack 900 A 100 % Basic kit 0.05 – 0.06 / 1,2 – 1,6 13.45 / 6,100*


Recommended areas of useConstruction of plant, containers, machinery,structural steelAutomobile and allied vendor industriesConstruction of special vehicles and construction machineryConstruction of chemical plantsRobot weldingMaintenance and repairConstruction of rail vehicles & rolling stockShipbuilding and offshore engineering


Recommended base metalsDuplex steelsAluminium materials

Standard equipmentTorch bodyContact tube, CuCrZr alloy withcentre boreWire electrodes insulated from one anotherSpatter protection, with high thermal stabilityForced contacting arrangement for welding-wireHose packGraphit innerliner ø 2,5 mm for Al- and CrNi-wireExact speed regulation assured by digital encoder

Robacta Drive Twin

Toothed drive and pressure rollersWirefeed FWD/BACK buttonGas-test buttonSeparate gas and blow-out linesSwirl-free gas-flow – no loss of gasUV, temp. and ozone-resistant rubber fabric hosesRubber anti-kink feature at machine and torch endHolding clamp mounted

OptionsTorch bodyContact tip mounting toolWrench for RA-union nutHose pack Steel inner liner for steel wireAdapter for other power-off boxesBasic kitSpecial lengths 1,1 – 10,1 m

Robacta TC 1000*)

Recommended areas of useConstruction of plant, containers, machinery,structural steelAutomobile and allied vendor industriesConstruction of special vehicles and construction machineryConstruction of rail vehicles & rolling stockShipbuilding and offshore engineering

ProcessesElectromagnetic and touchless cleaning ofMIG/MAG robot torches

Recommended base metalsConstructional steelsCoated constructional steel

Standard equipmentCompletely remote-controllableGalvanic separated controlConstant, defined cleaning efficiencySelf-test if cleaning process has been performedQuick-stop functionCooling liquid sensor (Robacta TC 1000 / Twin)

OptionsAutotrafo Robacta TC 1000Wire cutterInterface for fieldbus connectionCompressed air blow out 16 bar

Overtemperature protectionCE-markLiquid reservoir (Robacta TC 1000 / Twin)Discharge coilControl with Standard I/OElectrolyte spraying system

30

*) Not for use in Japan, due to patent reasons.

Robacta TC 1000 / Robacta TC 1000 TwinCleaning station Robacta TC 1000 Twin compact Robacta TC 1000 ext.Mains voltage +/–15 % 50/60 Hz 230 V 230 VRated power 180 W 180 WCompressed air supply 6 bar –Min. cycle time 45 sec 45 secDischarging current 1500 A 1500 ADischarging voltage 270 V DC 270 V DCCoolant reservoir capacity gal / l 0.20 / 0,75 –Protection class IP 21 IP 21Dimension l x w x h inch 12.99 x 9.84 x 16.61 12.99 x 9.84 x 16.61

mm 330 x 250 x 422 330 x 250 x 422Weight (without coolant) lbs. / kg 28.66 / 13 25.35 / 11,5

Cleaning unit S Cleaning unit PCleaning unit S Twin Cleaning unit P Twin

Cleaning units Cleaning unit S Twin compact Cleaning unit P Twin compactCompressed air supply 6 bar 6 barDimension l x w x h inch 8.35 x 4.76 x 4.69 14.37 x 7.95 x 11.81

mm 212 x 121 x 119 365 x 202 x 300Weight (without anti spatter injection) lbs. / kg 13.23 / 6 17.64 / 8

Cleaning station Robacta Reamer V Robacta Reamer Robacta Reamer Alu Robacta Reamer TwinSupply voltage +24 VDC +24 VDC +24 VDC +24 VDCRated power 12 W 3,2 W 3,2 W 6 WCycle time 3 – 5 sec 3 – 5 sec 3 – 5 sec max. 7,5 secAir consumption max. 6 bar at 7,3 l/sec max. 6 bar at 7 l/sec max. 6 bar at 7 l/sec max. 6 bar at 7 l/secTank coolant capacity gal / l 0.26 / 1 0.07 / 0,25 – 0.07 / 0,25Dimension l x w x h inch 6.70 x 8.66 x 13.60 9.45 x 6.50 x 11.02 6.69 x 6.50 x 11.02 12.80 x 8.66 x 13.78

mm 170 x 222 x 345 240 x 165 x 280 170 x 165 x 280 325 x 220 x 350Weight lbs. / kg 25.35 / 11,5 22.05 / 10 19.84 / 9 37.48 / 17

Robacta Reamer / Alu EditionRobacta Reamer Twin

Recommended areas of useConstruction of plant, containers, machinery,structural steelAutomobile and allied vendor industriesConstruction of special vehicles and construction machineryConstruction of chemical plantsRobot weldingMaintenance and repairConstruction of rail vehicles & rolling stockShipbuilding and offshore engineering

ProcessesMechanical cleaning ofMIG/MAG robot torches

Recommended base metalsFerritic / austenitic CrNi steelsDuplex steelsNickel-based materialsAluminium materialsMagnesium materialsCopper materialsSpecial materials

Standard equipmentCompletely remote-controllableWire cutter (Robacta Reamer Twin)Button for manual cleaningEqual milling- and spray-in position

Spray-in amount adjustableConstant spray-in time360° mountableCE-mark

OptionsMounting socketInterface for fieldbus connection

Robacta TC 1000*)

31

Power source TT 1600 TT 1700Mains voltage +15 /–20 % 50/60 Hz 1 x 230 V 1 x 230 VCos phi 0,99 (160 A) 0,99 (120 A)Welding current range TIG 2 – 160 A 2 – 170 A

EL 2 – 140 A 2 – 140 AWelding current TIG 10 min/40° C 35 % d.c. 160 A 170 A

10 min/40° C 100 % d.c. 110 A 120 A10 min/25° C 100 % d.c. 130 A 150 A

Open-circuit voltage 45 V 92 VOperating voltage TIG 10,1 – 16,4 V 10,1 – 16,8 V

EL 20,1 – 25,6 V 20,1 – 25,6 VProtection class IP 23 IP 23Dimension l x w x h inch 16.93 x 7.09 x 11.02 16.93 x 7.09 x 11.02


OptionsRemote control unitCalibrationdocument

Recommended areas of useConstruction of plant, containers, machinery,structural steelIndustry plant & pipeline construction Maintenance, repair and assemblingConstruction of chemical and paper plants

ProcessesTIG-DCManual electrode (MMA) welding

Recommended base materials:Constructional steelsFerritic / austenitic CrNi steelsDuplex steelsNickel-based materialsMagnesium materialsCopper materialsSpecial materials

Standard equipmentTouch-down ignition / HF switch-selectableRemote-controllableGenerator-compatibleSecurity codeS-mark, CE-mark Thermostat-controlled fan

TransTig 1600 / 1700

Carrying strapUpDown control from torch Overtemperature protection2-step mode, 4-step modeDigital display

32

Power source TT 800 Job TT 2200 (Job)Mains voltage –20 % / +15 % 230 V 230 VCos phi 0,99 0,99Welding current range TIG 0,5 – 80 A 3 – 220 A

Electrode 10 – 80 A 10 – 180 AWelding current at 10 min/40° C 40 % d.c. - 220 A



Electrode 20,4 – 23,2 V 20,4 – 27,2 VProtection class IP 23 IP 23Dimension l x w x h inch 19.09 x 7.09 x 13.54 19.09 x 7.09 x 15.35


Cooling unit FK 2200 (FC)Cooling capacity (25° C) Q = 1l/min 500 WMax. throughput gal/min / l/min 0.79 / 3,0Coolant volume gal / l 0.40 / 1,5Protection class IP 23Dimension l x w x h inch 21.26 x 7.09 x 7.09

mm 540 x 180 x 180Weight (without coolant) lbs. / kg 14.55 / 6,6

OptionsRemote-controllableRobot Interface, digitalTIG JobMasterCalibrationdocument

Recommended areas of useConstruction of plant, containers, machinery,structural steelIndustry plant & pipeline construction Maintenance, repair and assemblingConstruction of chemical and paper plantsAutomobile and allied vendor industriesRobot welding



Standard equipmentAutomatic cooling-unit cut-outTouch-down ignition / HF switch-selectableGas-test buttonGenerator-compatibleJob modeS-mark, CE-mark Thermostat-controlled fanCarrying strap

UpDown control from torch Overtemperature protection2-step mode, 4-step modeSpot-welding / Puls modeDigital displayCompatible for bus-systemTAC – special tack modeEarth leakage monitoring

TransTig 800 Job / 2200 / 2200 Job

33

Cooling unit FK 2500 / FK 2500 FC / FK 2500 RobCooling capacity (25° C) Q = 1l/min 800 WMax. throughput gal./min / l/min 0.92 / 3,5Coolant volume gal. / l 1 / 4Weight (without coolant) lbs. / kg 19.8 / 9Protection class IP 23Dimension l x w x h inch 24.6 x 9.4 x 8.8

mm 625 x 240 x 225

TT 2500 TT 2500 TT 3000 TT 3000Power source (Job/Comfort) (Job/Comfort) MV (Job/Comfort) (Job/Comfort) MVMains voltage 3x400 V 3x400- 3x200- 1x200- 3x400 V 3x400- 3x200- 1x200-

460 V 240 V 240 V 460 V 240 V 240 VMain voltage tolerance +/–15 % 50/60 Hz +/–10 % 50/60 Hz +/–15 % 50/60 Hz +/–10 % 50/60 HzCos phi 0,99 0,99 0,99 0,99Welding current at 10 min/40° C 45 % d.c. – – 250 A – – – 300 A –

10 min/40° C 50 % d.c. 250 A 250 A – – 300 A 300 A – –10 min/40° C 55 % d.c. – – – 220 A – – – 220 A10 min/40° C 100 % d.c. 190 A 190 A 180 A 170 A 240 A 240 A 220 A 190 A

Open-circuit voltage 85 V 85 V 85 V 85 VOperating voltage TIG 10,1 – 20,0 V 10,1 – 20,0 V 10,1 – 22,0 V 10,1 – 22,0 V

Electrode 20,4 – 30,0 V 20,4 – 30,0 V 20,4 – 32,0 V 20,4 – 32,0 VProtection class IP 23 IP 23 IP 23 IP 23Dimension l x w x h inch 22 x 9.8 x 17.1 22 x 9.8 x 17.1 22 x 9.8 x 17.1 22 x 9.8 x 17.1


Digital displayTAC – special tack modeEarth leakage monitoring



Standard equipmentAutomatic cooling-unit cut-outTouch-down ignition / HF switch-selectableGas-test buttonGenerator-compatibleJob mode (only for TT 4000 / 5000 Job)S-mark, CE-mark

TransTig 2500 / 3000 / 2500 Job / 3000 Job / 2500 Comfort / 3000 Comfort

Thermostat-controlled fanUpDown control from torchOvertemperature protection2-step mode, 4-step modeSpot-welding / Puls mode

Recommended areas of useConstruction of plant, containers, machinery,structural steelIndustry plant & pipeline construction Maintenance, repair and assemblingConstruction of chemical and paper plantsAutomobile and allied vendor industriesRobot weldingConstruction of rail vehicles & rolling stockShipbuilding and offshore engineering

OptionsRemote-controllableRobot interfaceTIG JobMasterCalibration documentRate-of-flow watchdog for torch cooling

34

Cooling unit FK 4000 R (FC)Cooling capacity (25° C) Q = 1l/min 1360 WMax. throughput gal./min / l/min 0.92 / 3,5Coolant volume gal. / l 1.45 / 5,5Weight (without coolant) lbs. / kg 35.94 / 16,3Protection class IP 23Dimension l x w x h inch 27.56 x 11.42 x 9.84

mm 700 x 290 x 250

Digital displayTAC – special tack modeEarth leakage monitoring



Standard equipmentAutomatic cooling-unit cut-outTouch-down ignition / HF switch-selectableGas-test buttonGenerator-compatibleJob mode (only for TT 4000 / 5000 Job)S-mark, CE-mark

TransTig 4000 / 5000 / 4000 Job /5000 Job

Thermostat-controlled fanUpDown control from torchOvertemperature protection2-step mode, 4-step modeSpot-welding / Puls mode



Power source TT 4000 (Job) TT 4000 (Job) MV TT 5000 (Job) TT 5000 (Job) MVMains voltage +/–10 % 50/60 Hz 3 x 220 – 240 V 3 x 220 – 240 V

+/–10 % 50/60 Hz 3 x 380 – 460 V 3 x 380 – 460 V+/–15 % 50/60 Hz 3 x 400 V 3 x 400 V

Cos phi 0,99 (400 A) 0,99 (400 A) 0,99 (500 A) 0,99 (500 A)Welding current range TIG 3 – 400 A 3 – 400 A 3 – 500 A 3 – 500 A

Electrode 10 – 400 A 10 – 400 A 10 – 500 A 10 – 500 A Welding current at 10 min/40° C 40 % d.c. – – 500 A 500 A

10 min/40° C 45 % d.c. 400 A 400 A – –10 min/40° C 60 % d.c. 365 A 365 A 450 A 450 A10 min/40° C 100 % d.c. 310 A 310 A 350 A 350 A


Electrode 20,4 – 36,0 V 20,4 – 36,0 V 20,4 – 40,0 V 20,4 – 40,0 VProtection class IP 23 IP 23 IP 23 IP 23Dimension l x w x h inch 24.61 x 11.42 x 18.70 24.61 x 11.42 x 18.70 24.61 x 11.42 x 18.70 24.61 x 11.42 x 18.70


35

OptionsRemote-controllableRobot interfaceTIG JobMasterCalibrationdocument

ProcessesTIG-DCTIG-AC/DCManual electrode (MMA) welding

Recommended base materials:Constructional steelsFerritic / austenitic CrNi-steelsDuplex steels Nickel-based materials Aluminium, aluminium alloyed materialsMagnesium materialsCopper materials Special materials

Standard equipmentAutomatic cap-shapingAutomatic cooling-unit cut-outTouch-down ignition / HF switch-selectableGas-test buttonGenerator-compatibleJob modePolarity reversalS-mark, CE-mark Thermostat-controlled fanCarrying handle (MW 2200)

MagicWave® 1700 / 2200 / 1700 Job /2200 Job

Carrying strapUpDown control from torchOvertemperature protection2-step mode, 4-step modeSpot-welding / Puls modeDigital displayTAC – special tack modeQuiet arc, due to fuzzy logicEarth leakage monitoring Compatible for bus-system

Power source MW 1700 (Job) MW 2200 (Job)Mains voltage –20 % / +15 % 230 V 230 VCos phi 0,99 0,99Welding current range TIG 3 – 170 A 3 – 220 A

Electrode 10 – 140 A 10 – 180 AWelding current at 10 min/40° C 35 % d.c. 170 A 220 A



Electrode 20,4 – 25,6 V 20,4 – 27,2 VProtection class IP 23 IP 23Dimension l x w x h inch 19.09 x 7.09 x 13.54 19.09 x 7.09 x 15.35

mm 485 x 180 x 344 485 x 180 x 390Weight lbs. / kg 33.07 / 15 38.36 / 17,4

Cooling unit FK 2200 (FC)Cooling capacity (25° C) Q = 1l/min 500 WMax. Throughput gal/min / l/min 0.79 / 3,0Coolant volume gal / l 0.40 / 1,5Protection class IP 23Dimension l x w x h inch 21.26 x 7.09 x 7.09

mm 540 x 180 x 180Weight (without coolant) lbs. / kg 14.55 / 6,6

Recommended areas of useConstruction of plant, containers, machinery,structural steelIndustry plant & pipeline construction Maintenance, repair and assemblingConstruction of chemical and paper plants Automobile and allied vendor industriesConstruction of rail vehicles & rolling stockAerospace industryRobot welding

36

Recommended areas of useConstruction of plant, containers, machinery,structural steelIndustry plant & pipeline construction Maintenance, repair and assemblingConstruction of chemical and paper plants Automobile and allied vendor industriesConstruction of rail vehicles & rolling stockAerospace industryShipbuilding and offshore engineeringRobot welding



Standard equipmentAutomatic cap-shapingAutomatic cooling-unit cut-outTouch-down ignition / HF switch-selectableGas-test buttonGenerator-compatibleJob mode (only for MW 4000 / 5000 Job)Polarity reversalS-mark, CE-markThermostat-controlled fan

MagicWave® 2500 / 3000 / 2500 Job /3000 Job / 2500 Comfort / 3000 Comfort

UpDown control from torchOvertemperature protection2-step mode, 4-step modeSpot-welding / Puls modeDigital displayTAC – special tack modeQuiet arc, due to fuzzy logicEarth leakage monitoringCompatible for bus-system


Cooling unit FK 2500 / FK 2500 FC / FK 2500 RobCooling capacity (25° C) Q = 1l/min 800 WMax. throughput gal./min / l/min 0.92 / 3,5Coolant volume gal. / l 1 / 4Weight (without coolant) lbs. / kg 19.8 / 9Protection class IP 23Dimension l x w x h inch 24.6 x 9.4 x 8.8

mm 625 x 240 x 225

MW 2500 MW 2500 MW 3000 MW 3000Power source (Job/Comfort) (Job/Comfort) MV (Job/Comfort) (Job/Comfort) MVMains voltage 3x400 V 3x400- 3x200- 1x200- 3x400 V 3x400- 3x200- 1x200-

460 V 240 V 240 V 460 V 240 V 240 VMains voltage tolerance +/–15 % 50/60 Hz +/–10 % 50/60 Hz +/–15 % 50/60 Hz +/–10 % 50/60 HzCos phi 0,99 0,99 0,99 0,99Welding current at 10 min/40° C 30 % d.c. – – – – – – 300 A –

10 min/40° C 35 % d.c. – – 250 A – 300 A 300 A – –10 min/40° C 40 % d.c. 250 A 250 A – – – – – 220 A10 min/40° C 45 % d.c. – – – 220 A – – – –10 min/40° C 100 % d.c. 170 A 170 A 160 A 150 A 190 A 190 A 170 A 150 A


Electrode 20,4 – 30,0 V 20,4 – 30,0 V 20,4 – 32,0 V 20,4 – 32,0 VProtection class IP 23 IP 23 IP 23 IP 23Dimension l x w x h inch 22 x 9.8 x 17.1 22 x 9.8 x 17.1 22 x 9.8 x 17.1 22 x 9.8 x 17.1


37

Cooling unit FK 4000 R (FC)Cooling capacity (25° C) Q = 1l/min 1360 WMax. throughput gal./min / l/min 0.92 / 3,5Coolant volume gal. / l 1.45 / 5,5Weight (without coolant) lbs. / kg 35.94 / 16,3Protection class IP 23Dimension l x w x h inch 27.56 x 11.42 x 9.84

mm 700 x 290 x 250

Power source MW 4000 (Job) MW 4000 (Job) MV MW 5000 (Job) MW 5000 (Job) MVMains voltage +/–10 % 50/60 Hz 3 x 220 – 240 V 3 x 220 – 240 V

+/–10 % 50/60 Hz 3 x 380 – 460 V 3 x 380 – 460 V+/–15 % 50/60 Hz 3 x 400 V 3 x 400 V

Cos phi 0,99 (400 A) 0,99 (400 A) 0,99 (500 A) 0,99 (500 A)Welding current range TIG 3 – 400 A 3 – 400 A 3 – 500 A 3 – 500 A

EL 10 – 400 A 10 – 400 A 10 – 440 A 10 – 440 A Welding current at 10 min/40° C 40 % d.c. – – 500 A 500 A

10 min/40° C 45 % d.c. 400 A 400 A – –10 min/40° C 60 % d.c. 365 A 365 A 440 A 440 A10 min/40° C 100 % d.c. 310 A 310 A 350 A 350 A


EL 20,4 – 36,0 V 20,4 – 36,0 V 20,4 – 37,6 V 20,4 – 37,6 VProtection class IP 23 IP 23 IP 23 IP 23Dimension l x w x h inch 24.61 x 11.42 x 27.76 24.61 x 11.42 x 27.76 24.61 x 11.42 x 27.76 24.61 x 11.42 x 27.76





Standard equipmentAutomatic cap-shapingAutomatic cooling-unit cut-outTouch-down ignition / HF switch-selectableGas-test buttonGenerator-compatibleJob mode (only for MW 4000 / 5000 Job)Polarity reversalS-mark, CE-markThermostat-controlled fan

MagicWave® 4000 / 5000 / 4000 Job /5000 Job

UpDown control from torchOvertemperature protection2-step mode, 4-step modeSpot-welding / Puls modeDigital displayTAC – special tack modeQuiet arc, due to fuzzy logicEarth leakage monitoringCompatible for bus-system


38

Power source Stand AloneMains voltage +/–15 % 230 V 50/60 HzRated power 300 WCleaning current range 5 – 20 AOpen-circuit voltage 17 VOperating voltage 5 – 17 VThroughput gal/h / l/h 0.07 – 0.58 / 0,27 – 2,2Cleaning agent volume gal / l 0.40 / 1,5Protection class IP 23Dimension l x w x h inch 16.93 x 7.09 x 11.02

mm 430 x 180 x 280Weight lbs. / kg 11.02 / 5

Recommended areas of useConstruction of chemical plantsMaintenance and repairIndustry plant & pipeline construction,site-erection firms

ProcessesElectrochemical cleaningElectrochemical polishing / burnishingElectrochemical labelling / printing

Recommended base materials:Ferritic / austenitic CrNi steelsCopper materials

Standard equipmentCleaning current is continuously adjustableElectrolyte feed is continuously adjustableAdjustable current waveform (AC/DC)Short-circuit detection and cut-outGenerator-compatibleCE mark

MagicCleaner®

OptionsMagicCleaner printing setMains voltage 110V - 115V, 50/60Hz

39

2

3

4

57

1

6

2

3

4

5

8

1

6

7

TIG cold wireweldingMW2200 Job / KD 4000 D-11manual

TAC special tack mode (only Job mode)Quiet arc due to Active WaveEarth leakage monitoringSynchronized wire puls modeBus compatible

Standard equipment 4-roller driveAutomatic cap shapingAutomatic cooling-unit cut outAutomatic cold wire retractHF ignitionGas-test buttonGenerator compatibleJob mode (only with Job mode)Polarity reversal (only MW-series)S-mark, CE-markThermostat controlled fanRate-of-flow watchdog for torch cooling(FK2200 FC)Up-down control from torch Overtemperature protection2-step mode, 4-step modeSpot-welding / Pulse mode (only Job mode)Digital Display

Recommended areas of useAutomobile and allied vendor industriesConstruction of chemical plantsConstruction of plant, containers, machinery,structural steelRobot weldingIndustry plant & pipeline construction, site-erection firmsConstruction of rail vehicles & rolling stockShipbuilding and offshore engineeringAerospace industry

OptionsRemote controllableRobot interfaceJobMaster TIG (only Job mode)Calibration documentJobexplorer / WinRCUUpgrades by add-on modulesService moduleOPC-Data

ProcessTIG-DCTIG-AC/DC

Recommended base materialsConstructional steelsNickel-based materialsAluminium materialsMagnesium materialsSpecial materials


ProcessTIG-DC

Recommended base materials:Constructional steelsFerritic / austenitic CrNi-steelsDuplex steels Nickel-based materials Magnesium materialsCopper materials Special materials

TIG cold wireweldingTT 3000 Job / KD 4000 D-11manual

Digital displayQuiet arc, due to fuzzy logicEarth leakage monitoringSynchronized wire pulse modeCompatible for bus system

Standard equipment4-roller driveAutomatic cap-shapingAutomatic cooling-unit-cut-outAutomatic cold-wire retractTouch-down ignition / HF switch-selectableGas-test-buttonGenerator compatibleJob modePolarity reversal (only MW-series)S-mark, CE-markThermostat-controlled fanFlow conrol for torch cooling system FK 4000R FCUpDown control from torchOvertemperature protection2-step mode, 4-step modeSpot welding / Puls mode

OptionsRemote controllableRobot InterfaceCalibration documentJobexplorer / WinRCUUpgrades by add-on modulesService ModuleOPC-Data

40

2

3

4

5

6

1

RobotControl

ROB 5000

1

2

4

5

6

7

8

9

12

11

3

10

TIG cold wire weldingMW4000 Job / KD 4000 D-11manual

TAC special tack mode (only Job mode)Quiet arc due to Active WaveEarth leakage monitoringSynchronized wire puls modeBus compatible

Standard equipment 4-roller driveAutomatic cap shapingAutomatic cooling-unit cut outAutomatic cold wire retractHF ignitionGas-test buttonGenerator compatibleJob mode (only with Job mode)Polarity reversal (only MW-series)S-mark, CE-markThermostat controlled fanRate-of-flow watchdog for torch cooling(FK4000 R FC)Up-down control from torch Overtemperature protection2-step mode, 4-step modeSpot-welding / Pulse mode (only Job mode)Digital Display


OptionsRemote controllableRobot interfaceJobMaster TIG (only Job mode)Calibration documentJobexplorer / WinRCUUpgrades by add-on modulesService moduleOPC-Data

ProcessTIG-DCTIG-AC/DC


Robotset MW 3000 Comfortwith cold wire feeding PushPull

ProcessesTIG-DCTIG-AC/DC

41

KD 7000D-11

RobotControl

ROB 5000

1

2

7

8b

9

3

4

8a

9

10

56

Robotset MW 3000 Comfort with cold wire feeding PushPull










Robotset MW 4000 Job withCold wire feedingPushStandard I/O



42

RobotControl

1

2

7

9

3

4

8

10

5

6

11

12

DEVICE NETEXTERN

Digital displayTAC - special tack modeQuiet arc, due to fuzzy logicEarth leakage monitoringSynchronized wire pulse mode (only Jobmode)Compatible for bus system (only Job mode)

Standard equipment4-roller driveAutomatic cap-shapingAutomatic cooling-unit-cut-outAutomatic cold wire retractTouch-down ignition / HF switch-selectableGas-test-buttonGenerator compatibleJob modePolarity reversal (only MW-series)S-mark, CE-markThermostat-controlled fanFlow conrol for torch cooling system FK 4000R FCUpDown control from torchOvertemperature protection2-step mode, 4-step modeSpot welding / Puls mode



Robotset MW 5000 Job withCold wire feedingPush/PullFeldbus - DeviceNet



43

4,100,4324,100,4694,100,2144,100,2154,100,2254,100,38840,0009,004640,0009,0075

FK 2200FK 2200 FC

FK 2500 / FCFK 2500 RobFK 2500 MVFK 2500 MV FCFK 2500 MV Rob

FK 4000-RFK 4000-R FCFK 4000 ROB

FK 9000-R

FK22

00 4

,045

,886

FK22

00 F

C 4

,045

,886

,632

FK25

00 4

,045

,985

FK 2

500

FC 4

,045

,985

,632

FK 2

500

Rob

4,0

45,9

85,6

33

FK 2

500

MV

4,04

5,98

5,80

0

FK 2

500

MV

FC 4

,045

,985

,832

FK 2

500

MV

Rob

4,0

45,9

85,8

33

FK40

00-R

4,0

45,8

37

FK40

00-R

FC

4,0

45,8

37,6

32

FK40

00 R

OB

4,0

45,8

37,6

33

FK90

00-R

4,0

45,9

06

FK 2500 FK 2500 MV FK 4000 RFK 2500 FC FK 2500 MV FC FK 4000 R FC

Cooling unit TIG FK 2200 FK 2500 Rob FK 2500 MV Rob FK 4000 Rob FK 9000 RCooling capacity (25°C) Q 1l/min 500 W 800 W 800 W 1360 W 1700 WCooling capacity (40°C) Q 1l/min 310 W 500 W 500 W 870 W 1100 WMax. lift of the pump ft / m 98.43 / 30 98.43 / 30 98.43 / 30 98.43 / 30 147.64 / 45Max. throughput gal/min / l/min 0.79 / 3 0.92 / 3,5 0.92 / 3,5 0.92 / 3,5 1.32 / 5Max. pump pressure bar 4,2 4,2 4,2 4,2 6,0Mains voltage 50/60 Hz ±10% 230 V (-20/+15%) 400 V 200-240/400-460 V 400 V 400 VProtection class IP 23 IP 23 IP 23 IP 23 IP 23Weight lbs. / kg 14.55 / 6,6 19.8 / 9 25.5 / 11,6 35.27 / 16 61.73 / 28Coolant volume gal / l 0.40 / 1,5 1.00 / 4 1.00 / 4 1.45 / 5,5 2.38 / 9Dimension l x w x h inch 20.8x7.09x7.09 24.6x9.4x8.8 24.6x9.4x8.8 27.56x11.42x9.84 27.56x11.42x9.84

mm 510x180x180 625x240x225 625x240x225 700x290x250 700x290x250

S S S S S S O O S SO S O S S

S S S S SO O S S S

S S S O O O OS S S S S S S S S

S S SS S S S S S S S S S S SS S S S S S S S S S S S

Cooling units TIG

TT2200 / TT2200JobTT2500/3000 Job / Comfort TT4000 / TT5000 / TT4000Job / TT5000JobMW1700 / MW2200 / MW1700Job / MW2200JobMW2500/3000 Job / ComfortMW4000 / MW5000 / MW4000Job / MW5000JobI-Kit water flow control FK 2200 I-Kit water flow control FK2200 no Filter I-Kit water flow control FK 4000 R I-Kit thermal guard FK 4000 I-Kit Autotrafo FK4000-R 200V-460V I-Kit Autotrafo FK9000-R 200V-460V Torch-cooling liquid 5l Torch-cooling liquid 30l Thermal guardWater flow control Water flow sensorWater filterMultivoltage (Autotrafo) Rotary vane pumpMagnetic coupled rotary vane pump50/60 Hz - suitable5l torch-cooling liquid

O= OptionS= Standard equipment

44

XX

X X X XXXXXXXXXX

X

4,100,1674,100,1844,100,5404,100,3914,100,2184,001,5904,045,8584,045,8654,045,9774,001,5774,045,8724,100,3214,100,380

KD

400

0 D

-11

4,04

5,95

9

KD

700

0 D

-11

4,04

5,96

0

KD

150

0 D

-11

4,04

5,95

8

4,100,4554,100,3744,100,5384,100,3714,100,3704,100,322

TT1600 / TT1700TT2200 / TT2200JobTT2500 / 3000Job / ComfortTT4000 / TT5000 / TT4000Job / TT5000JobMW1700 / MW2200 / MW1700Job / MW2200JobMW2500 / 3000Job / ComfortMW4000 / MW5000 / MW4000Job / MW5000JobC-Kit Carriage Easy (strengthening for watercooled sets)C-Kit bottle mounting plate AllroundMounting set TT/MW2200/2500/3000I-Kit Pick-Up strengtheningI-Kit feeder swivel mount VR4000I-Kit bottle mounting plate PickUpBottle mounting plate DuoCrane transport PickUpCrane transport PickUp MW/TT 4000/5000Transport handels PickUp (only with feeder swivel mount)Wire feeder mounting double headI-Kit wheel brake PickUpI-Kit feeder swivel mount podium

Car

riage

Easy

-LT

Car

riage

Eas

y

Car

riage

Easy

250

0

Car

riage

Allr

ound

Car

riage

Pick

Up

Podi

umdi

gita

l mac

hine

s

Carriages TIG

CarriageEasy-LTEasy 2500

Carriage Easy

Carriage Allround

Carriage PickUp Podiumdigital machines

Cold wire

TT2500/3000 Job / ComfortTT4000Job / TT5000JobMW2200 JobMW2500/3000 Job / ComfortMW4000Job / MW5000JobI-Kit KD-DriveI-Kit digital gas sensor GAS30I-Kit digital gas sensor 0,2 - 10,0 l/minI-Kit wire end KD 4000 DI-Kit wire end KD 7000 DI-Kit wire end plug VR1500

45

Technical Data acc. to EN 60974-7 Welding current at Duty cycle Standard equipment Electrode WeightGascooled AC DC Ø mm/inch Ø mm/inch kg/lbs.TTG1600A 120 A 160 A 35% 2,4 / 0,09 1,0-3,2 / 0,03-0,12 0,65 / 1,43TTG2200A 180 A 220 A 35% 2,4 / 0,09 1,0-4,0 / 0,03-0,15 0,96 / 2,11TTG2600A 220 A 260 A 35% 3,2 / 0,12 1,6-6,4 / 0,06-0,25 0,57 / 1,25PL10 60 A 80 A 40% 1,6 / 0,06 1,0-2,4 / 0,03-0,09 0,55 / 1,21

TTG1600A / 2200A / 2600A / PL10

Standard equipmentPlug-on gas nozzle systemTorch body rotates through 60°Easy-to-use rocker switchSwivel-mounted protective hose with corrugated hoseUV and ozone-resistant protective hoseGas nozzle, tungsten electrode, torch cap longAnti-kink feature at machine and torch end

OptionsFlexible leather protection hose L = 0,7 mGas lensesP-system (screw-on gas nozzle)Fabric-reinforced protection hoseSpecial lengths of hose pack 1,0 – 16,0 mKD-feeding for TTG2200Adapter for old machines

Recommended areas of useAutomobile and allied vendor industriesConstruction of chemical plantsMaintenance and repairPipeline constructionStructural steel

ProcessesTIG-DC TIG-AC/DC

Recommended base metalsFerritic / austenitic CrNi steelsAluminium materialsMagnesium materials

Technical Data acc. to EN 60974-7 Welding current at Duty cycle Standard equipment Electrode WeightGascooled AC DC Ø mm/inch Ø mm/inch kg/lbs.TTG1600A WKZ 120A 160A 15% 2,4 / 0,09 1,0-3,2 / 0,03-0,12 0,35 / 0,77TTG1600A POT - 160A 35% 2,4 / 0,09 1,0-3,2 / 0,03-0,12 0,45 / 0,99TTG2200-TCS - 160A 35% 2,4 / 0,09 1,0-4,0 / 0,03-0,15 0,57 / 1,25

TTG1600A WKZ / 1600A-POT / 2200-TCS

46

Technical Data acc. to EN 60974-7 Welding current at Duty cycle Standard equipment Electrode WeightWatercooled AC DC Ø mm/inch Ø mm/inch kg/lbs.TTW2500A 180 A 250 A 40% 2,4 / 0,09 1,0-3,2 / 0,03-0,12 0,47 / 1,03TTW3000A 250 A 300 A 60% 2,4 / 0,09 1,0-3,2 / 0,03-0,12 0,75 / 1,65TTW4000A 350 A 400 A 60% 2,4 / 0,09 1,0-4,0 / 0,03-0,15 0,96 / 2,11TTW5000A 400 A 500 A 60% 3,2 / 0,12 1,6-6,4 / 0,06-0,25 0,985 / 2,17PW18 140 A 180 A 60% 1,6 / 0,06 1,0-2,4 / 0,03-0,98 0,60 / 1,32

Standard equipmentPlug-on gas nozzle systemTorch body rotates through 60°Easy-to-use rocker switchSwivel-mounted protective hose with corrugated hoseUV and ozone-resistant protective hoseGas nozzle, tungsten electrode, torch cap longAnti-kink feature at machine and torch end

Recommended areas of useConstruction of plant, containers, machinery,structural steelAutomobile and allied vendor industriesConstruction of special vehicles and construction machineryConstruction of chemical plantsMaintenance and repairPipeline constructionConstruction of rail vehicles & rolling stockShipbuilding and offshore engineering


Recommended base metalsFerritic / austenitic CrNi steelsDuplex steelsNickel-based materialsAluminium materialsMagnesium materialsCopper materials

OptionsFlexible leather protection hose L = 0,7 mGas lensesP-system (screw-on gas nozzle)Fabric-reinforced protection hoseSpecial lengths of hose pack 1,0 – 16,0 mKD-feeding for TTW4000Adapter for old machines

TTW2500A / 3000A / 4000A / 5000A /PW18

Technical Data acc. to EN 60974-7 Welding current at Duty cycle Standard equipment Electrode WeightWatercooled AC DC Ø mm/inch Ø mm/inch kg/lbs.TTW2500A WKZ 180A 250A 40% 2,4 / 0,09 1,0-3,2 / 0,03-0,12 0,39 / 0,85TTW3000P-KD internal 250A 300A 60% 2,4 / 0,09 1,0-3,2 / 0,03-0,12 0,64 / 1,41TTW4000 FumeEx 350A 400A 60% 2,4 / 0,09 1,0-4,0 / 0,03-0,15 1,01 / 2,22TTW4000 KD internal 350A 400A 60% 2,4 / 0,09 1,0-4,0 / 0,03-0,15 0,84 / 1,85TTW5500P 440A 550A 60% 4,8 / 0,18 3,2-6,4 / 0,12-0,25 0,98 / 2,16

TTW2500A WKZ / TTW3000P-KD internal / 4000A FumeEx / 4000A-KDinternal / 5500P

47

3

2

1

1

32

1

4

12

51 2

Automatic welding torchesTTG2200A-M, TTW4000A-M

Standard equipment TIG automatic welding torchScrew-on or plug-on gas nozzle systemUV and ozone-resistant protective hoseAutomatic tube diameter 32 mm

Reducer ring from ø 32 mm to ø 35 mmAnti-kink feature at machine- and torch end



Recommended base metalsFerritic / austenitic CrNi steelsDuplex steels (watercooled torches)Nickel-based materials (watercooled torches)Aluminium materialsMagnesium materialsCopper materials (watercooled torches)

Options TIG automatic welding torchGas lensesCold wire feeding like for TIG robot torches

Technical Data acc. to EN 60974-7 Welding current at Duty cycle Electrode WeightGascooled AC DC Ø inch/mm lbs./kgTTG2200-M 180 A 220 A 35 % 0.040 – 0.157 / 1,0 – 4,0 2.2 / 1,000WatercooledTTW4000-M 350 A 400 A 60 % 0.040 – 0.157 / 1,0 – 4,0 2.2 / 1,000

Robot welding torches TTW4000

Standard equipmentTorch headScrew-on gas nozzle systemGas lensHose packAutomatic tube diameter 32 mmUV- and ozone-resistant protective hose pack

Coldwire feeding Push:3 x 90° mountableWire feeder tube rotatableHolding clampTeflon inner liner 0,8 – 1,2

Coldwire feeding Pull:Wire feed speed 0 – 11 m/minGraphit innerliner ø 2,5 mm for Al- and CrNi-wire3 x 90° mountableWire feeder tube rotatableHolding clampExact speed regulation assured by digital encoderToothed drive and pressure rollersWirefeed FWD/BACK button



Recommended base metalsFerritic / austenitic CrNi steelsDuplex steels Nickel-based materials Aluminium materialsMagnesium materialsCopper materials

Options TIG robot automatic hose packAdjusting device for torch headSpecial lengths 1,0 – 16mHolding clamp for TIG RO without KD-feedingBasic kit for TIG RO KD-DriveWearing parts cold wire feeding PullWire feed speed 0 – 5 m/minor 0 – 22 m/min

Welding current at Duty cycle Electrode WeightTechnical Data acc. to EN 60974-7 AC DC Ø inch/mm lbs./kgHose pack 280 A 400 A 60 % 0.040 – 0.157 / 1,0 – 4,0 3.09 / 1,400Torch head 280 A 400 A 60 % 0.040 – 0.157 / 1,0 – 4,0 0.58 / 0,263Robacta KD Drive 6.61 / 3,000

48

3

2

1

1

1

Robot welding torches TTW4500

Standard equipmentTorch headGas nozzle thread type-systemGas lensesAdjusting device for electrodesHose packUV and ozone-resistant corrugated hoseHolding clamp (4x90° mountable)Line for shutoff boxCold wire feeding PushSwivel-mounted wire guide tube with lockingCombi inner liner 0,8-1,2

Cold wire feeding PullWire guide speed 0-11m/minGraphit inner liner ø2,5mm for Al- and CrNi-wireSwivel-mounted wire guide tube with lockingExact DC-servomotor with digital encoderToothed drive and pressure rollerWire feed FWD/BACK button



Recommended base metalsFerritic / austenitic CrNi steelsDuplex steels Nickel-based materials Aluminium materialsMagnesium materialsCopper materials

Options TIG Robot welding torchCustomer specific hose pack length 1,0-16mExtension for holding clampBasic Kit for TIG RO KD DriveWearing parts cold wire feeding PullWire feed speed 0-5m/min or 0-22m/minIgnition aidGas lens for 3/4"-gas nozzle

Welding current at Duty cycle Electrode WeightTechnical Data acc. to EN 60974-7 AC DC Ø inch/mm lbs./kgRobacta TTW4500 330 A 450 A 60 % 0.06 – 0.189 / 1,6 – 4,8 2.42 / 1,100Robacta KD Drive 6.61 / 3,000

49

Power source WTU 307 WTU 457 WTU 657Mains voltage +/–10 % 50/60 Hz 3 x 230 / 400 V 3 x 230 / 400 / 500 V 3 x 230 / 400 / 500 VCos phi 0,88 (300 A) 0,75 (450 A) 0,85 (650 A)Welding current at 35 % d.c. 300 A 450 A 650 A

60 % d.c. 230 A 340 A 490 A100 % d.c. 180 A 260 A 380 A

Welding current range 5 – 300 A 5 – 450 A 5 – 650 AOpen-circuit voltage 75 V 75 V 75 VOperating voltage 20 – 32 V 20 – 38 V 20 – 44 VProtection class IP 23 IP 23 IP 23Dimension l x w x h inch 26.77 x 17.72 x 21.65 39.17 x 29.13 x 25.79 39.17 x 29.13 x 25.79

mm 680 x 450 x 550 995 x 740 x 655 995 x 740 x 655Weight lbs. / kg 209.44 / 95 487.22 / 221,5 590.84 / 268

Recommended areas of useConstruction of special vehicles and construction machineryConstruction of plant, containers, machinery,structural steelConstruction of rail vehicles & rolling stock


WTU 307 / 457 / 657

Recommended base metalsConstructional steelsFerritic / austenitic CrNi steelsDuplex steels

Standard equipmentAnti-stick function (WTU 457, 657)Generator-compatibleCrane-hoisting lugs (WTU 457, 657)S-mark, CE-mark Overtemperature protectionArc force (WTU 307)

OptionsRemote control unitDigital display, (Calibrationdocument)

50

TransPocket 1100 / 1500 / 1500 RC /1500 TIG

TransPocket 1200 / 1500 / 1500 RC /1500 TIG

Power source TP 1200 TP 1500Mains voltage ± 15 % 50/60 Hz 230 V 230 VCos phi 0,85 0,99Welding current range stepless 10 – 120 A 10 – 150 AWelding current at 230 V 10 min/40° C 35 % d.c. - 140 A

10 min/40° C 100 % d.c. 40 A 80 AOpen-circuit voltage 105 V 92 VOperating voltage 20,4 – 24,8 V 20,4 – 25,6 VProtection class IP 23 IP 23Dimension l x w x h inch 10.43 x 4.33 x 7.87 12.40 x 4.33 x 7.87

mm 265 x 110 x 200 315 x 110 x 200Weight lbs. / kg 8.16 / 3,7 10.36 / 4,7 (RC)

lbs. / kg 10.58 / 4,8 (TIG)

Recommended areas of useConstruction of chemical plantsMaintenance and repairConstruction of plant, containers, machinery,structural steelIndustry plant & pipeline construction, site-erection firms

ProcessesTIG-DCManual electrode (MMA) weldingCel-compatible


Standard equipmentGenerator compatibleS-mark, CE-markAnti-Stick functionAutomatic gas post-flow (dep. on welding current – TIG-version)Touch-down ignition (except TP 1100)Energy-saving inverter technologyV-down-compatible welding of CEL electrodes

(except TP 1400 MV)Remote-controllable (RC version)Thermostat-controlled fanCarrying strapOvertemperature protectionDust filter (except TP 1100/1400MV)

OptionRemote control unit

Recommended areas of useConstruction of chemical plantsMaintenance and repairConstruction of plant, containers, machinery,structural steelIndustry plant & pipeline construction, site-erection firms

ProcessesTIG-DCManual electrode (MMA) weldingCel-compatible


51

Standard equipmentGenerator compatibleS-mark, CE-markAnti-Stick FunctionAutomatic post flow(depending on welding current - TIG-Version)Touch-down ignitionEnergy-saving inverter technologyCapability of vertical down welding

Remote controllable (TIG Version)Thermostat-controlled fanCarrying strapOvertemperature protectionDust filterHot-StartSoft-StartDynamic

TransPocket 2500 / 3500

Power source TP 2500 TP 2500 MV TP 3500 TP 3500 MVMains voltage +/- 10% 50/60 Hz 3 x 380 – 460 V 3 x 200 – 240 V 3 x 380 – 460 V 3 x 200 – 240 V

3 x 380 – 460 V 3 x 380 – 460 VCos phi 1 0,99 0,99 0,99 0,99Welding current range stepless 10 – 250 A 10 – 250 A 10 – 350 A 10 – 350 AWelding current at 10 min/40° C 35 % d.c. 250 A 250 A 350 A 350 A

10 min/40° C 60 % d.c. 200 A 200 A 280 A 280 A10 min/40° C 100 % d.c. 175 A 175 A 230 A 230 A

Open-circuit voltage 88 V 88 V 88 V 88 VOperating voltage 20,4 – 30 V 20,4 – 30 V 20,4 – 34 V 20,4 – 34 VProtection class IP 23 IP 23 IP 23 IP 23Dimension l x w x h inch 16.93 x 7.09 x 12.60 16.93 x 7.09 x 12.60 19.29 x 7.48 x 15.35 19.29 x 7.48 x 15.35

mm 430 x 180 x 320 430 x 180 x 320 490 x 190 x 390 490 x 190 x 390Weight lbs. / kg 27.56 / 12,5 29.76 / 13,5 44 / 20 46.3 / 21

Recommended areas of useConstruction of chemical plantsMaintencance and repairConstruction of plant, containers, machinery,structural steelIndustry plant & pipeline constructionSite erection firms

ProcessesManual electrode (MMA) weldingTIG-DCCel-capable

Recommended base metalsConstructional steelsFerritic / austenitic CrNi steelsDuplex-steelsAluminium materials

OptionsRemote control unitCalibration document (TP3500 Comfort)Wireless remote control

52

Power source TP 4000 Cel TP 4000 Cel MV TP 5000 Cel TP 5000 Cel MVMains voltage +/–10 % 50/60 Hz 3 x 220 – 240 V 3 x 220 – 240 V

+/–10 % 50/60 Hz 3 x 380 – 460 V 3 x 380 – 460 V+/–15 % 50/60 Hz 3 x 400 V 3 x 400 V

Cos phi 0,99 0,99 0,99 0,99Welding current range Electrode 10 – 380 A 10 – 380 A 10 – 480 A 10 – 480 A

TIG 10 – 380 A 10 – 380 A 10 – 480 A 10 – 480 AWelding current at 10 min/40° C 40 % d.c. 380 A 380 A 480 A 480 A

10 min/40° C 60 % d.c. 360 A 360 A 415 A 415 A10 min/40° C 100 % d.c. 320 A 320 A 360 A 340 A

Open-circuit voltage 95 V 95 V 95 V 95 VOperating voltage Electrode 20,4 – 35,2 V 20,4 – 35,2 V 20,4 – 39,2 V 20,4 – 39,2 V

TIG 14,5 – 33 V 14,5 – 33 V 14,5 – 38 V 14,5 – 38 VProtection class IP 23 IP 23 IP 23 IP 23Dimension l x w x h inch 24.61 x 11.42 x 18.70 24.61 x 11.42 x 18.70 24.61 x 11.42 x 18.70 24.61 x 11.42 x 18.70

mm 625 x 290 x 475 652 x 290 x 475 625 x 290 x 475 625 x 290 x 475Weight lbs. / kg 79.59 / 36,1 88.18 / 40 81.57 / 37 89.29 / 40,5

Standard equipmentGenerator compatible (except MV)Microprocessor controlS-mark, CE-markDigital welding process controlEarth leakage monitoring

TransPocket 4000 Cel / 5000 Cel

Recommended areas of useShipbuilding and offshore engineeringMaintenance and repairIndustry plant & pipeline construction,site-erection firms

ProcessesTIG-DCManual electrode (MMA) weldingArc-air gouging

Recommended base metalsConstructional steelsFerritic / austenitic CrNi steelsAluminium materials

V-down-compatible welding of CEL electrodesRemote-controllableThermostat-controlled fanOvertemperature protection

OptionsWireless remote control unitKeylock switchRemote control unitAnti-stick functionCalibrationdocument

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12

3

4

5

2

3

4

5

1

6

7

9

8

10

RobotControl

ROB 5000

ROB 4000

1

2

3

4

5

6

7

8

10

11

12

131415

9

TRANSPOCKET 1500

KD 7000D-11

SoftPlasma andMicroPlasma withTT power sourcemanual

Technical data PlasmaModule 10Mains voltage +15 % 50/60 Hz 230 VMains fuse slow 16 AOpen-circuit voltage 88 VOperating voltage 10 – 16 VProtection class IP 23Pilot current range 3 – 30 APlasmagas control gal/min / l/min 0.078 – 2.64 / 0,3 – 10,0Dimension l x w x h inch 19.9 x 7.1 x 13.6

mm 505 x 180 x 344Weight lbs. / kg 31.2 / 14,2

Standard equipment PlasmaModule 10Gas check buttonStepless adjustable pilot current (acc. to type of torch)Digital indication of amps of pilot currentDigital indication of plasma gas quantityTouchless ignition of pilot arcPreselection of addressing (internal/external)Mountable on carriage

Options and accessoriesDigital welding power source MIG/MAGTIG power sourceRobot interfacePlasma torchHot wireColdwire feeder unitPush Pull system (not for manual welding)Water recooler

Recommended areas of useConstruction of plant, containers, machinery,structural steelAutomobile and allied vendor industriesConstruction of special vehicles and construction machinery Construction of rail vehicles & rolling stock

ProcessesSoftPlasma, PlasmaKeyhole, Plasma brazing(DC mode)

Softplasma with TTpower source andKD manual

Recommended base metalsStainless steelConctructional steelNickel-based materialsAluminium materials TitaniumCopper materials

Softplasma with TTpower source andKD mechanised

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1

2

3

4

5

6

7

8

10

11

12

13

149

RobotControl

ROB 5000

RCU 2000

Plasma keyholewelding with TTpower source andKD mechanised

Plasma welding torch PTW 1500 / PTW 3500 / PMW 350

Standard equipment Robacta PTW 1500UV and ozone-resistant protective hoseFix defined TCP with alu-square-fastening bolt4 x 90° mountableHolding bracketAdjust gauge for tungsten electrode to plasmanozzle ø2,5mm Standard equipment cold wire feeding Push(Robacta Plasma KD)Locking rocker for defined cold wire feeding-positionWire feeding tube swivel mountedCopper wire tube for hot wire applicationsø1,2mmCombi inner liner 1,2

Standard equipment cold wire feeding Pull(Robacta Plasma KD Drive)Wire feed speed 0-11 m/minExact speed regulation assured by digitalencoderWirefeed FWD/BACK buttonLocking rocker for defined cold wire feeding-positionWire feeder tube rotatable Graphit inner linerStandard equipment hot wireDrive rollers made of plasticLeather hose 3,0m with hook and look fastenerStandard equipment Plasma manual torchSwivel-mounted protective hose UV- and ozone-resistant protective hoseFlexible leather protection hose 0,7mAnti-kink feature at machine and torch endEasy-to-use rocker switch

Recommended areas of useAerospace industryConstruction of plant, containers, machinery,structural steelAutomobile and allied vendor industriesConstruction of special vehicles and construc-tion machineryConstruction of chemical plantsMaintenance and repairPipeline construction

ProcessesPlasma DC negative pole

Recommended base metalsFerritic / austenitic CrNi steelsDuplex steelsNickel-based materialsAluminium materialsTitan tantalum zirconium

Options Adjusting device for Plasma nozzle ø1,5mmBasic kit for Robacta Plasma KD-DriveSpecial lengths up to 8,0 mSpare parts setAdaptor TT/MW (G/F) - F gas ext.Adaptor hose packExtension holding clamp / 120mm/140mm/160mmHolding clamp mountingOptions Plasma manual torchFabric-reinforced protection hoseKD-feeding externalSpecial lengths of hose pack up to 8,0 m

Technical Data acc. to EN 60974-7 Welding current Duty Plasma nozzles WeightWatercooled range of performance cycle Ø inch/mm lbs./kgPTW 1500 3 – 150 A 100 % 0.06 – 0.12 / 1,5 – 3,0 2.43 / 1,100

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RobotControlRobot

Control

ROB 5000

I/O2

3

4

5

1

6

7

LaserHybrid headWeight (without optical system) lbs. / kg 41.89 / 19Dimension l x w x h inch / mm 30.30 x 6.26 x 16.37 / 769,5 x 159 x 415,7Current-carrying capacity max. (100 % d.c.) 250 A

Standard equipment4-roller driveWire-inching without gas or currentGas-test buttonS-mark, CE-mark Protective glass changerCollision unit (+/–0,05 mm)Adjustment unit for Arc / Laser 360 mm(x, y, z nonius)Crossjet with integrated exhaust ductMirror inverted mountingPrecision torch (+/–0,05 mm)

Recommended areas of useConstruction of plant, containers, machinery,structural steelAutomobile and allied vendor industriesAerospace industryConstruction of rail vehicles & rolling stock

OptionsHolder for opticProfi wire feeder rolls (grounded)Holding device for different torchesPrecision contact tipsPlug-in, watercooled gas nozzle, lockablePrecision wire guide innerlinerGuide nozzleCalibrationdocumentSoftware Laser brazing CC/CVRoboter Interface FeldbusGas sensorSynchroPuls

ProcessesMIG/MAG pulsed arc weldingLaserHybrid weldingLaser weldingLaserHotwire brazingLaser brazing

LaserHybrid

Recommended base metalsConstructional steelsFerritic / austenitic CrNi steelsDuplex steelsAluminium materialsMagnesium materialsSpecial materialsZinc-plated sheet metal

56

RobotControl

KD 7000

RobotControl

RCU 5000i

Laser Coldwire

Laser Hotwire

Standard equipment4-roller driveWire-inching without gas or currentGas test buttonS-mark, CE-mark

Recommended areas of useConstruction of plant, containers, machinery,structural steelAutomobile and allied vendor industriesAerospace industryConstruction of rail vehicles & rolling stock

ProcessLaser weldingLaser hotwire-brazing (hotwire)Laser-brazing (coldwire)

Laser Coldwire & Hotwire

Recommended base metalsFerritic / austenitic CrNi steelsDuplex-steelsSpecial materialsZinc-plated plate metal

57

Cooling system

RobotControl

Welding-GunControl

PowerSource

Technical information Welding gunRated power at 50% ED (Medium frequency) 77 kVA Gun force (X500) 5 KNGun weight (X500) lbs. / kg 220.46 / ca. 100

The power source is not included in the standard equipmentGun body X500Servoelectrical main driveServoelectrical Gun balance

Recommended areas of useAutomobile and allied vendor industriesWhite good industryConstruction of plant, containers, machinery and structural steel

OptionsRobot communicationControl visualisation

Drive unit process bandStore unit process bandMedium frequency transformerGun-control (can be used as control of thepower source)

ProcessResistance spot welding

DeltaSpot

Recommended base metalsAluminium materialsGalvanised sheetsOrganic coated platesHigh strength steels Advanced high strength steelsMild steels

Standard equipment for the recommended configuration

Technical information Gun controlMains voltage 230 VNominal current 16 A

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OptionTracking Set

Recommended areas of useSite-erection firmsClimatisation and ventilation constructionCarriage constructionMaintenance and repairIndustry plant & Pipeline constructionBoiler and container constructionMetal- and portal construction, locksmitheryand smith's shop

ProcessPlasma cutting with liquid operating agent

Recommended base metalsMild steelsCrNi steelsAluminium materials

Standard equipmentGenerator compatibleEnergy-saving inverter technologyContact ignitionRegenerative torch-cooling-systemClosed liquid systemLiquid level sensor for operating agent

TransCut 300

Thermostat controlled fanOvertemperature protectionCarrying strapS-mark, CE-mark

Power source TransCut 300Mains voltage + 10 % / - 15 % 50/60 Hz 230 VMains fuse 16 ACos phi 0,99Cutting current range 16 – 30 ACutting current at 10 min / 40 °C 35 % d.c. 30 A

10 min / 40 °C 60 % d.c. 22 A10 min / 40 °C 100 % d.c. 18 A

Recommended material thickness inch / mm 0.24 / 6Rough-cut capacity inch / mm 0.39 / 10Operating time per tank 3 hTank capacity gal / l 0.40 / 1,5Protection class IP 23Dimension l x b x h inch 18.11 x 7.09 x 10.83

mm 460 x 180 x 275Weight (with Plasmas-cutting-torch) lbs. / kg 32.19 / 14,6

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FCU-20 / FCU-20.OFCU-10

FRC-2FRC-1 FRC-3 FRC-5 FRC-9 FRC-30

FCU-50 / FCU-50.O FRC-60FCU-11 FCU-12

FRC-40

Control units FCU and remote controls FRC

Technical data FTT 10/MA FTT 40/MA FTT 150/MAMax. loading capacity horizontal kg 10 40 150Diameter faceplate / thickness mm 240 / 10 350 / 16 450 / 16 Working height horizontal mm 352 540 643Speed rpm 1,0 – 11,0 1,5 – 11,0 0,8 – 6,0Tilting range via tooth segment (+/–90°) Clamp lever Crank CrankBacklash 1,2° 1,2° 1,2°Max. welding current transfer 400 A 400 A 400 AMains voltage / frequency 230 V / 50 – 60 Hz 230 V / 50 – 60 Hz 230 V / 50 – 60 HzHollow shaft diameter mm none none 28Net weight kg 15 85 120Max. load capacity/torque [rotating: M =G.g.e = const.] 10 Nm 20 Nm 73 Nm

[tilting: M =G.g.a = const.]

Lifting facility for hook-inLimit switch function 360 ° (rotation unit)Faceplate machined for clamp chucksProtection-housing (tilting- / rotation unit)Base

Standard equipmentStepless tilting range +/–90°Constant rotation speedAC-motorWelding current transfer 400 A/ 50mm2

Prepared for segment welding (FTT 40 / 150)Hollow shaft (FTT 150)

Recommended areas of useUniversal use for all welding process and positioning of workpiece

OptionsControl unit FCU-10Control unit FCU-20Control unit FCU-50Foot switch FRC-1 (start-stop) with cable 3 mFoot switch FRC-2 (start-stop-speed) with cable 3 mFoot switch FRC-3 (start-stop-selection direction) with cable 3 mFoot switch FRC-5 (start-stop-selection direction-roll speed) with cable 3 mChucks FGC, FSG, FMCMounting sets for chucksI-kit welding current transfer 800 AActuating cam for segment weldingSpecial gear box

Tilting turntablesFTT 10 / 40 / 150From 10 up to 150 kg

60

FTT 3000/MO

Tilt by AC geared motor (MO) fitted w. fail-safeelectro-magnetic brakeCam operated limit switch’s to prevent overrunand fixed tilting speedFaceplate with concentric circular markings andmachine with slots for rapid centering and clampingControl unit with main switchRemote control with cable

Functions• Switch rotation left-stop-right• Button tilting up-down (MO)• Potentiometer for rotation speed• Emergency-stop

Standard equipmentFabricated frame of mild steel plate and channel section materialStepless tilting range 0-135° (manual/MA ormotorized/MO) Stepless adjusting of rotation speedTable rotation by AC motor controlled by inverter unit, through worm reduction gearsand spur gearsTable supported on large diameter crossrollbearingMachine cut precision gearing for smooth rotation of tableTable tilting by crank through worm reductionand steel spur gear (MA)

Recommended areas of useUniversal use for all welding-processes andpositioning of workpieces

OptionsI-kit limit switch 360° and actuating cam forrotation unitI-kit encoderControl unit FCU-20.OControl unit FCU-50.OFoot switch FRC-1 (start-stop) with cable 3 mFoot switch FRC-2 (start-stop-speed) withcable 3 mFoot switch FRC-3 (start-stop-selection direction) with cable 3 mFoot switch FRC-5 (start-stop-selection direction-roll speed) w. cable 3 mChucks FGC, FSG, FMCMounting sets for chucks

Tilting turntables FTT 380 / 750 / 1500(Type MA)Tables (manual tilting) from 380 up to 1500 kg with remote control unit

Tilting turntables FTT 380 up to FTT 70000 (Type MO)Tables (motorized tilting) from 380 up to 70000 kg with remote control unit

61

FRT 50/HS125/V

Limit switch function 360°Faceplate machined for clamp chucksProtection-housing (rotation device)

Standard equipmentConstant speed controlAC-motorWelding current transfer 400 A/ 50mm2

Prepared for segment weldingHollow shaft 125 mm

Recommended areas of useUniversal use for all welding-process and positioning of workpieces

Rotation tables FRT 50/HS125/H/V,FRT 150/HS125/H/VTurntable horizontal/vertical with hollow shaft

Technical data FRT 50/HS125/H/V FRT 150/HS125/H/VMax. load capacity kg 50 150Diameter faceplate/ thickness mm 450/16 450/16 Slots 3 x 120° 3 x 120°Faceplate (slots and holes) DIN 6350 DIN 6350Drive AC Motor AC MotorSpeed range rpm 0,9-7,0 0,3-6,0Dimensions • A mm 340 542

• B mm 540 710• C mm 590 490• D mm 571 481• E mm 315 432• F mm 450 450

Backlash on faceplate max. 1,2 ° 0,25 °Max. current transfer 400 A 400 AMains voltage/ frequency 230 V / 50-60 Hz 230 V / 50-60 HzHollow shaft inside-diameter mm 125 125Net weight kg 90 145

Options and accessoriesControl unit FCU-10Control unit FCU-20Control unit FCU-50Foot switch FRC-1 (start-stop) with cable 3 mFoot switch FRC-2 (start-stop-speed) withcable 3 mFoot switch FRC-3 (start-stop-selection direction) with cable 3 mFoot switch FRC-5 (start-stop-direction-rollspeed) Chucks FGC, FSG, FMCMounting sets for chucksI-kit current transfer 800 AActuating cam for segment weldingSpecial gear boxEncoderBase

62

FRT 2000/H

Technical data FRT 1000/H FRT 2000/H FRT 5000/H FRT 10000/HMax. load capacity horizontal kg 1000 2000 5000 10000Drive AC motor AC motor AC motor AC motorRotation speed rpm 0,08 – 2,0 0,06 – 1,5 0,06 – 1,5 0,04 – 1,00Max. rotation torque Nm 1500 3000 7500 15000T-slots for bolts M16 M16 M16 M16• rated eccentricity mm 150 150 150 150• diameter faceplate mm 1000 1100 1200 1300• working height mm 300 310 320 330Remote control unit with cable m 3 3 3 3Mains cable with plug included included included includedMains voltage/ frequency 230 V / 1 / 50 Hz 230 V / 1 / 50 Hz 230 V / 1 / 50 Hz 230 V / 1 / 50 HzMax. welding current transfer 400 A 400 A 600 A 600 ANet weight turntable kg 300 350 400 480

Faceplate with concentric circular markingsand machine with slotsControl unit with main switch and emergency-stop

Remote control unit with cable

Functions• Switch rotation left-stop-right• Potentiometer for rotation speed

Standard equipmentStepless adjusting of rotation speedTable rotation by AC motor controlled by inverter unit, through worm reduction gearsand spur gearsTable supported on large diameter crossrollbearing

OptionsI-kit limit switch 360° and actuating cam forrotation unitI-kit encoderControl unit FCU-20.OControl unit FCU-50.OFoot switch FRC-1 (start-stop) with cable 3 mFoot switch FRC-2 (start-stop-speed) withcable 3 mFoot switch FRC-3 (start-stop-selection direction) with cable 3 m

Rotation tables FRT 1000/H - 2000/H -5000/H – 10000/HHorizontal turntables for 1000 up to 10000 kg with remote control unit

Recommended areas of useUniversal use for all welding-processes andpositioning of workpieces

Foot switch FRC-5 (start-stop-selection direction-roll speed) with cable 3 mChucks FGC, FSG, FMCMounting sets for chucks

63

FRU 5000/CR/DriveFRU 5000/CR/Idler

Quick adjust via mounting-boltLift-facilities to hook-inMachine feet adjustable

Standard equipmentWheel driven motorized sectionIdler sectionPolyurethane rollsAC-motor with frequency transformerHF-compliant

OptionsControl unit FCU-10Foot switch FRC-1 (start-stop) with cable 3 mFoot switch FRC-2 (start-stop-speed) with cable 3 mFoot switch FRC-3 (start-stop-selection direction) with cable 3 mFoot switch FRC-5 (start-stop-selection direction-roll speed) with cable 3 mEarth connection endless rotating

Rotator unit FRU 1000 (Type CR)For 2000 kgs

Recommended areas of useFor turning and positioning of workpieces (vessels, tanks, pipes, …)

Technical data FRU 1000/D50-3000/CR/Drive FRU 1000/D50-3000/CR/IdlerMax. loading capacity per section kg 1000 1000Quantity of driven wheels 1Min. - max. outside-diameter mm 50 – 3000 50 – 3000Rotation speed cm/min 16 – 260Quantity of wheels per section 2 2Wheel-diameter/ -width mm 200 / 50 200 / 50Net weight per section kg 77 55

OptionsI-kit tachogenerator for speed indicatorI-kit encoderI-kit anti-creep function to prevent axial movement of workpieceEarth connection endless rotatingDrive sections synchronized controlledDriving vehicle (DV-MO motorized/DV-MAmanual)Rail A 55Interface 0-10 Volt

Remote control unit with cable 8 m

Functions• Button for rotation forward-stop-reverse• Potentiometer for stepless adjusting of

rotation speed• Emergency-stop

AC motors and reduction gearing with dynamicbraking, giving variable speed drive (standardspeed range 75 mm - 1500 mm per minute).Inverter control panel attached to main framehouses mains isolator, overload fuses andemergency-stop pushbutton.Machine painted in Red (RAL 3020)Motors to have Class F insulation.Control cabinet to IP54 dustproof regulations.Equipment suitable for operation at maximumambient temperature 50°C, maximum humidity85%, and maximum height above sea level1.000m

Standard equipmentFour interchangeable reduction gearbox connecting shafts to permit adjustment of rollers across frames to suit varying diameters.Manual adjustment of rollers across frames (noleadscrew)Robust fabricated all steel frames. Base frameon top and roll mounting below ex FRU12500/CR machined to give accurate alignmentof rollers. Each section equipped with two rollers having steel centers with interchangeable solid polyurethane tyres, mountedon machined steel axles carried in sealedheavy duty bearings. Drive Section equippedwith 20:1 ratio inverter controlled

Recommended areas of useFor rotation and positioning of workpieces/vessels in the range of machine-, container-and pipe-construction

Rotator units FRU (Type CR)From 3000 kg up to 100000 kg with remote control unit

64

FRU 30000/VP/DriveFRU 30000/VP/Idler

OptionsI-kit tachogenerator for speed indicatorI-kit encoderI-kit anti-creep function to prevent axial movement of workpieceEarth connection endless rotatingDrive sections synchronized controlledDriving vehicle (DV-MO motorized/DV-MAmanual)Rail A 55Interface 0-10 Volt

Recommended areas of useFor turning and positioning of workpieces inthe range of machine-, container- and pipe-construction

Rotator units FRU (Type VP – self-aligning)From 3000 up to 50000 kg with remote control unit

easy-pivot roller brackets operate in reverse,moving to their resting position, ready to takenext piece. Idler Section can incorporatemanual or electric anti-creep feature to restrictvessel “creep” to +/- 1 mm (option).

Mains cable with plugRemote control unit with cable 8 m

Functions• Switch for rotation forward-stop-reverse• Potentiometer for stepless adjusting of

rotation speed• Switch for drive forward-stop-reverse with fix

speed (option)• Emergency-stop

rotation through hydrostatic variator or invertercontrol.FRU VP types are all bogie-mounted to carryvessels of various lengths, and to allow for traversing motorized (option) or manually (option), in addition to rotation at the work site.The “low loading” bogie design integral to therotator construction ensures that unlike standard bogies, their closeness to the groundeliminates the risk of excess vessel loadheights. Robust, all-steel construction invertercontrolled traversing (option) and rotation atwelding speeds. All rollers of the Drive Sectionpositively driven. Clutches incorporated in toprollers of the Drive Section to prevent damageto transmission during loading. On unloading

Standard equipmentSelf-Aligning Rotator Units (type VP) follow thewell established reputation of their static counter-parts for ease of use and reliability.Like their counter-parts they provide an economical and practical platform for all cylindrical vessel rotating problems. Their patented and unique designs allow therollers to automatically align themselves to anyworkpiece, without any form of manual adjust-ment and irrespective of irregularity in theshape of the circular workpiece. This exceptio-nal facility not only saves time, but in ensuringthat the item being worked on remains centralto the rotator frames.Clutches incorporated in top rollers of DriveSection to prevent damage to variable speed

Technical data FSB 720-420 FSB 720-720Max. load capacity kg 40 40Net weight kg 20 40Way vertical mm 720 720 Way horizontal mm 420 720 Diameter column mm 120 120 Diameter boom mm 118 118

Self-locking trapezoid-threaded spindle (verti-cal axis)Fixing of the horizontal axis via clamping lever

Standard equipmentModular system / constructionEasy assembly, high stabilityLinear guides

OptionsFSU 3 swivel unitPlug 30/L45FTH 4 torch holder for machine torch inside-ø30 / 44,2 mmFSU 7/SR360° ball joint and FTH torch holderSupport FGU 4Mounting setFPT pneumatic torch movementSlewing ring

Stand brackets FSB 720-420, FSB 720-720Small column and boom – manual adjustment

Recommended areas of useManual torch adjusting / positioning via handwheel (vertical axis) and handle (horizontalaxis)

65

FCB 2400-3000/ML170/DV-MO

OptionsRemote control FRC-30 (for positioning)I-kit welding step axis FCU-30 (in combinationwith FCU-20/ FCU-50)Remote control FRC-60 (for positioning andmechanized welding)Slewing ring 600 manualFRF 1600 three point base

Standard equipmentHF-compliantConstant speedAC-motorVertical axis – trapezoidal spindle driveHorizontal axis – rack and pinion driveLinear guidesLimit switch function

Uptake wire feeder unitBall joint FSU 7 with FTH torch holderMounting setSupports FGU

Tripod units FTU 1000-500FTU 1500-1000 FTU 2000-1500Column & boom – motorized motion

Recommended areas of useTripod unit for motorized positioning of thetorch and for mechanized welding (MIG-MAG)via one of the travel-axis

Technical data FTU 1000-500 FTU 1500-1000 FTU 2000-1500Max. dynamical loading capacity kg 100 60 40 Speed horizontal m/min 0,15 – 1,18 0,15 – 1,18 0,15 – 1,18 Speed vertical m/min 0,15 – 1,18 0,15 – 1,18 0,15 – 1,18 Way vertical mm 500 1500 2000 Way horizontal mm 1000 1000 1500 Mains voltage / frequency 230 V / 50 – 60 Hz 230 V / 50 – 60 Hz 230 V / 50 – 60 HzNet weight kg 150 170 190

Standard equipmentColumn rotating on crossroll bearing to enablethe boom to be moved manual through 360°manual rotationColumn dimensions 250 x 320 mmMounted on all rigid fabricated base completewith machined guideways for elevation ofboom carriageRobust fabricated steel boom carriage counter-balanced and fitted with an anti-fall safety device

Carriage raised and lowered by electric motorfitted with electro-magnetic brake through rackand pinionBoom machined accurately throughout it’slength and mounted in adjustable guide rollersrunning in totally enclosed bearings, givingvibrationless movement of mounted devicesand mounted on a fixed baseBoom dimensions 80 x 230 mm

Horizontal traverse of boom through an inverter controlled variable speed AC-motorHosepack carrier and cable managementLift facilities to hook-inElectric cabinet mounted at base of column(forward/ stop/ reverse/ 2x speed pot. one foreach direction/ raise/ lower/ emergency stop)Remote control unit (forward/ stop/ reverse/raise/ lower/ emergency stop) with cable 8 mMains cable 10 m without plug

OptionsPlateform for control unit, power sourcesMounting platesBrackets suitable for weld torchEncoder-system for weld axisDriving vehicle motorized (DV-MO) or manual(DV-MA)Rail-system

Column and boom FCBMedium-Duty column and boom mountable on stationary base or vehicle

Recommended areas of useColumn and boom for motorized positioning ofa compound slide system FCS or weld headfor internal and external welding

66

FCB 3000-4000/ML420

OptionsPlateform for control unit, power sourcesMounting platesBrackets suitable for weld torchEncoder-system for weld axisDriving vehicle motorized (DV-MO) or manual(DV-MA)Rail-system

Standard equipmentColumn rotating on crossroll bearing to enablethe boom to be moved manual through 360°Column dimensions 412 x 540 mmMounted on all rigid fabricated base completewith machined guideways for elevation ofboom carriageRobust fabricated steel boom carriage counter-balanced and fitted with safety device againstcounterbalance wire rope breakage

Carriage raised and lowered by electric motorfitted with electro-magnetic brake through rackand pinionBoom machined accurately throughout it’slength and mounted in adjustable guide rollersrunning in totally enclosed bearings, givingvibrationless movement of mounted devicesand mounted on a fixed baseBoom dimensions 220 x 390 mm

Hosepack carrier and cable managementLift facilities to hook-in4 pc. concrete anchor with M24 nut4 pc. leveling device (metal plates and screws)Electric cabinet mounted at base of column(forward/ stop/ reverse/ 2x speed pot. one foreach direction/ raise/ lower/ emergency stop)Remote control unit (forward/ stop/ reverse/raise/ lower/ emergency stop) with cable 8 mMains cable 10 m without plug

Column and boom FCB Heavy-DutyHeavy-Duty unit - column and boom mountable on stationary base or under motorized carriage

Recommended areas of useColumn and boom for motorized positioning ofa compound slide system FCS or weld headfor internal and external welding

Technical data FCB 3000-4000 FCB 4000-5000 FCB 4000-4000 FCB 5000-4000Max. loading capacity end of boom kg 420 420 420 420 Speed horizontal cm/min 10-200 10-200 10-200 10-200 Speed vertical cm/min 200 200 200 200 Travel vertical mm 3000 4000 4000 5000 Travel horizontal mm 4000 5000 4000 4000 Mains voltage/ frequency 3 x 415 V / 60 Hz 3 x 415 V / 60 Hz 3 x 415 V / 60 Hz 3 x 415 V / 60 HzNet weight kg 5600 6050 5812 6000

OptionsFRR reducer rings for torch holder

Driving vehicle FDV 10Carriage with remote control unit

Recommended areas of useFor mechanized welding of longitudinal welds(MIG-MAG)

67

Standard equipmentCompact design4-wheel drive via stepper motorSteel wheels with rubber (O-rings)Welding seam tracking with adjustable guide rollsMicroprozessor controlledLimit switch function in both directionsManual cross joint 75 x 50 mm

Torch holder (swivelling and rotatable inside-dia. 38 mm)Remote control unit FCU-RC (LCD-display / 2-lines) w. cable 800mm Language selection with LED-display

Functions FCU-RC• Value up-down• Weld length• Rapid speed length• Ending current time• Welding on-off (2- / 4-step mode)• Segment on-off• Direction left-right• Stop drive / welding / segment

Driving vehicle FDV 10Carriage with remote control unit

Technical data FDV 10Max. loading capacity kg 10Welding position horizontalWelding process MIG-MAGWelding signal 2- / 4-step modeDrive stepper motorSpeed mm/min 100 – 1500Power supply external boxMains voltage / frequency 230 V / 50 – 60 HzPower consumption 50 VAControl voltage 24 V DCMains cable with plug m 10Control line – motor m 5Control line – power source (Tuchel) m 3Track width mm 185Dimension l x w x h mm 380 x 240 x 800Net weight vehicle kg 14

Standard equipmentCompact design4-wheel drive via stepper motorWheels with vulcanised rubberPerfect track reliabilityWelding seam tracking with adjustable guiderolls

Integrated way measurement systemPower supply and PLC integrated in vehicleLimit switch function in both directions

OptionsRemote control unit FRC-40 with cable 3 mUptake for remote control unitFGU 4 spindle cross jointPlug 30/L45Mounting setFSU 7/SR360° ball joint aluminium with FTH torch holderFRR reducer rings for torch holder

Driving vehicle FDV 25Carriage


Technical dataMax. loading capacity FDV 25 kg 25Welding position horizontalWelding process MIG-MAGWelding signal 2- / 4-step modeDrive stepper motorSpeed mm/min 10 – 3000Power supply integrated in vehicleMains voltage / frequency 230 V / 50 – 60 Hz

FDV 25Power consumption 180 VAControl voltage 24 V DCMains cable with plug m 12Control line – power source (Tuchel) m 10Track width mm 240Dimension FDV 25 l x w x h mm 515 x 275 x 220

Net weight vehicle FDV 25 kg 19,5

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FDV 50 FDV 80

Standard equipmentRobust, compact and modular designPerfect track reliabilityPower supply and PLC integrated in vehicleRobust frame and adequate uptake for wirefeederMotor coupling (FDV 50)Viscose damper for constant drive (FDV 80)

Integrated way measurement-system (FDV 80)4 pcs. lift facilities to hook-in (FDV 80)

OptionsRemote control unit FRC-9 with cable 3 m(FDV 50)Remote control unit FRC-40 with cable 3 m(FDV 80)Uptake for remote control unitMechanical seam tracking system (FDV 40)Torch holder and adjustment devicesFRR reducer rings for torch holderCustomized wheelsRail systemI-kit limit switch functionAdjustable guide rollsTwin holder for two wire feeders

Driving vehicles FDV 50 / FDV 80Carriage


Technical data FDV 50 FDV 80Max. loading capacity kg 50 80Welding position horizontal horizontalWelding process MIG-MAG MIG-MAGWelding signal 2-step mode 2-step / 4-step modeDrive AC motor (2-wheel drive) stepper motor (4-wheel drive)Wheels steel wheels with groove with Polyurethane-surface (one side with groove)Speed mm/min 10 – 2400 10 – 3000Power supply integrated in vehicle integrated in vehicleMains voltage / frequency 230 V / 50 – 60 Hz 230 V / 50 – 60 HzPower consumption 180 VA 300 VAControl voltage 24 V DC 24 V DCMains cable with plug m 5 12Control line – motor m 3,5 integratedControl line – power source (Tuchel) m 6,5 10Track width mm 370 380Dimension l x w x h mm 790 x 433 x 345 803 x 450 x 390Net weight vehicle kg 41 70

69

FTV 25 FTV 20/50

Technical data FTV 20 FTV 25 FTV 50Max. loading capacity kg 20 25 50 Welding position PA PA PA, PC, PG, PFWelding process MIG-MAG / TIG / PLASMA MIG-MAG MIG-MAG / TIG / PLASMAWelding signal 2- / 4-step mode 2-step mode 2- / 4-step modeDrive stepper motor AC motor stepper motor (electromag. brake)Speed mm/min 10 – 3000 10 – 1800 10 – 1800Power supply integrated in vehicle external box integrated in vehicleMains voltage / frequency 230 V / 50 – 60 Hz 230 V / 50 – 60 Hz 230 V / 50 – 60 HzPower consumption 180 VA 180 VA 300 VAControl voltage 24 V DC 24 V DC 24 V DCMains cable with plug m 12 5 12 Control line – motor m integrated 3,5 integratedControl line – limit switch m integrated 3,5 integratedControl line – power source (Tuchel) m 10 6,5 10 Dimension l x w x h mm 440 x 230 x 260 520 x 320 x 210 440 x 230 x 375 Net weight vehicle kg 18 15,4 25

OptionsRemote control unit FRC-9 with cable 3 m (FTV 25)Remote control unit FRC-40 with cable 3 m (FTV 20/ FTV 50)Uptake for remote control unitFGU 4 spindle cross joint way manual 140 x 75 mmPlug 30/L45FSU 7/SR360° ball joint aluminium and FTH torch holder

Standard equipmentCompact design4x maintenance-free linear guide rollsRack and pinion driveLimit switch function

Recommended areas of useFor mechanized welding of longitudinal welds(MIG-MAG) in PA-position (FTV 20/ FTV 25)and in PA-, PC-, PG-, PF-position (FTV 50)

FRR reducer rings for torch holderUptake wire feederRail-system with toothed rackCable management systemTrack connector (rail to rail)Actuating camMounting system for railsVacuum-equipment complete

Tracking vehiclesFTV 20 / FTV 25 /FTV 50 Carriage

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Technical data FCU-11Mains voltage 230 V/ 50-60 HzProtection class IP 23Power consumption 350 VADimensions l x w x h mm 220 x 120 x 160Net weight kg 4

Technical data FOU 40/ML5/RMax. loading capacity kg 5Oscillation width mm 5-50Torch positioning manual via handwheel – supportMotor 24 V DCAbmessung l x w x h mm 320 x 240 x 230Net weight kg 8

Standard equipment FOU 40/ML5/RMechanical oscillation unit with swivelling bracket dia. 30 mmOscillation movement radialDC-motor0-150 strokes/min (step less regulation)Rotating and swivelling uptake for supportTorch amplitude adjustable (way +/- 20 mm)Torch holder FTH 10 for inside-dia 44,2 mm

Standard equipment FCU-11EMV compatibleHF-compliantCompact designMains cable 5m with plugControl line 3,5 m to FCU-11 Designed for external start-stop

Functions• Main switch on-off• Potentiometer for oscillation speed

Recommended area of useControl unit for oscillation unit FOU 40 in combination with MIG-MAG welding

OptionsFRR reducer rings for torch holder

Oscillation-systemControl unit FCU-11 with oscillation FOU 40

71

FOU 50

Technical data FCU-12 FRC-12Mains voltage/ frequency 230 V/ 50-60 Hz 230 V/ 50-60 HzMains fuse 1,6 A 1,6 APower consumption 350 VA 350 VADimensions l x w x h mm 235 x 160 x 350 240 x 145 x 185Weight kg 7 2

Technical data FOU 50/ ML 5 FOU 100/ ML 5 FOU 50/ ML 10 FOU 100/ ML 10Max. load capacity kg 5 5 10 10 Welding process MIG-MAG/ TIG/ Plasma MIG-MAG/ TIG/ Plasma MIG-MAG/ TIG/ Plasma MIG-MAG/ TIG/ PlasmaControl voltage 36 V DC 36 V DC 36 V DC 36 V DCPower consumption 80 VA 80 VA 80 VA 80 VAMax. frequency (strokes/ min) 100 bei 15 mm way 100 bei 15 mm way 100 bei 15 mm way 100 bei 15 mm way

125 bei 7,5 mm way 125 bei 7,5 mm wayAmplitude mm +/ - 25 +/ - 50 +/ - 25 +/ - 50 Dimensions l x w x h mm 160 x 145 x 140 230 x 150 x 80 160 x 145 x 140 230 x 150 x 80 Net weight kg 3,5 4 4 4,5

Standard equipment FOU 50/ FOU 100Compact protected designStepper motor driveExact positioningRecirculating ball screw and precision linearguides

Parameters:• Oscillation speed/ oscillation path• Dwell time (left/right)• Start delay• Offset• Start up delay• Zero-position• Language selection

Standard equipment FCU-12/ FRC-12Touchscreen-display for easy navigation/parameter inputGraphical user interfaceMultifunction-wheel for selecting and adjustingparameters also while automatic programsequence is runningInternal memory for 99 programsDesigned for external start-stopEMC-compatibleHF-compliantCompact design

Functions:• Main switch on-off• Button start-stop• Button for fine positioning• Selector switch oscillation unit on-off• Multifunction-potentiometer for setting

parameters

Recommended areas of useLinear drive- and oscillation axis for all weldingprocesses

OptionsUptake FOU/1 (vertical or horizontal mountabledia. 30 mm) Mounting platesTorch holders and swivel units according totorch typeFRR reducer rings for torch holderControl unit FCU-12 or remote control versionFRC-12/cable 3 mSystem-Controller FPA 2003/FPA 9000Connection lines

Oscillation-systemControl unit FCU-12/ FRC-12 with oscillationunits FOU 50/FOU 100

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Recommended areas of useFronius Process Automation - FPA System-Controller are universal and functional withorbital weld heads useable for tube-tube/ tube-flange/ tube-tube sheet welding

• Microelectronics• Pharmacy/ Biochemical Industry• Food Industry• Climate Technology• Aeronautics/ Aerospace• Heat Exchangers

ProcessesTIG welding AC/DC with or without filler wire

AccessoriesEarth cable, gas hoseCarriage with console and tool box PickUpGas pressure regulatorClosed and open weld heads with or without filler wireAdaptor cable for MW weld headsHosepack extensionManual TIG torchUSB-stickPrinter paper

Standard equipment FPA 2020 Orbital ControllerRemote control unit FPA 2020-RC with cable10 mIntegrated inverter 200 A, single phaseGenerator compatibleIntegrated water coolingMains cable 2,5 m with plugSmall, compact and transportableMountable on carriageIntegrated gas and water flow controlSimple programming via intuitive menueTouch-screen operation with graphical process-visualisation (colour)Language selection (De/Gb/Fr/It)

Display during weld cycle:- Welding currrent (A)- Arc Voltage (V)- Torch position (degree)- Welding speed (cm/min)- Wire feed speed (cm/min)

Programming welding parameter- Internal memory (200 programs)- 3 special tack programs with up to 20 tack

points- 10 sectors/ program free definable

Orbital system-controller FPA 2020 AC/DCOrbital welding power source with integrated microprocessor-controller

Additional memory of programs on USB-stickCreation of backup on USB-stickWelding-data documentation on USB-stickAddressing torch rotation axis and wire axisSynergicMode (Material, pipe outside diameter,wall thickness, gas, ..)Auto-Diagnose-System (Error-Code)

Optimum control of weld process via remotecontrol unitFPA 2020-RC remote control with cable 9 m

Functions on remote control:- Selection of program- Start/stop with slope, immediate weld stop- Emergency-stop- Manual positioning of axes- Manual wire inching (forward/reverse)- Parameter adjusting during welding (on the

fly)- Test button for shielding- and on-off purging

gas

1 pc. USB-stick Welding data-documentationInstalled printer

Duty cycle AC 200 A (10min/40°C) 30% d.c.150 A (10min/40°C) 60% d.c.110 A (10min/40°C) 100% d.c.

Duty cycle DC 200 A (10min/40°C) 35% d.c.160 A (10min/40°C) 60% d.c.130 A (10min/40°C) 100% d.c.

Cooling power 570 WThroughput l/min min. 0,2Max. pump pressure bar 4,5Coolant volume l ca. 1,5Isolation class FProtection class IP 23Dimensions l x w x h mm 625 x 290 x 480Net weight w.o. rem. control unit kg 35

Technical dataMicroprocessor-control Addressing welding parameter

Addressing torch rotation axisAddressing wire feeder unitAddessing USB-stickAddressing printer

Operating voltage 10-18 VOpen-circuit voltage 88 VMains fuse 16 AMains cable m 2,5Mains voltage 1 phase 230 V/ 50-60 HzCos phi 0,99Welding current stepless AC/DC 3-200 A

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Technical dataMains voltage (via welding power source) 55 VProtection class IP23Dimensions l x w x h mm 500 x 390 x 320Net weight kg 15

Recommended areas of useFronius Process Automation – FPA System-Controller are universal and func-tional with orbital weld heads useable for tube-tube/ tube-flange/ tube-tube sheet welding• Microelectronics• Pharmacy/ Biochemical Industry• Food Industry• Climate Technology• Aeronautics/ Aerospace• Heat Exchangers• Chemical industry• Shipbuilding• Energy / boilers• Power stations• Measurement sensors• Tank manufacturers

ProcessesTIG welding DC or AC / DC

FPA 2030 Orbital system-controllerGenerator compatibleMounted on carriageIntegrated gas flow controlIntegrated printer USB-stick Remote control FPA 2030-RC with cable 10 m

Easy programming via intuitive program inter-faceTouch-screen operation with graphical process-visualisation (colour)Language selection (De/Gb/Fr/It)

Addressing welding power source parameterAddressing torch rotation axis with encoderAddressing wire feederAddressing purging gas

Standard equipment

Orbital system-controller FPA 2030Orbital system-controller with integrated microprocessor-controller

Load and save programs to USB-stickCreation of backup on USB-stickWelding-data documentation on USB-stickSynergicMode (Material, pipe outside diameter,wall thickness, gas, ..)Auto-Diagnose-System (Error-Code)Ethernet and RS232 interface for service

Programming welding parameter:- Internal memory (200 programs)- 3 special tack programs with up to 20 tack

points- 10 sectors/ program free definable

Display during weld cycle:- Welding current (A)- Arc Voltage (V)- Torch position (degree)- Welding speed (cm/min)- Wire feed speed (cm/min)

Functions on remote control FPA 2030-RC:- Selection of program- Start/stop with slope, immediate weld stop- Emergency-stop- Manual positioning of axes- Manual wire inching (forward/reverse)- Parameter adjusting during welding cycle (on

the fly)- Test button for shielding gas and on/off

purging gas - Touch & Retract- Automatic torch centering

Interfaces:- USB - RS 232- Ethernet

Options and accessories

Addressing AVC / Touch & Retract (MUIV, TS,Polycar 60-2)Addressing OSC / electrode-centering (MUIV,Polycar 60-2)Software ’FPA Xplorer’ for offline mode (Datadocumentation/ -archiving)Ethernet cableRemote diagnosis via modem (analogue/digital)Adaptor-set for welding headsWelding power sources, cooling units, coldwire supplyCarriage PickUpOrbital welding headsHosepack extensionUSB-stickPrinter paper

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UHP 500-2 UHP 1500-2

Technical data Tube outer-diameter DimensionsA B C D E F

UHP 250-2 mm 1,6 up to 6,35 31,6 257,0 11,9 5,60 22,3 27,8 UHP 500-2 mm 3,0 up to 12,70 51,3 261,0 12,0 5,70 23,0 25,4 UHP 1500-2 mm 6,0 up to 33,70 92,0 291,0 29,5 14,75 – 32,5

Standard equipmentClosed chamber weld head with hosepack 5,5 mSturdy construction, featuring reduced dimensionsProtection chamber for gas covering to avoidcolorationCompact design for use in areas with limitedaccessNon-symmetrical design allows welding of fitting featuring reduced straight sections

Closed chamber weld heads UHP 250-2 / UHP 500-2 / UHP 1500-2Welding of tube to tube joints

Titanium tube clamps for optimum hold andpositioningModular system for welding of tube to fittingSpecial gas arrival to avoid particle emissionsAir-cooledHigh-precision drive unit Modular cassette-/ clamping insert-systemTransport case

AccessoriesClamping inserts (titanium) for one tube outer-diameter Clamping cassettes for one tube outer-diameterSpecial clamping inserts or cassettes for micro-fittings

Recommended areas of useSpecial for welding of thin-walled tubes (tubeouter diameter 1,6 up to 33,7 mm) in High-Purity-IndustriesUHP 250-2 up to wall-thickness of max. 1,0 mmUHP 500-2 up to wall-thickness of max. 1,5 mmUHP 1500-2 up to wall-thickness of max. 2,5 mm• Microelectronics• Pharmacy / biochemical Industry• Food industry• Aerospace / aeronautics• Heat exchangers• Measurement sensors

ProcessesTIG weldingFlush joint welding without filler wire

Recommended base metalsStainless steelTitaniumInconeletc.

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MW 40

MW 170

MW 115MW 65

Standard equipmentClosed chamber weld head with hosepack 5,5 mProtection chamber for gas covering to avoidcolorationCompact design for use in areas with limitedaccess“Flex” Titanium tube clamps for optimum holdand positioningSpecial gas arrival to avoid particle emissionsConsistent high quality welding due to watercoolingDC-motor drive with encoder-system (vibrationfree drive)Modular clamping insert-system (quick change)Transport caseViewport for weld joint inspectionControl buttons integrated in handle of weldhead• Out of weld cycle (rotation movement, gas

and water-circuit test)• During weld cycle (start cycle, downslope,

stop)

AccessoriesClamping inserts (titanium) for one tube outer-diameterSpecial designed clamping insertsAdapter for clamping inserts of previous MW modelOffset electrode holder (tubes with reduced straight length)Shield for one tube outer-diameter (tube-elbow)Extension hosepack

Recommended areas of useSpecial for welding of thin-walled tubes andhigh productivity applications (tube outer-diameter 6,0 up to 170,0 mm)• Microelectronics• Pharmacy / biochemical industry• Food industry• Aerospace / aeronautics• Heat exchangers• Measurement sensors

ProcessesTIG welding DC respectively AC/DCFlush joint welding without filler wire

Recommended base metalsStainless steelTitaniumInconelAluminium (limited)etc.

Technical data Tube outer-diameter DimensionsA B C C* D E

MW 40 mm 6,00 up to 40,00 100 430 38,0 38,0 19,0 50 MW 65 mm 12,00 up to 65,00 126 458 38,0 57,5 19,0 63 MW 115 mm 25,00 up to 115,00 200 547 46,0 68,0 23,0 100 MW 170 mm 80,00 up to 170,00 290 580 63,0 63,0 31,5 145

C* width with adapter and clamping inserts of previous MW model

Closed chamberweld headsMW 40 / MW 65 / MW 115 / MW 170Welding of tube to tube joints

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MU IV 19/80 P MU IV 19/80 AVC-OSC

Standard equipmentOpen weld head with hosepack 9 mStepless adjustable centering- / clamping systemMechanical side adjustment (electrode) +/– 2,5 mm (MU IV P)Simple adaptation to different tube geometriesTorch tiltable 0° up to 45° (flange)Button clutch for rotation axisand manual turnable for rapid cable unwind (MU IV 195)Modular design (wire feeder-, AVC-, OSC-unit)Mechanical height tracking (MU IV P)2-axes wire adjustment device and wire liner(MU IV AVC-OSC)High duty cycle due to water coolingTransport caseToolings and wear part box

Open weld headsMU IV P /MU IV withAVC-OSCWelding of tube to tube joints

Options and accessoriesIntegrated (mounted) wire feeder with wire spool 100 mmExternal wire feeder KD 4000 with wire spool300 mm / 20 kgAdapter-set for connecting wire guideConnection line 9 m KD 4000 to controller2-axes wire adjustment device and wire inliner (MU IV P)Motorized cross-slide-system (AVC- and OSC-slides) for arc lenght control and torchoscillationHosepack-extensionAngle gear box for tilting the motor (90° / 180°)Flange-kitBalancerGas drags for purging

Recommended areas of useSpecial for welding of thin-walled and thick-walled tubes / pipes(tube / pipe outer-diameter 8 up to 275 mm)• Pharmacy / biochemical industry• Food industry• Aerospace / aeronautics• Chemical industry• Shipbuilding• Energy / boilers• Power plants

ProcessesTIG welding with or without filler wireWelding of multi-pass with filler wire in combi-nation with arc length control (AVC) and torchoscillation (OSC)

Recommended base metalsSteelStainless steelTitaniumInconelAluminiumetc.

Technical data Tube DimensionsMU IV P outer-diameter A B C D EMU IV 8/28 mm 8 up to 28 116 16,0 5 96,0 70,0 MU IV 8/38 mm 8 up to 38 126 16,0 5 96,0 72,0 MU IV 19/64 mm 19 up to 64 155 16,0 5 98,0 93,0 MU IV 19/80 mm 19 up to 80 172 16,0 5 97,0 103,0 MU IV 19/104 mm 19 up to 104 204 16,0 5 90,0 121,5 MU IV 25/115 mm 25 up to 115 215 16,0 5 101,0 148,0 MU IV 25/128 mm 25 up to 128 240 16,0 5 99,0 173,0 MU IV 76/195 mm 76 up to 195 410 30,5 14 158,5 208,0 MU IV 101/245 mm 101 up to 245 470 30,5 14 174,5 254,0 MU IV 114/275 mm 114 up to 275 500 30,5 14 172,5 276,0

Technical data Tube- DimensionsMU IV AVC-OSC outer-diameter A B Ca/Cb D EMU IV 8/38 mm 8 up to 38 142 23 20 150 72,0 MU IV 19/64 mm 19 up to 64 184 16 20 136 93,0 MU IV 19/80 mm 19 up to 80 200 16 20 136 103,0 MU IV 30/104 mm 30 up to 104 222 16 20 140 121,5 MU IV 25/115 mm 25 up to 115 235 16 20 139 148,0 MU IV 42/128 mm 42 up to 128 340 16 20 134 173,0 MU IV 76/195 mm 76 up to 195 410 16 20 165 208,0 MU IV 101/245 mm 101 up to 245 500 16 20 179 254,0 MU IV 114/275 mm 114 up to 275 530 16 20 179 276,0

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Wire feeder unit KD 4000Wire feeder Orbital for external addressing

Recommended areas of useWire feeder for mechanized orbital coldwireTIG welding

Standard equipmentWire feeder unitExternal addressing wire speed via interface4 rolls for wire diameter 0,8 mm (trapezoid-groove)Closed wire spool cover for 300 mm / 15 kg

Protection cover motorplateHandle

AccessoriesSystem-Controller FPA 2020 / 2030Connection line 9 m KD 4000 to controller2-axes wire adjustment device and wire liner dia. 0,8 mmTIG power sources

Technical dataMotor 42 V/DCWire feeder sped cm/min 10 – 750Motor power consumption 146 WGear 49:1Dimensions l x w x h mm 625 x 250 x 300Weight kg 14

78

Technical data Polycar 60-2 Polycar 60-2 LPTube outer-diameter mm from 114 from 114Max. wall-thickness of tube mm 30 30Welding process TIG/ TIG cold-/ hotwire TIG/ TIG coldwireDimension

• A (min. space around tube) mm 190 / 167 146 / 135• B (min. axial clearance guide ring) mm 146,5 146,5• C (overall axial clearance) mm 375 up to 435 (OSC=60 mm) 375 up to 435 (OSC=60 mm)• Ca (AVC – travel way) mm 60 30• Cb (OSC – travel way) mm 60 60

Drive motor-slides (AVC/ OSC) stepper motor stepper motorAVC-axis speed range mm/min 10 – 500 10 – 500OSC-axis speed range mm/min 20 – 1000 20 – 1000Tilting range torch +/ - 35 ° +/ - 35 °Max. welding current 300 A 300 ADiameter electrode mm 2,4 (standard) / 3,2 / 4,0 2,4 (standard) / 3,2 / 4,0Drive rotation DC Motor DC MotorDrive speed rotation mm/min 20 – 400 20 – 400Integrated wire spool mm 200 100Drive wire feeder DC Motor DC MotorWire feed speed – coldwire mm/min 95 – 2068 95 – 2408Wire feed speed – hotwire mm/min 360 – 7929 -Wire diameter mm 0,8 0,8

(other diameters on request) (other diameters on request)Net weight orbital tracking vehicle kg 9 9

Standard equipmentOrbital tracking vehicle with hosepack 9 mHigh duty cycle due to water coolingIntegrated wire feeder 5 rolls 0,8 (trapezoid-groove)Special 2-axes wire holder and adjustmentdeviceCold- / hotwire linerUptake torch and tilting device with scale +/–45°Using a position based on integrated pulsegenerator rotation and an encoder coordinatesthe weld cycle. Current and wire are synchroni-sed relative to the position of the electrode onthe tube. Closed loop feedback regulates thetravel speed and wire feed rates to a closetoleranceMotorized cross-slide-system (AVC- and OSC-slide) for arc length control and torchoscillationSimple adaptation to different tube geometriesTransport case

AccessoriesPrecise guide ringRail-system2” or 4” distance-feet for guide ring and railCamera-SystemHosepack-extensionPurging gas dragInstallation-kit MIG-MAG (machine torch)

Recommended areas of useFlexible and adaptable tracking vehicle for allwelding tasks on welding of pipe constructionsfrom tube outer-diameter 114 mm• Chemical industry• Shipbuilding• Power plant construction

ProcessesTIG welding DC, AC/DC with filler wire (cold- / hotwire)Multi pass with filler wire in combination witharc length control (AVC) and torch oscillation(OSC)


Orbital trackingvehiclePolycar 60-2Welding of pipe to pipe joints

79

Technical data Polycar PIPETube outer-diameter mm from 168 Welding process MIG-MAGWelding direction 2 x 180° vertical down or vertical upDimensions • A mm 530

• B mm 332 • C mm 225 • D mm 120 • E mm 223

Drive motor-slides (SOM / OSC) Stepper motorSOM-axis stroke / max. speed mm / mm/min 50 / 2500OSC-axis stroke / max. speed mm / mm/min 69 / 2500Torch inclination longitudinal motorized +/–35° / 100°/minTorch tilting longitudinal manual –20°Drive rotation with bracket DC-MotorSpeed range with / without welding mm / mm/min 30 – 1000 / 30 – 2000Net weight tracking vehicle kg ca. 20

Standard equipment4 wheel driveTorch bracket and tilting device with scaleMotorized cross-slide for torch motion SOM,OSCMotorized slide for torch angle motionIntegrated encoder for speed regulation and synchronization of weld parametersaccording to real torch positionHosepack 15 m Simple adaption to different tube geometriesStorage case

AccessoriesPrecise guide ringSystem-Controller FPA 2030Power source set MIG-MAGCamera-SystemHosepack-extensionPurging gas drag

Recommended areas of useFlexible and adaptable tracking vehicle for allwelding tasks on welding of pipe constructionsfrom tube outer-diameter 168 mm• Chemical industry• Shipbuilding• Power plant construction

ProcessesMIG-MAG weldingMulti pass in combination with arc length control (SOM) and torch oscillation (OSC)


Orbital tracking vehicle Polycar PIPEOrbital tracking vehicle for MIG/MAG-welding of pipe-to-pipe joints

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flush tube

Closedweld head TS 25Welding of tube to tubesheet joints

Standard equipmentClosed weld head with hosepack 9 mSmall, light and very compactLever for fixing and opening of the clamping- /positioning-systemModular designFront ring and shielding gas chamberCentering spindle for centering mandrelTransport case

AccessoriesExpandable mandrel for one tube inside-diameterCustomized clamp system (monobloc-system)

Recommended areas of useSpecial for welding of flush tubes (highly oxidisable materials) on tube-sheet (from tube inside-dia. 10,0 mm up totube outside-dia. 25,4 mm)Tube / tube sheet: max. 1 mm recessed / max. 0,5 mm protruding• Pharmacy / Biochemical Industry• Food Industry

ProcessesTIG welding without filler wire


Technical data TS 25Tube inside-diameter mm from 10,0 (diameter 7,0 up to 10 on request)Tube outside-diameter mm up to 25,4 Welding current 100 A (d.c. 20%)Torch cooling water cooledNet weight kg 1,5

81

flush tube

Closedweld head TS 34Welding of tube to tubesheet joints

Standard equipmentClosed weld head with hosepack 9mSmall, light and very compact Lever for fixing and opening of the clamping-/positioning-systemModular designFront ring and shielding gas chamberCentering spindle for centering mandrel Storage case

AccessoriesExpandable mandrel for one tube inside-dia-meterFront ring with gas protection (gas protectionchamber)Customized clamp system

Recommended areas of useSpecial for welding of flush tubes (highly oxidisable materials) on tube-sheet (from tube inside-dia. 9,5 mm up to tubeoutside-dia. 37,7 mm)Tube / tube sheet: max. 1 mm recessed / max. 0,5 mm protruding• Pharmacy / Biochemical Industry• Food Industry

ProcessesTIG welding without filler wire


Technical data TS 34Tube inside-diameter mm 9,5 - 33,7Welding current 120 A (d.c. 60%)Torch cooling water cooledNet weight kg 1,5

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Open weld headTS 2000Welding of tube to tubesheet joints

Standard equipmentOpen weld head with hosepack 9 mManual regulation distance electrode to tubesheetVersion – TS 2000 without wire feeder (compatible for KD 4000)Version – TS 2000 with wire feeder on board(spool dia. 100 mm)Motorized arc length control – AVCVersion – TS 2000-AVC without wire feeder(compatible for KD 4000)Version – TS 2000-AVC and wire feederon boardWire guide, wire inliner and adjustmentAdjustable three point supportSwivelling handle for balancerModular designConsistent high quality welding due to water cooling

Continuous rotating torch (current, water, gas, ...)Transport case

ProcessesTIG welding with or without filler wire

Recommended areas of useWeld head for welding tube to tubesheet(from tube inside-diameter 10,5 mm up to tubeouter-diameter 60 mm)for high duty cycleTube / tubesheet: max. 2 mm recessed / max. 13 mm protuding• Energy technology• Heat exchangers

AccessoriesSpindle suitable to mandrelMandrel for one tube inside-diameterTorch- / electrode holder applicated to your requestPneumatic clamping system for one tube inside-diameterShielding gas chamber (Titanium)Inside / – internal special torch (for welding tube behind tubesheet)Components for adaptation of pneumatic clamping systemBalancer

Technical data TS 2000Tube inside-diameter mm from 10,5Tube outer-diameter mm up to 60Welding current 200 ATorch cooling water cooledAVC (optional) – travel way mm 10Wire feeder (optional) mm/kg on board (spool dia. 100/1,5) / external (spool dia. 300/20)Wire diameter mm 0,8 (standard)/1,0Net weight kg 5,6 (without wire feeder)Net weight kg 11 (with wire feeder on board and pneum. clamp system)


flush tube protruding tube

recessed tube tube behind tubesheet

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Distance footControl box FCU-FTWSwivel unit with torch holder diameter 44,2 mmSpindleHosepack holder and cable support

Standard equipmentHandleHand wheel for fixing mandrelSupport horizontal 130 mm for manual torchpositioningSupport vertical 25 mm for manual torchpositioning

Necessary accessoriesRemote control unit FRC-40 with cable 3 m Mandrel FTW/D35,0- 40,0/ L117/PA/PBMandrel FTW/D40,5- 45,0/ L117/PA/PBMandrel FTW/D45,5- 50,0/ L117/PA/PBMandrel FTW/D50,5- 55,0/ L117/PA/PBMandrel FTW/D55,5- 60,5/ L117/PA/PBMandrel FTW/D60,6- 80,5/ L152/PA/PBMandrel FTW/D80,6-108,0/ L197/PA/PBMandrel FTW/D90,6-118,0/ L197/PA/PBCustomized mandrelsFRR reducer rings for torch holderSupport ring for fillet weld

Tubesheet welder FTW 35-118Welding of tube to tubesheet joints

ProcessWelding process MIG-MAG

Recommended areas of useSpecial for welding of tube to tubesheet in horizontal welding position PA of thick-walled tubes(tube inside-diameter 35 up to 118 mm)• Tank- / container construction• BoilersRecommended base metals

SteelAluminiumetc..

Technical data FTW 35-118Tube inside-diameter mm 35 – 118Welding position PA / PG on requestWelding process MIG-MAG / TIG on requestWelding signal 2- / 4-step modeDrive stepper motorSpeed 0 – 2160°/minDimensions

• A mm 890 • B mm max. 445 • C mm 250 • D mm 130 • E mm 25 • F (mandrel 35,0 – 60,5) mm 117 • F (mandrel 60,6 – 80,5) mm 152 • F (mandrel 80,6 – 118,0) mm 197

Net weight without mandrel kg 12,4

Technical data Control box FCU-FTWMains switch on-offMains voltage / frequency 230 V / 50 – 60 HzPower consumption 300 VAControl voltage 36 V DCMains cable with plug m 5Control line FTW 35 – 118 m 5Control line power source (Tuchel) m 3Net weight FCU-FTW kg 9,7

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Vizor 1000 Air Professional Vizor 1000 Air Standard Air flow gal/min / l/min constant 39.6 / 150 constant 39.6 / 150Filter P3 (EN 143) particle filter P3 (EN 143) particle filterApplication temperature +2°C bis +55°C +2°C bis +55°CWeight lbs. / g 2.97 / 1350 2.97 / 1350(fan unit incl. standard battery & filter)

Vizor 1000 Standard areas of useMIG/MAGMMA welding

Adjustable parametersShade level adjustment 10/11Sensor slide

Recommended Areas of use: Service and Repair, MetalbuildingConstruction of plant, containers, machinery,structural steelAutomotive and allied vendor industries,Robot welding, Construction of special vehicles,

General featuresAutomatic darkening due to LCD-technology Solar-driven technologyPermanent UV-IR-Radiation protectionAdjustable distance betweel cartridge and eyesAdjustable helmet inclinationHeight and diameter adjustable head bandSimple and quick changing of the front coverlens2 spare-front cover lenses per set

Vizor 1000 recommended areas of useMIG/MAG (standard and pulsed arc welding)TIG (AC-DC)MMA weldingPlasma weldingGrinding

Adjustable parametersOpening speed adjustment Stepless Shade level adjustment from 5-13 Sensitivity adjustment Grinding modeSensor slide

Vizor 1000 Professional / StandardVizor 1000 Air Professional / Standard

Vizor 1000 Professional Vizor 1000 Standard Type of cartridge Automatic switch-over Automatic switch-over

between 4/5–9, 4/9–13 between 4/10, 4/11Switching time light / dark 0,3 msec. at 25°C 0,4 msec. at 25°CSwitching time dark / light sec. 0,1 – ,035 (fast pos.) 0,2 – 0,3

sec. 0,3 – 0,6 (slow pos.)Application temperature - 10°C – +70°C - 10°C – +70°CEnergy supply Solar cells Solar cellsWeight lbs. / g 1.26 / 572 1.23 / 560Cartridge size inch / mm 3.54 x 4.33 x 0.28 / 90 x 110 x 7 3.54 x 4.33 x 0.28 / 90 x 110 x 7

85

Pos. 4

Pos. 2 Pos. 5

Pos. 6

Pos. 1

Pos. 3

Pos. 1

Pos. 2Pos. 3

Pos. 4

Pos. 5

Pos. 6Pos. 7

Pos. 1 Pos. 3

Pos. 5

Pos. 4Pos. 2

Pos. 6

International welding accessories

Recommended areas of useTechnical collegesTechnical universitiesFurther educationTraining workshops

Teachware Set

86

Calibration systemMains voltage +/- 15 % 230 VAccuracy of measurement outputs Current ± 0,5 % of measured value (w/o offset)

Voltage ± 0,5 % of measured valueResistance range in 20mΩ-steps 0 – 300 mΩMax. perm. load on resistors 20 kW for 30 sec./max. 500 AMax. perm. input voltage 113 V peakWeight (with cooling unit) lbs. / kg 116 / 53Dimensions with cooling unit l x w x h inch / mm 24 x 11 x 27 / 625 x 290 x 710

Calibration system

Area of useCalibration of welding machineStatic loadTesting & inspectionUse on the spotDC and AC machinesAny pulsed waveformsTIG, MIG/MAG and manual electrode

Standard equipmentCooling unit FK 4000RAdapter setMeasurement outputs short-circuit-proofTemperature and water-flow monitoringOver-temperature indication3 mains socket with mains filter for poweringexternal measuring devicesU/I display (mean value)

Welding samplessteel / aluminium / chrome nickelpreservedinsribedpunchedsingle packed5 pcs. – packing acc. picture

Area of useWelding technologyBuilding suitesLeisure time

EquipmentUV-resistandPermanent flame-retardantHighly functionalFashionable

QualityQuality: 100 % cotton, tested according to EN 470-1, EN EN 531A,B1,C1,E1, EN 533 index3 and EN 1149-2. Product can be washed up to 75°C industry wash

Fronius Collection

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