PRODUCT BULLETIN

805 Liberty Lane Product: Fronius Power Sources for NX100

West Carrollton, OH 45449
937.847.6200
Release Date: 3/19/04
www.motoman.com Part Number: Description:
info@motoman.com
152770-1 Power Source Kit, Fronius, Trans Pulse, Synergic, 4000MV, EA1400N
152770-2 Power Source Kit, Fronius, Trans Pulse, Synergic, 4000MV, EA1900N
Fronius power sources
152771-1 Power Source Kit, Fronius, Trans Pulse, Synergic, 5000MV. EA1400N
152771-2 Power Source Kit, Fronius, Trans Pulse, Synergic, 5000MV. EA1900N
152772-1 Power Source Kit, Fronius, Trans, Synergic, 4000CMV, EA1400N
152772-2 Power Source Kit, Fronius, Trans, Synergic, 4000CMV, EA1900N
152773-1 Power Source Kit, Fronius, Trans, Synergic, 5000CMV, EA1400N
152773-2 Power Source Kit, Fronius, Trans, Synergic, 5000CMV, EA1900N
150734-1 Power Source Kit, Fronius, Trans Pulse, Synergic, 4000MV, HP6,
Aluminum Package With Robacta Drive
150734-2 Power Source Kit, Fronius, Trans Pulse, Synergic, 4000MV, HP20,
Aluminum Package With Robacta Drive
150734-3 Power Source Kit, Fronius, Trans Pulse, Synergic, 4000MV, HP20-6,
Aluminum Package With Robacta Drive
150734-4 Power Source Kit, Fronius, Trans Pulse, Synergic, 4000MV, HP50-20,
Aluminum Package With Robacta Drive
for NX100

Description:
The Fronius TS (synergic, non-pulse) and TPS (synergic, pulse) power sources are totally
digitized, microprocessor-controlled inverter power sources. An interactive power source
manager is coupled with a digital signal processor to control and regulate the entire
welding process. The weld data is measured continuously, and the machine responds to
any changes. The control algorithms developed by Fronius ensure that the specified target
status is maintained. This gives the weld process an unrivaled degree of precision with
exact repeatability of results.
All Fronius power sources are multiprocess-capable and fully synergic, and their
programmable output slope characteristics are from flat to drooping. All power sources are
rated for 230/440 VAC, 50/60 Hertz, and have S, CE, CSA approval markings.
The ROB 5000 power source-to-controller interface is designed for DIN rail-mounting
inside the robot controller cabinet and converts controller analog signals to Local-Net
digital format for the welding system components. The signal identifications for all wires
are clearly labeled, making connections much easier. Molex-type plugs make separating
the wiring harness from the interface easy and save time when troubleshooting a malfunction.
On the EA-series robots, the Fronius “split-feeder” design is used. This positions the feed
motor on top of the “L-axis,” while locating the motor control box on the side of the “L-axis.”
This keeps all the advantages of the sleek and compact EA robot while utilizing all the
features of Fronius’ VR1500 feeder. On the HP-series robots welding aluminum, the
VR1500 is packaged to mate to the water-cooled Robacta torch (see below for details). The
VR1500 weighs 7.0 kg. The EA feeder design also uses a unique Fronius power pin which
adapts to the EA torch cable.
Both wire feeders are equipped with 42-volt motors which powers four drive rolls.
Pressure is controlled by dual manual adjustments. Feeding speeds range from 0.5 meters
per minute to 22 meters per minute. A solid-state motor control located in the VR1500 or in
an enclosure on the EA robot regulates the feeding speed. The feeder and all other welding
system components communicate via the Local-Net Bus network.

©2007 MOTOMAN Copies of Product Bulletins can be found on the Motoman iNet on the Marketing web page. The information within this document is the
STANDARD SYSTEMS GROUP proprietary property of Motoman Inc., and may not be copied, reproduced or transmitted to other parties without the expressed written
JANUARY 2007, PB-144-B authorization of Motoman Inc. Technical specifications are subject to change without notice.
 PRODUCT BULLETIN
Page 2 of 3 Description (continued):
The aluminum packages designed around HP-series robots include the VR1500 feeder and
the Robacta assist feeder. The torch-mounted Robacta drive resides at the end of the robot
wrist and is controlled via a four-quadrant motor control. This 2-roll assist motor is critical
Fronius power sources
in aluminum applications because of features such as “spatter-free ignition” (software for
improved arc-starting) and “syncropulse” (software for dual-pulse/layered-penny look)
which are only available with the addition of the Robacta drive. The aluminum packages
also include the Fronius water circulator designed to mount underneath the power source.
The aluminum packages also includes a bracket to house a 30# wire spool on the side of
the robot. Large pay-off packs are not suggested unless a assist feeder is used at the pay-off
spool.
Features:
• Easy to understand front panel with multi-functional meters that can display amps, volts,
wire feed speed in meters/minute or inches/minute, system resistance, inductance, etc.
• Three channels of analog inputs: amperage/wirefeed speed, voltage/trim, and inductance/
pulse shape.*
• Pulse programs and synergic data points are factory programmed.
• Reduced shipping time, cost and risk of shipping damage due to the power source’s small
for NX100

footprint and light weight.

* The standard Fronius power source kit uses three analog channels and 10-12 outputs to
provide full remote control. Most applications do not require this level of functionality and
could operate with less I/O and without the third channel. Disconnecting the wiring will
deactivate the function.
Drawings:
GAS HOSE
WIRE FEED
MOTOR WELD +

FEEDER CONTROL CABLE

POWER SOURCE CONTROL CABLE

CUSTOMER
MOTOR SUPPLIED
CONTROL DISCONNECT
BOX

WORK
GROUND
TERMINAL
GAS

FRONIUS
EA1400N ROBOT NX100 CONTROLLER TransPuls Synergic
GAS BOTTLE AND
REGULATOR SHOWN
4000 MV
FOR REFERENCE ONLY.
WELD - POWER SOURCE
CUSTOMER-SUPPLIED

WELD +

MOTOR CONTROL BOX WATER HOSE

AND WIRE FEED MOTOR WATER HOSE
GAS HOSE
FEEDER CONTROL CABLE

NX100 CONTROLLER CUSTOMER

SUPPLIED
DISCONNECT

WORK
GROUND
TERMINAL
GAS
FRONIUS
TransPuls Synergic
POWER SOURCE 4000 MV GAS BOTTLE AND
CONTROL CABLE POWER SOURCE REGULATOR SHOWN
HP20 ROBOT FOR REFERENCE ONLY.
CUSTOMER-SUPPLIED
WELD -

©2007 MOTOMAN Copies of Product Bulletins can be found on the Motoman iNet on the Marketing web page. The information within this document is the
STANDARD SYSTEMS GROUP proprietary property of Motoman Inc., and may not be copied, reproduced or transmitted to other parties without the expressed written
JANUARY 2007, PB-144-B authorization of Motoman Inc. Technical specifications are subject to change without notice.
 PRODUCT BULLETIN
Page 3 of 3 Power Source Specifications:
Power Source Part Number Rated Amperage 100% Duty Cycle Rated Power
TPS 5000 148497-1 500 Amps @ 40% 340 Amps @ 100% 16.0 kVA
Fronius power sources
TPS 4000 148496-1 400 Amps @ 50% 320 Amps @ 100% 12.4 kVA
TS 4000 148495-1 400 Amps @ 50% 300 Amps @ 100% 11.5 kVA
TS 5000 148494-1 500 Amps @ 40% 320 Amps @ 100% 15.8 kVA

Optional Items:
• Water circulator – designed to bolt to the base of the welder (included with aluminum packages).
• Program devices – RS232 adaptor for downloading data to a laptop computer. Other
options include an RCU-5000 programming pendant, Ethernet IP communication board,
and computer software for weld management. These items are not needed for most applications.
Consumable Parts:
P/N Description
for NX100

717484-1 Feedroll, .045", For VR1500, Aluminum Wire, Semicircular (4 per feeder required)
717484-2 Feedroll, 1/16", For VR1500, Aluminum Wire, Semicircular (4 per feeder required)
717484-3 Feedroll, .045", For VR1500, Steel Wire, Trapesoid Groove (2 per feeder required)
717484-4 Feedroll, Pressure, Any Size Wire, Steel Wire, Smooth Top Roll (2 per feeder required)
717486-1 Feedroll, Kit, Robacta, 1/16" Drive Roll Size (includes 2 rolls and needed wire guides)
717486-2 Feedroll, Kit, Robacta, .045" Drive Roll Size (includes 2 rolls and needed wire guides)
717492-1 Tip, Contact, 1/16", M10, L40, ZB4.8, for Aluminum Weld Wire
717492-2 Tip, Contact, .045"/M10x1.25, L40/ZB E-Cu for Steel Wire
717492-3 Tip, Contact, 3/64", Fronius, Robacta Drive, Aluminum
717491-1 Liner, Steel, .040"-.045"
717491-2 Liner, Steel, .045"/11.5 ft, Water-Cooled Torch
150927-1 Liner, Torch, Aluminum Wire, 5 ft
150927-2 Liner, Torch, Aluminum Wire, 12 ft
150927-3 Liner, Torch, Aluminum Wire, 7 ft
150927-4 Liner, Torch, Aluminum Wire, 44 ft
150927-5 Liner, Torch, Aluminum Wire, 18 ft
150982-1 Liner, Neck, .030"/.045", Fronius, Alum, .95 ft, RA280
150984-1 Liner, Torch, 3/64" Aluminum, 4.5F, Fronius Robacta Torch, Combi
150984-2 Liner, Torch, 1/16" Aluminum, 4.5F, Fronius Robacta Torch, Combi

©2007 MOTOMAN Copies of Product Bulletins can be found on the Motoman iNet on the Marketing web page. The information within this document is the
STANDARD SYSTEMS GROUP proprietary property of Motoman Inc., and may not be copied, reproduced or transmitted to other parties without the expressed written
JANUARY 2007, PB-144-B authorization of Motoman Inc. Technical specifications are subject to change without notice.