COURSE: WEL211 ASAP Name: John Moen

TOPIC: Fronius CMT wire feeders Date:

INSTRUCTOR: RYAN GOOD Score:

PENNSYLVANIA COLLEGE OF TECHNOLOGY

Introduction

This exercise manual is meant to assist you in navigating the equipment manual for the Fronius CMT wire feeders. There
are many options contained in this wire feeder, and the more comfortable you are with those options, the better you
will be able to troubleshoot welds and use the technology to solve problems instead of creating them.

There will be answers that you must find out of the equipment manual, and there will also be small exercises to perform
in the lab, collect data, and then write a brief summary as to how you understand the parameter or variable works.

These manuals are developed to help you become more familiar with both the information that is contained in manuals
and how to read them, and give you an opportunity to work with the technology to build a connection with what these
power supplies are capable of via lab exercises. At the conclusion of the exercise manual, you will be required to type
your answers into the manual, including a 300-word reflection on the lab in the area provided, and upload the file into
PLATO before the due date.

Instructions

Work through the Manual Review portion of this document and answer all the questions with the information that can
be found in the equipment manuals. Try to become familiar with the manual and how to use it. Manuals aren’t often
read like books, so they contain indicators on where to find the information; try to use those indicators. Also, try be
become familiar with the information and start to notice the differences between one manufacturers approach or
terminology as compared to another.

Manual Review

CMT VR 7000
1. List all the components of the GMAW circuit that could be live at any time the power supply is turned on
according to the manual:
a. the welding wire
b. the wirespool,
c. the feed rollers
d. all pieces of metal that are in contact with the welding wire

2. What must be done if work needs to be performed on any live parts?

a. Before working on the device, switch it off and pull out the mains plug.

3. What must be done if the machine is placed on an electrically conductive floor?

 a. If the floor is electrically conductive, the device must be set up with sufficient insulating material to
insulate it from the floor.
_________________________________________________________________
4. Machines fitted with a carrying strap or carrying handle are only intended for what type of transport?
a. If the device has a carrying strap or handle, this is intended solely for carrying
by hand. The carrying strap is not to be used if transporting with a crane, counterbalanced lift truck or
other mechanical hoist.

5. How many degrees off of 0 can a machine be tilted and still be safe for operation?
a. A device toppling over could easily kill someone. Place the device on a solid,
level surface such that it remains stable
- The maximum permissible tilt angle is 10°.

6. What is the maximum size welding wire spool that can be used?
a. Weight(lbs)__ 16 kg (35.27 lbs)_________________________Diameter(inches)_ 300 mm (11.81 in)
_________________________________
7. What are the 4 trigger mode options on this wire feeder?
a. 2-step mode
b. 4 -stepmode___________
c. Special 4-step mode________________________________________________________________
d. Spot welding____________________________________________
8. What type of hosepack is required to connect the VR 7000 CMT to a Fronius CMT power source?
a. a special CMT interconnecting hosepack with additional LHSB cable is required for connecting the VR
7000 CMT to the CMT power source

9. What must be used when a basket type welding wire spool is used?
a. When working with basket-type spools, only use the basket-type spool adapter supplied with the
device

10. What contact pressure is recommended for steel welding wires with Semi-cylindrical rollers being used?
a. 3 – 4 on the contact pressure

11. What are the 2 types of wire feeding hoses when external welding wire is being used?
a. _ For steel (blue)
b. For aluminium (white)
12. List the requirements needed in order to commission the wire feeder into service?
a. Wirefeeder connected to the power source using the interconnecting hosepack
b. Welding torch connected to wirefeeder
c. _ Feed rollers inserted in the wirefeeder
d. Wirespool or basket spool and adapter inserted in the wirefeeder
e. _ Welding wire fed in
f. _ Braking force set
g. Feed roller contact pressure set
h. All covers closed, all side panels in place, all protection devices intact and in their proper place

13. What checks must be made before every startup?

 a. _ Check welding torch, interconnecting cable and grounding (earthing) connection for signs of damage
b. Perform a visual check on the feed rollers and wire for signs of damage
c. Check wirefeeder rolls’ contact pressure and adjust if necessary
d. Check brake and adjust if necessary
14. What supply voltage is needed from the power source?
a. 55 V DC

15. What is the wire feed speed range in inches per minute?
a. _ 0.5 -22 m/min
19.69 - 866.14 ipm.
___________________________________________________________________________________
16. What is the max shielding gas pressure?
a. 7 bar -101 psi

CMT 4000 ADVANCED

17. What button is used to select parameters such as sheet thickness, welding current, wire feed speed, arc
length, and voltage?
a. _____________________________________________________________________________________
18. How can you be certain when using the adjustment dial what parameter you are altering?
a. _____________________________________________________________________________________

19. List the steps used to change the set gas pre/post flow times:
a. _____________________________________________________________________________________
b. _____________________________________________________________________________________
c. _____________________________________________________________________________________
d. _____________________________________________________________________________________
e. _____________________________________________________________________________________
20. What are CMT remote control panels used for?
a. _____________________________________________________________________________________
21. What lights up when a robot or field bus is connected to the LocalNet?
a. _____________________________________________________________________________________
22. Based on the option on page 103 under “CMT welding” name 4 different material types that CMT can
successfully weld:
a. _____________________________________________________________________________________
b. _____________________________________________________________________________________
c. _____________________________________________________________________________________
d. _____________________________________________________________________________________
23. What are the next 2 steps after choosing type of filler material being used?
a. _____________________________________________________________________________________
b. _____________________________________________________________________________________
24. What is the “Boost correction” function used for and what are the 3 different option? Explain?
a. _____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
25. What does CMT stand for?
a. _____________________________________________________________________________________