Fronius TT 400 FCW Smart Arc-i Welding Industries Instructions

Fronius TT 400 FCW Smart Arc-i Welding Industries

Product Information

• The FCW Smart is a welding equipment system that offers low investment costs, simple and intuitive operation and programming, and motorized torch slides for automatic distance control (AVC) and oscillation (OSC). It features a CE-compliant protective housing with automatic anti-glare protection and has multi-process capability.
• The FCW Smart includes various components such as a protection cabin with an automatic front door and manual sliding doors, a welding table with a size of 1500 x 1000 mm and D28 system holes, a rotation unit with motorized rotary capabilities, a tailstock option with electro-pneumatic operation, and motorized linear slides for horizontal oscillation and vertical distance control.
• It also comes with a control unit that features a 5-inch touch screen operator panel for easy operation and programming. The FCW Smart is designed for optimal accessibility with rail-guided manual side doors and offers a crane loading option for convenience.
• The welding equipment options for the FCW Smart include TIG (TT 400), MIG/MAG (TPS 320i), and CMT (TPS 400i). The system is also compatible with various accessories such as cooling units, purging gas units, and WF 25i reels.
• For technical specifications, the FCW Smart requires power and air supply. Its dimensions are approximately 2320.4 x 2540.9 x 2336.5 mm (B x T x H) and it weighs around 2800 kg. The maximum part dimensions may vary depending on the specific variant of the FCW Smart.

Product Usage Instructions

To use the FCW Smart welding equipment system, follow these steps:

1. Ensure that the power and air supply are connected to the system.
2. Position the FCW Smart on a stable surface or base frame.
3. If using the protection cabin, open the automatic front door and manually slide open the side doors as needed for access.
4. If using the welding table, place the workpiece on the table within the specified dimensions.
5. Choose the desired welding process (TIG, MIG/MAG, or CMT) and select the appropriate welding equipment (e.g., TT 400, TPS 320i, TPS 400i).
6. Adjust the motorized torch slides (AVC and OSC) as required for automatic distance control and oscillation during welding.
7. Use the control unit’s touch screen operator panel to operate and program the FCW Smart. Familiarize yourself with the graphical user interface for intuitive operation.
8. If using the rotation unit, adjust the motorized rotary capabilities as needed for welding in different orientations.
9. For additional options such as tailstock, push-pull CMT TPS400i, fume extraction, weldcube, gripper chucks, or camera system, follow the specific instructions provided for each option.
10. After usage, power off the FCW Smart and disconnect the power and air supply.

For specific details on usage, maintenance, and safety precautions, refer to the complete user manual provided with the FCW Smart welding equipment system.

Application examples

• Tube–tube connections
• Tube–flange connections
• Valve seats
• Bearing seats

FCW Smart

• +Low investment costs
• + Simple, intuitive operation and programming
• + Motorized torch slides (AVC / OSC)
• + CE-compliant protective housing with
• + automatic anti-glare protection
• + Multi
• +process capability

Optimal accessibility

Individual positioning

Welding-equipment

WIG TT/MW:

• TransTIG 4000 Job
• Cooling unit FK 4000 Rob
• KD 4000 D-11

MIG/MAG (Push):

• TPS 320i
• Cooling unit CU 1400i
• WF 25i

CMT:

• TPS 400i
• Cooling unit CU 1400i
• WF 25i Reel

Technical data

POWER / AIR SUPPLY:

• Mains voltage: 400V/N/PE 50-60 Hz
• Power consumption: 15 kVA
• Compressed air: 6 – 7 bar

DIMENSIONS / WEIGHT:

• Dimensions B x T x H: 2320,4 x 2540,9 x 2336,5 mm
• Net weight approx. 2800 kg

MAX. PART DIMENSIONS

• L= 860 mm (with Tailstock)
• L= 1200 mm (without Tailstock)
• ø= 450 mm
• Part weight = max. 300 kg

FCW Smart Lean variant

• + Cost-effective solution
• + Low space requirement
• + Easy, intuitive operation and programming
• + Motorized torch slides (AVC / OSC)
• + Multiprocess
• + Capable

Anwendungsbeispiele:

• Rohr–Rohr Verbindungen
• Rohr–Flansch Verbindungen
• Ventilate
• Lagersitze

FCW Smart Lean variant

Individual positioning

Technical data

• POWER / AIR SUPPLY:
  • Mains voltage: 400V/N/PE 50-60 Hz
  • Power consumption: 15 kVA
  • Compressed air: 6 – 7 bar
• DIMENSIONS / WEIGHT:
  • Dimensions W x D x H: 2591,1 x 1921 x 1750 mm
  • Net weight: approx. 1400 kg
• PARTS DIMENSIONS:
  • L= 860 mm (with Tailstock)
  • L= 1200 mm (without tailstock)
  • ø= 450 mm
  • Part weight= max. 300 kg

System controller

HMI T5

• 3 axes addressable
• 2 welding power sources
• 5“ Touch screen
• Graphical uner interface
• Intuitive operation

Options

Basic equipment / options

• FCW SmartBasic equipment:
  • Base frame with welding table
  • Rotation unit with welding head
  • TIG/MAG/CMT welding equipment
  • Protection cabin
  • HMI-T5 System controller
• FCW Smart – Lean variantBasic equipment:
  • Base frame with welding table
  • Rotation unit with welding head
  • TIG/MAG/CMT welding equipment
  • HMI-T5 System controller
• Options
  • Tailstock
  • Push Pull CMT TPS400i
  • Fume extraction
  • Weldcube
  • Gripper chucks
  • Camera system

Market positioning & product benefit

Launch concept Market positioning

Product benefit

Features – advantages – benefits

• Shortage of skills: No robot expertise required
  By using the simple automation solution and the short-term availability of the FCW-Smart, the existing skilled workers are relieved, the productivity in your production is increased and thus counteracts the current shortage of skilled workers.

• Weld seam parameterization: made easy
  The simple operation of the user interface of the HMI-T5 guarantees a short training period and thus faster use of the FCW-Smart in production.

• Everything from a single source: Core competence welding
  We offer our customers everything from a single source. From the feasibility check in sales to commissioning, training, and service – always combined with the innovative welding technology from FRONIUS. You have a competent contact person for the realization of your project.

• CE – certified: Liability lies with the manufacturer and not with the operator
  The FCW Smart is designed according to the current Machinery Directive and is CE-certified. The design of this system ensures safe operation, no additional customer adjustments are required in terms of security.

• Health & Safety: Total protection from welding fumes and arc
  No compromises in terms of occupational health and safety. The safety-related design of the FCW Smart guarantees the protection of your employees from harmful welding fumes and your eyes from the arc.

• Cost-optimized (lean) variant
  Thanks to a well-thought-out safety concept, the operation is possible without safety-relevant housing. This enables a cost-optimized solution in the sense of a lean variant.

• Parameter changes anytime
  With the concept of safe speeds, e.g. in the course of determining parameters for the creation of a WPS, the protective doors can remain open without the safety concept becoming invalid.

• Plug & Play: Fast commissioning
  Due to the welding cell concept, the FCW Smart is ready for use immediately after connecting the power, compressed air, and protective gas supply. Thanks to the intuitive user interface, welding parameters can be created in a very short

• Best accessibility: Sliding doors, lift door, and crane loading
  Due to the design of the FCW Smart, 4 sides are freely accessible, which ensures optimal accessibility of the system operator

• On-site service: Commissioning, user training, process optimization and maintenance
  Thanks to our worldwide network, we support our customers locally throughout the entire product lifecycle

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