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42,0426,0001,EN 012005 TransSynergic 4000 / 5000 TransPuls Synergic 2700 TransPuls Synergic 3200 / 4000 / 5000 TIME 5000 Digital Operating Instructions Spare Parts List MIG/MAG power source GB

Fronius TPS Operating Instructions

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Page 1: Fronius TPS Operating Instructions

42,0426,0001,EN 012005

TransSynergic 4000 / 5000

TransPuls Synergic 2700

TransPuls Synergic 3200 / 4000 / 5000

TIME 5000 DigitalOperating Instructions

Spare Parts List

MIG/MAG power source

GB

Page 2: Fronius TPS Operating Instructions
Page 3: Fronius TPS Operating Instructions

ud_fr_st_et_00493 012004

Dear Reader

Thank you for choosing Fronius - and congratulations on your new, technically high-

grade Fronius product! This instruction manual will help you get to know your new

machine. Read the manual carefully and you will soon be familiar with all the many

great features of your new Fronius product. This really is the best way to get the most

out of all the advantages that your machine has to offer.

Please also take special note of the safety rules - and observe them! In this way, you

will help to ensure more safety at your product location. And of course, if you treat your

product carefully, this definitely helps to prolong its enduring quality and reliability - things

which are both essential prerequisites for getting outstanding results.

Introduction

Page 4: Fronius TPS Operating Instructions
Page 5: Fronius TPS Operating Instructions

ud_fr_st_sv_00467 012005I

Safety rules

DANGER!

WARNING!

CAUTION!

“NOTE!” indicates a situation which implies a risk of impaired welding result

and damage to the equipment.

NOTE!

This equipment has been made in accordance with the state of the art and

all recognised safety rules. Nevertheless, incorrect operation or misuse may

still lead to danger for

- the life and well-being of the operator or of third parties,

- the equipment and other tangible assets belonging to the owner/operator,

- efficient working with the equipment.

All persons involved in any way with starting up, operating, servicing and

maintaining the equipment must

- be suitably qualified

- know about welding and

- read and follow exactly the instructions given in this manual.

The instruction manual must be kept at the machine location at all times. In

addition to the instruction manual, copies of both the generally applicable

and the local accident prevention and environmental protection rules must be

kept on hand, and of course observed in practice.

All the safety instructions and danger warnings on the machine itself:

- must be kept in a legible condition

- must not be damaged

General remarks

Important!

“DANGER!” indicates an imminently hazardous situation which, if not

avoided, will result in death or serious injury. This signal word is to be

limited to the most extreme situations. This signal word is not used for

property damage hazards unless personal injury risk appropriate to this

level is also involved.

“WARNING!” indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury. This signal word is not used

for property damage hazards unless personal injury risk appropriate to this

level is also involved.

“CAUTION!” indicates a potentially hazardous situation which, if not avo-

ided, may result in minor or moderate injury. It may also be used to alert

alert against unsafe practices that may cause property damage.

“Important!” indicates practical hints and other useful special-information. It

is no signal word for a harmful or dangerous situation.

Whenever you see any of the symbols shown above, you must pay even

closer attention to the contents of the manual!

Page 6: Fronius TPS Operating Instructions

ud_fr_st_sv_00467 012005 II

Operation or storage of the power source outside the stipulated range is

deemed to be “not in accordance with the intended use”. The manufacturer

shall not be liable for any damage resulting herefrom.

Temperature range of ambient air:

- when operating: - 10 °C to + 40 °C (14 °F to 104 °F)

- when being transported or stored: - 25 °C to + 55 °C (-13 °F to 131 °F)

Relative atmospheric humidity:

- up to 50 % at 40 °C (104 °F)

- up to 90 % at 20 °C (68 °F)

Ambient air: Free of dust, acids, corrosive gases or substances etc.

Elevation above sea level: Up to 2000 m (6500 ft)

Ambient

conditions

The machine may only be used for jobs as defined by the “Intended

purpose”.

The machine may ONLY be used for the welding processes stated on the

rating plate.

Utilisation for any other purpose, or in any other manner, shall be deemed to

be "not in accordance with the intended purpose". The manufacturer shall not

be liable for any damage resulting from such improper use.

Utilisation in accordance with the “intended purpose” also comprises

- complete reading and following of all the instructions given in this manual

- complete reading and following of all the safety instructions and danger

warnings

- performing all stipulated inspection and servicing work.

The appliance must never be used for the following:

- Thawing pipes

- Charging batteries/accumulators

- Starting engines

The machine is designed to be used in industrial and workshop

environments. The manufacturer shall not be liable for any damage resulting

from use of the machine in residential premises.

Likewise the manufacturer will accept no liability for defective or faulty work

results.

Utilisation for

intended purpose

only

- must not be removed

- must not be covered, pasted or painted over

For information about where the safety instructions and danger warnings are

located on the machine, please see the section of your machine’s instruction

manual headed “General remarks”.

Any malfunctions which might impair machine safety must be eliminated

immediately - meaning before the equipment is next switched on.

It’s your safety that’s at stake!

General remarks

(continued)

Page 7: Fronius TPS Operating Instructions

ud_fr_st_sv_00467 012005III

Before starting work, all persons to be entrusted with carrying out work with

(or on) the machine shall undertake

- to observe the basic regulations on workplace safety and accident

prevention

- to read the sections on “safety rules” and the “warnings” contained in this

manual, and to sign to confirm that they have understood these and will

comply with them.

Before leaving the workplace, personnel must ensure that there is no risk of

injury or damage being caused during their absence.

Obligations of

personnel

Protection for

yourself and

other persons

When welding, you are exposed to many different hazards such as:

- flying sparks and hot metal particles

- arc radiation which could damage your eyes and skin

- harmful electromagnetic fields which may put the lives of cardiac pace-

maker users at risk

- electrical hazards from mains and welding current

- increased exposure to noise

The owner/operator undertakes to ensure that the only persons allowed to

work with the machine are persons who

- are familiar with the basic regulations on workplace safety and accident

prevention and who have been instructed in how to operate the machine

- have read and understood the sections on “safety rules” and the “war-

nings“ contained in this manual, and have confirmed as much with their

signatures

- be trained in such a way that meets with the requirements of the work

results

Regular checks must be performed to ensure that personnel are still working

in a safety-conscious manner.

Obligations of

owner/operator

Anybody working on the workpiece during welding must wear suitable pro-

tective clothing with the following characteristics:

- flame-retardant

- isolating and dry

- must cover whole body, be undamaged and in good condition

- protective helmet

- trousers with no turn-ups

- noxious welding fumes and gases.

Page 8: Fronius TPS Operating Instructions

ud_fr_st_sv_00467 012005 IV

The fumes given off during welding contain gases and vapors that are

harmful to health.

Welding fumes contain substances which may cause birth defects and

cancers.

Keep your head away from discharges of welding fumes and gases.

Do not inhale any fumes or noxious gases that are given off.

Extract all fumes and gases away from the workplace, using suitable means.

Ensure a sufficient supply of fresh air.

Where insufficient ventilation is available, use a respirator mask with an

independent air supply.

If you are not sure whether your fume-extraction system is sufficiently power-

ful, compare the measured pollutant emission values with the permitted

threshold limit values.

The harmfulness of the welding fumes will depend on e.g. the following

components:

- the metals used in and for the workpiece

- the electrodes

- coatings

- cleaning and degreasing agents and the like

For this reason, pay attention to the relevant Materials Safety Data Sheets

and the information given by the manufacturer regarding the components

listed above.

Keep all flammable vapors (e.g. from solvents) well away from the arc

radiation.

Hazards from

noxious gases

and vapours

Keep other people - especially children - well away from the equipment and

the welding operation while this is in progress. If there are still any other

persons nearby during welding, you must

- draw their attention to all the dangers (risk of being dazzled by the arc or

injured by flying sparks, harmful welding fumes, high noise immission

levels, possible hazards from mains or welding current ...)

- provide them with suitable protective equipment and/or

- erect suitable protective partitions or curtains.

Protection for

yourself and

other persons

(continued)

“Protective clothing” also includes:

- protecting your eyes and face from UV rays, heat and flying sparks with

an appropriate safety shield containing appropriate regulation filter glass

- wearing a pair of appropriate regulation goggles (with sideguards) behind

the safety shield

- wearing stout footwear that will also insulate even in wet conditions

- protecting your hands by wearing appropriate gloves (electrically insula-

ting, heat-proof)

To lessen your exposure to noise and to protect your hearing against injury,

wear ear-protectors!

Page 9: Fronius TPS Operating Instructions

ud_fr_st_sv_00467 012005V

Hazards from

mains and weld-

ing current

Flying sparks can cause fires and explosions!

Never perform welding anywhere near combustible materials.

Combustible materials must be at least 11 meters (35 feet) away from the

arc, or else must be covered over with approved coverings.

Have a suitable, approved fire extinguisher at the ready.

Sparks and hot metal particles may also get into surrounding areas through

small cracks and openings. Take suitable measures here to ensure that there

is no risk of injury or fire.

Do not perform welding in locations that are at risk from fire and/or explosion,

or in enclosed tanks, barrels or pipes, unless these latter have been

prepared for welding in accordance with the relevant national and

international standards.

Welding must NEVER be performed on containers that have had gases,

fuels, mineral oils etc. stored in them. Even small traces of these substances

left in the containers are a major explosion hazard.

Hazards from

flying sparks

An electric shock can be fatal. Every electric shock is hazardous to life.

Do not touch any live parts, either inside or outside the machine.

In MIG/MAG and TIG welding, the welding wire, the wire spool, the drive

rollers and all metal parts having contact with the welding wire are also live.

Always place the wirefeeder on an adequately insulated floor or base, or else

use a suitable insulating wirefeeder holder.

Ensure sufficient protection for yourself and for other people by means of a

dry base or cover that provides adequate insulation against the ground/frame

potential. The base or cover must completely cover the entire area between

your body and the ground/frame potential.

All cables and other leads must be firmly attached, undamaged, properly

insulated and adequately dimensioned. Immediately replace any loose

connections, scorched, damaged or underdimensioned cables or other

leads.

Do not loop any cables or other leads around your body or any part of your

body.

Never immerse the welding electrode (rod electrode, tungsten electrode,

welding wire, ...) in liquid in order to cool it, and never touch it when the

power source is ON.

Twice the open-circuit voltage of one single welding machine may occur

between the welding electrodes of two welding machines. Touching the

potentials of both electrodes simultaneously may be fatal.

Have the mains and the machine supply leads checked regularly by a

qualified electrician to ensure that the PE (protective earth) conductor is

functioning correctly.

Only run the machine on a mains network with a PE conductor, and plugged

into a power outlet socket with a protective-conductor contact.

Page 10: Fronius TPS Operating Instructions

ud_fr_st_sv_00467 012005 VI

If the following instructions are ignored, stray welding currents may occur.

These can cause:

- fires

- overheating of components that are connected to the workpiece

- destruction of PE conductors

- damage to the machine and other electrical equipment

Ensure that the workpiece clamp is tightly connected to the workpiece.

Attach the workpiece clamp as close as possible to the area to be welded.

On electrically conductive floors, the machine must be set up in such a way

that it is sufficiently insulated from the floor.

When using current supply distributors, twin head wire feeder fixtures etc.,

please note the following: The electrode on the unused welding torch/welding

tongs is also current carrying. Please ensure that there is sufficient insula-

ting storage for the unused welding torch/tongs.

Stray welding

currents

Hazards from

mains and weld-

ing current

(continued)

If the machine is run on a mains network without a PE conductor and

plugged into a power outlet socket without a protective-conductor contact,

this counts as gross negligence and the manufacturer shall not be liable for

any resulting damage.

Wherever necessary, use suitable measures to ensure that the workpiece is

sufficiently grounded (earthed).

Switch off any appliances that are not in use.

When working at great heights, wear a safety harness.

Before doing any work on the machine, switch it off and unplug it from the

mains.

Put up a clearly legible and easy-to-understand warning sign to stop anybody

inadvertently plugging the machine back into the mains and switching it back

on again.

After opening up the machine:

- discharge any components that may be storing an electrical charge

- ensure that all machine components are electrically dead.

If work needs to be performed on any live parts, there must be a second

person on hand to immediately switch off the machine at the main switch in

an emergency.

Page 11: Fronius TPS Operating Instructions

ud_fr_st_sv_00467 012005VII

It is the responsibility of the owner/operator to ensure that no electromagnetic

interference is caused to electrical and electronic equipment.

If electromagnetic interference is found to be occurring, the owner/operator is

obliged to take all necessary measures to prevent this interference.

Examine and evaluate any possible electromagnetic problems that may

occur on equipment in the vicinity, and the degree of immunity of this

equipment, in accordance with national and international regulations:

- safety features

- mains, signal and data-transmission leads

- IT and telecoms equipment

- measurement and calibration devices

Ancillary measures for preventing EMC problems:

a) Mains supply

- If electromagnetic interference still occurs, despite the fact that the mains

connection is in accordance with the regulations, take additional

measures (e.g. use a suitable mains filter).

b) Welding cables

- Keep these as short as possible

- Arrange them so that they run close together (to prevent EMI problems

as well)

- Lay them well away from other leads.

c) Equipotential bonding

d) Workpiece grounding (earthing)

- where necessary, run the connection to ground (earth) via suitable

capacitors.

e) Shielding, where necessary

- Shield other equipment in the vicinity

- Shield the entire welding installation.

Electromagnetic fields may cause as yet unknown damage to health.

- Effects on the health of persons in the vicinity, e.g. users of heart pace-

makers and hearing aids

- Users of heart pacemakers must take medical advice before going

anywhere near welding equipment or welding workplaces

- Keep as much space as possible between welding cables and head/body

of welder for safety reasons

- Do not carrywelding cables and hose pack over shoulder and do not loop

around body or or any part of body

EMC and EMI

Precautions

Keep your hands, hair, clothing and tools well away from all moving parts,

e.g.:

- fans

- toothed wheels, rollers, shafts

- wire-spools and welding wires

Do not put your fingers anywhere near the rotating toothed wheels of the

wirefeed drive.0

Covers and sideguards may only be opened or removed for as long as is

absolutely necessary to carry out maintenance and repair work.

Particular danger

spots

Page 12: Fronius TPS Operating Instructions

ud_fr_st_sv_00467 012005 VIII

Particular danger

spots

(continued)

When hoisting the machines by crane, only use suitable manufacturer-

supplied lifting devices.

- Attach the chains and/or ropes to all the hoisting points provided on the

suitable lifting device.

- The chains and/or ropes must be at an angle which is as close to the

vertical as possible.

- Remove the gas cylinder and the wirefeed unit (from MIG/MAG and TIG

units).

When hoisting the wirefeed unit by crane during welding, always use a

suitable, insulating suspension arrangement (MIG/MAG and TIG units).

If a machine is fitted with a carrying strap or carrying handle, remember that

this strap is ONLY to be used for lifting and carrying the machine by hand.

The carrying strap is NOT suitable for transporting the machine by crane,

fork-lift truck or by any other mechanical hoisting device.

Power sources for use in spaces with increased electrical danger (e.g.

boilers) must be identified by the (for “safety”) mark.

However, the power source should not be in such rooms.

Allow welding torches - and other items of equipment that are used at high

operating temperatures - to cool down before doing any work on them.

Special regulations apply to rooms at risk from fire and/or explosion. Observe

all relevant national and international regulations.

Risk of scalding from accidental discharge of hot coolant. Before unplugging

the connectors for coolant forward flow and return flow, switch off the cooling

unit.

When the welding wire emerges from the torch, there is a high risk of injury

(the wire may pierce the welder’s hand, injure his face and eyes ...). For this

reason, when feeder-inching etc., always hold the torch so that it is pointing

away from your body (machines with wirefeeder).

While the machine is in use:

- ensure that all the covers are closed and that all the sideguards are

properly mounted ...

- ... and that all covers and sideguards are kept closed.

Do not touch the workpiece during and after welding - risk of injury from

burning!

Slag may suddenly “jump” off workpieces as they cool. For this reason,

continue to wear the regulation protective gear, and to ensure that other

persons are suitably protected, when doing post-weld finishing on

workpieces.

Danger of colourless and odourless inert gas escaping unnoticed, when

using an adapter for the inert gas protection. Seal the adapter thread for the

inert gas connection using Teflon tape before assembly.

Page 13: Fronius TPS Operating Instructions

ud_fr_st_sv_00467 012005IX

Shielding-gas cylinders contain pressurized gas and may explode if they are

damaged. As shielding-gas cylinders are an integral part of the overall

welding outfit, they also have to be treated with great care.

Protect shielding-gas cylinders containing compressed gas from excessive

heat, mechanical impact, slag, naked flames, sparks and arcs.

Mount the shielding-gas cylinders in the vertical and fasten them in such a

way that they cannot fall over (i.e. as shown in the instruction manual).

Keep shielding-gas cylinders well away from welding circuits (and, indeed,

from any other electrical circuits).

Never hang a welding torch on a shielding-gas cylinder.

Never touch a shielding-gas cylinder with a welding electrode.

Explosion hazard - never perform welding on a pressurized shielding-gas

cylinder.

Use only shielding-gas cylinders that are suitable for the application in

question, together with matching, suitable accessories (pressure regulators,

hoses and fittings, ...). Only use shielding-gas cylinders and accessories that

are in good condition.

When opening the valve of a shielding-gas cylinder, always turn your face

away from the outlet nozzle.

Close the shielding-gas cylinder valve when no welding is being carried out.

When the shielding-gas cylinder is not connected up, leave the cap in place

on the shielding-gas cylinder valve.

Observe the manufacturer’s instructions and all relevant national and

international rules applying to shielding-gas cylinders and accessories.

Danger from

shielding-gas

cylinders

Safety precauti-

ons at the instal-

lation site and

when being

transported

A machine that topples over can easily kill someone! For this reason, always

place the machine on an even, firm floor in such a way that it stands firmly.

- An angle of inclination of up to 10° is permissible.

Special regulations apply to rooms at risk from fire and/or explosion. Observe

all relevant national and international regulations.

By means of internal instructions and checks, ensure that the workplace and

the area around it are always kept clean and tidy.

The appliance must only be installed and operated in accordance with the

protection type stated on the specifications plate.

When installing the appliance, please ensure a clearance radius of 0.5 m

(1.6ft.) , so that cool air can circulate freely.

When transporting the appliance, please ensure that the valid national and

regional guidelines and accident protection regulations are followed. This

applies in particular to guidelines in respect of dangers during transportation

and carriage.

Page 14: Fronius TPS Operating Instructions

ud_fr_st_sv_00467 012005 X

With parts sourced from other suppliers, there is no certainty that these parts

will have been designed and manufactured to cope with the stressing and

safety requirements that will be made of them. Use only original spares and

wearing parts (this also applies to standard parts).

Do not make any alterations, installations or modifications to the machine

without getting permission from the manufacturer first.

Replace immediately any components that are not in perfect condition.

Preventive and

corrective main-

tenance

Only operate the machine if all of its protective features are fully functional. If

any of the protective features are not fully functional, this endangers:

- the life and well-being of the operator or other persons

- the equipment and other tangible assets belonging to the owner/operator

- efficient working with the equipment.

Any safety features that are not fully functional must be put right before you

switch on the machine.

Never evade safety features and never put safety features out of order.

Before switching on the machine, ensure that nobody can be endangered by

your doing so.

- At least once a week, check the machine for any damage that may be

visible from the outside, and check that the safety features all function

correctly.

- Always fasten the shielding-gas cylinder firmly, and remove it altogether

before hoisting the machine by crane.

- Owing to its special properties (in terms of electrical conductivity, frost-

proofing, materials-compatibility, combustibility etc.), only original coolant

of the manufacturer is suitable for use in our machines.

- Only use suitable original coolant of the manufacturer.

- Do not mix original coolant of the manufacturer with other coolants.

- If any damage occurs in cases where other coolants have been used, the

manufacturer shall not be liable for any such damage, and all warranty

claims shall be null and void.

- Under certain conditions, the coolant is flammable. Only transport the

coolant in closed original containers, and keep it away from sources of

ignition.

- Used coolant must be disposed of properly in accordance with the

relevant national and international regulations. A safety data sheet is

available from your service centre and on the manufacturer’s homepage.

- Before starting welding - while the machine is still cool - check the

coolant level.

Safety precau-

tions in normal

operation

Before transportation, completely drain any coolant and dismantle the follo-

wing components:

- Wire feed

- Wire wound coil

- Gas bottle

Before commissioning and after transportation, a visual check for damage

must be carried out. Any damage must be repaired by trained service per-

sonnel before commissioning.

Safety precauti-

ons at the instal-

lation site and

when being

transported

(continued)

Page 15: Fronius TPS Operating Instructions

ud_fr_st_sv_00467 012005XI

Equipment with CE-markings fulfils the basic requirements of the Low-

Voltage and Electromagnetic Compatibility Guideline (e.g. relevant product

standards according to EN 60 974). .

Safety markings

Equipment marked with the CSA-Test Mark fulfils the requirements made in

the relevant standards for Canada and the USA.

The owner/operator is obliged to have a safety inspection performed on the

machine at least once every 12 months.

The manufacturer also recommend the same (12-month) interval for regular

calibration of power sources.

A safety inspection, by a trained and certified electrician, is prescribed:

- after any alterations

- after any modifications or installations of additional components

- following repairs, care and maintenance

- at least every twelve months.

Observe the relevant national and international standards and directives in

connection with the safety inspection.

More detailed information on safety inspections and calibration is available

from your regional or national service centre, who will be pleased to provide

you with copies of the necessary documents upon request.

Safety inspection

Preventive and

corrective main-

tenance

(continued)

When ordering spare parts, please state the exact designation and the

relevant part number, as given in the spare parts list. Please also quote the

serial number of your machine.

The user is responsible for the data security of changes made to factory

settings. The manufacturer is not liable, if personal settings are deleted.

Data security

Do not dispose of this device with normal domestic waste!

To comply with the European Directive 2002/96/EC on Waste Electrical and

Electronic Equipment and its implementation as national law, electrical

equipment that has reached the end of its life must be collected separately

and returned to an approved recycling facility Any device that you no longer

require must be returned to our agent, or find out about the approved collec-

tion and recycling facilities in your area.

Ignoring this European Directive may have potentially adverse affects on the

environment and your health!

Disposal

Page 16: Fronius TPS Operating Instructions

ud_fr_st_sv_00467 012005 XII

Copyright to this instruction manual remains the property of the

manufacturer.

The text and illustrations are all technically correct at the time of going to

print. The right to effect modifications is reserved. The contents of the in-

struction manual shall not provide the basis for any claims whatever on the

part of the purchaser. If you have any suggestions for improvement, or can

point out to us any mistakes which you may have found in the manual, we

should be most grateful for your comments.

Copyright

Page 17: Fronius TPS Operating Instructions

1

Table of contents

General remarks ........................................................................................................................................... 5

Machine concept ...................................................................................................................................... 5

Functional principle .................................................................................................................................. 5

Areas of utilisation .................................................................................................................................... 5

Warning notices affixed to the machine ................................................................................................... 6

Special versions ............................................................................................................................................ 7

General remarks ...................................................................................................................................... 7

Alu-Edition ................................................................................................................................................ 7

CrNi-Edition .............................................................................................................................................. 7

CMT Variants ........................................................................................................................................... 7

TIME 5000 Digital ..................................................................................................................................... 8

System components ...................................................................................................................................... 9

General remarks ...................................................................................................................................... 9

Overview .................................................................................................................................................. 9

Descriptions of the control panels ............................................................................................................... 10

General remarks .................................................................................................................................... 10

Standard control panel ........................................................................................................................... 10

“Comfort” control panel .......................................................................................................................... 14

“US” control panel .................................................................................................................................. 18

TIME 5000 Digital control panel ............................................................................................................. 22

“Remote” operating panel ...................................................................................................................... 27

“CMT” control panel ............................................................................................................................... 28

Connections - switches - mechanical components ..................................................................................... 29

TPS 2700 power source ......................................................................................................................... 29

TS 4000 / 5000, TPS 3200 / 4000 / 5000 power sources ...................................................................... 30

Minimum equipment needed for welding..................................................................................................... 31

General remarks .................................................................................................................................... 31

MIG/MAG welding .................................................................................................................................. 31

TIG-DC welding...................................................................................................................................... 31

Rod electrode (MMA) welding ................................................................................................................ 31

Before commissioning ................................................................................................................................. 32

General remarks .................................................................................................................................... 32

Utilisation for intended purpose only ...................................................................................................... 32

Machine set-up regulations .................................................................................................................... 32

Mains connection ................................................................................................................................... 32

Connecting up the mains cable on US power sources ................................................................................ 33

General remarks .................................................................................................................................... 33

Stipulated mains cables and strain relief devices ................................................................................... 33

Safety ..................................................................................................................................................... 33

Connecting up the mains cable .............................................................................................................. 33

Exchanging the strain relief device ........................................................................................................ 34

Commissioning ........................................................................................................................................... 36

General remarks .................................................................................................................................... 36

Remarks on the cooling unit ................................................................................................................... 36

Overview ................................................................................................................................................ 36

Installation of the system components ........................................................................................................ 37

Installation of the system components (overview) .................................................................................. 37

Fixing strain relief device in place and connecting interconnecting hosepack ............................................ 38

Fixing the strain relief device in place .................................................................................................... 38

Connecting interconnecting hosepack ................................................................................................... 39

Connecting gas cylinder and making an earth connection .......................................................................... 40

Connecting up the gas cylinder .............................................................................................................. 40

Making an earth connection ................................................................................................................... 40

Page 18: Fronius TPS Operating Instructions

2

Fitting the welding torch and putting the cooling unit into service................................................................ 41

Fitting the welding torch ......................................................................................................................... 41

Putting the cooling unit into service ........................................................................................................ 41

MIG/MAG operating modes ........................................................................................................................ 42

General remarks .................................................................................................................................... 42

Symbols and abbreviations .................................................................................................................... 42

2-step mode ........................................................................................................................................... 43

4-step mode ........................................................................................................................................... 43

Special 4-step mode (aluminium welding start-up) ................................................................................ 44

Spot welding ........................................................................................................................................... 44

MIG/MAG welding ....................................................................................................................................... 45

MIG/MAG welding .................................................................................................................................. 45

Ignition time-out function ........................................................................................................................ 46

Arc break watchdog function .................................................................................................................. 47

Standard manual welding ....................................................................................................................... 47

“Spatter-free ignition” option ................................................................................................................... 48

SynchroPuls option ................................................................................................................................ 49

Special 2-step mode for robot interface ................................................................................................. 50

TIG welding ................................................................................................................................................. 52

General remarks .................................................................................................................................... 52

Preparations ........................................................................................................................................... 52

TIG welding ............................................................................................................................................ 52

Igniting the arc ........................................................................................................................................ 53

Finishing welding .................................................................................................................................... 53

TIG-Comfort-Stop option ........................................................................................................................ 54

TIG welding with TIG Comfort Stop ........................................................................................................ 56

CSS parameter ...................................................................................................................................... 56

Rod electrode (MMA) welding ..................................................................................................................... 57

General remarks .................................................................................................................................... 57

Preparations ........................................................................................................................................... 57

Rod electrode (MMA) welding ................................................................................................................ 57

Hot-Start function ................................................................................................................................... 58

Anti-stick function ................................................................................................................................... 58

Job mode .................................................................................................................................................... 59

General remarks .................................................................................................................................... 59

Creating a job ......................................................................................................................................... 59

Copying/overwriting a job ....................................................................................................................... 60

Deleting a job ......................................................................................................................................... 61

Retrieving a job ...................................................................................................................................... 61

Job correction.............................................................................................................................................. 62

General remarks .................................................................................................................................... 62

Accessing the job correction menu ........................................................................................................ 62

Changing a parameter ........................................................................................................................... 62

Exiting the job correction menu .............................................................................................................. 63

Available parameters ............................................................................................................................. 63

Permanently settable parameters .......................................................................................................... 63

Parameters that can be corrected at a later time ................................................................................... 66

Shielding gas set-up menu .......................................................................................................................... 68

General remarks .................................................................................................................................... 68

Standard control panel: Accessing ......................................................................................................... 68

“Comfort” / “US” control panel: Accessing .............................................................................................. 68

Gas test parameters .............................................................................................................................. 69

Set-up menu: Level 1 .................................................................................................................................. 70

General remarks .................................................................................................................................... 70

Standard control panel: Accessing ......................................................................................................... 70

Standard control panel: Parameters ....................................................................................................... 70

“Comfort” / “US” control panel: Accessing .............................................................................................. 70

“Comfort” / “US” control panel: Parameters ........................................................................................... 72

Page 19: Fronius TPS Operating Instructions

3

Process parameters .................................................................................................................................... 73

MIG/MAG standard synergic/pulse synergic welding ............................................................................. 73

TIG welding ............................................................................................................................................ 75

Rod electrode (MMA) welding ................................................................................................................ 75

Operating-mode parameters ....................................................................................................................... 76

Special 2-step mode for robot interface ................................................................................................. 76

Special 4-step mode (aluminium welding start-up) ................................................................................ 77

Spot welding ........................................................................................................................................... 77

Set-up menu: Level 2 .................................................................................................................................. 78

General remarks .................................................................................................................................... 78

Standard control panel ........................................................................................................................... 78

“Comfort” / “US” control panel ................................................................................................................ 78

Parameters 2nd........................................................................................................................................... 80

MIG/MAG standard synergic/pulse synergic welding ............................................................................. 80

Operating power sources in parallel ....................................................................................................... 82

TimeTwin Digital process ....................................................................................................................... 83

TIG welding ............................................................................................................................................ 83

Rod electrode (MMA) welding ................................................................................................................ 84

Push-pull unit .............................................................................................................................................. 87

General remarks .................................................................................................................................... 87

Calibrating the push-pull unit .................................................................................................................. 87

Service codes for push-pull calibration ....................................................................................................... 90

Safety ..................................................................................................................................................... 90

Error codes shown when the drive units are engaged (“engaged” calibration) ...................................... 90

Error codes shown when the drive units are engaged (“engaged” calibration) ...................................... 91

Measuring the welding circuit resistance “r” ................................................................................................ 93

General remarks .................................................................................................................................... 93

Measuring the welding circuit resistance “r” ........................................................................................... 93

Indicating the welding circuit inductivity L .................................................................................................... 95

Indicating the welding circuit inductivity L ............................................................................................... 95

Correct arrangement of the hosepack ................................................................................................... 95

Troubleshooting........................................................................................................................................... 96

General remarks .................................................................................................................................... 96

Displayed service codes ........................................................................................................................ 96

Power source - troubleshooting ........................................................................................................... 102

Care, maintenance and disposal ............................................................................................................... 105

General remarks .................................................................................................................................. 105

Every start-up ....................................................................................................................................... 105

Every 2 months .................................................................................................................................... 105

Every 6 months .................................................................................................................................... 105

Disposal ............................................................................................................................................... 105

Technical data ........................................................................................................................................... 106

Special voltages ................................................................................................................................... 106

TPS 2700 ............................................................................................................................................. 106

TPS 2700 MV ....................................................................................................................................... 107

TPS 3200 ............................................................................................................................................. 108

TPS 3200 MV ....................................................................................................................................... 109

TS/TPS 4000 ........................................................................................................................................ 110

TS/TPS 4000 MV .................................................................................................................................. 111

TS/TPS 5000 ........................................................................................................................................ 112

TS/TPS 5000 MV .................................................................................................................................. 113

Technical data - US power source ........................................................................................................ 113

Technical data Alu-Edition, CrNi-Edition and CMT variants ................................................................... 113

TIME 5000 Digital .................................................................................................................................. 114

Welding program databases ...................................................................................................................... 115

Explanation of symbols ......................................................................................................................... 115

Page 20: Fronius TPS Operating Instructions

4

Terms and abbreviations used ................................................................................................................... 116

General remarks ................................................................................................................................... 116

Terms and abbreviations ....................................................................................................................... 116

Spare parts lists

Fronius Worldwide

Page 21: Fronius TPS Operating Instructions

5

The TransSynergic (TS) 4000 and TS

5000, TransPuls Synergic (TPS) 2700,

TPS 3200, TPS 4000 and TPS 5000

power sources are completely digitised,

microprocessor controlled inverter power

sources.

The modular design and potential for

system add-ons ensure a high degree of

flexibility. The machines can be adapted to

any specific situation.

All machines except TS 4000/5000 have

multi-processer capability:

- MIG/MAG welding

- TIG welding with touch-down ignition

- Rod electrode (MMA) welding

VR 7000

Fig.1 The TS 4000 / 5000, TPS 3200 / 4000 /

5000 and TPS 2700 welding machines

The machines are used in workshops and industry: manual and automated applications

with classical steel, galvanised sheets, chrome/nickel and aluminium.

The integral 4-roller drive, high performance and low weight of the TPS 2700 power

source make it the ideal choice for portable applications on building sites or in repair

workshops.

The TS 4000/5000 and TPS 3200/4000/5000 power sources are designed for:

- automobile and component supply industry,

- equipment construction,

- chemical plant construction,

- machine and tracked vehicle manufacturing,

- shipyards, etc.

General remarks

Functional prin-

ciple

Machine concept

Areas of utilisati-

on

The central control and regulation unit of the power sources is coupled with a digital

signal processor. The central control and regulation unit and signal processor control the

entire welding process.

During the welding process, the actual data is measured continuously and the machine

responds immediately to any changes. The control algorithms developed by the manuf-

acturer ensure that the specified target status is maintained.

This results in:

- a precise welding process,

- exact reproducibility of all results

- excellent welding properties.

Page 22: Fronius TPS Operating Instructions

6

Warning notices

affixed to the

machine

US power sources come with extra warning labels affixed to the unit. The warning

labels must NOT be removed or painted over.

Fig.2 US “Remote” power source with additional warning signs

Only on the “TPS 2700” power source

and on wirefeeder units

Page 23: Fronius TPS Operating Instructions

7

Special versions

General remarks Professional processing of specific materials requires welding programs that are special-

ly matched to the different materials in question. The special versions of the digital power

sources are perfectly matched to these requirements. As a result the most important

welding programs can be called up directly from the operating panel. Furthermore, the

power sources are characterised by standard features that assist the user when welding

these materials.

Important! The Technical Data of the special versions corresponds to the Technical

Data of the standard power sources.

Alu-Edition

CrNi-Edition

The Alu-Edition power sources were developed for perfect and careful processing of

aluminium. Special aluminium welding programs assist in the professional processing of

aluminium. The Alu-Edition power sources are equipped as standard with the following

options:

- Special aluminium welding programs

- SynchroPuls option

The CrNi-Edition power sources were developed for perfect and careful processing of

CrNi. Special CrNi welding programs assist in the professional processing of high-grade

steels. The CrNi-Edition power sources are equipped as standard with the following

options:

- Special CrNi welding programs

- SynchroPuls option

- TIG-Comfort-Stop option

- TIG torch connection

- Gas solenoid valve

Important! It is not possible to install the “Uni Box” system add-on on the CrNi-Edition

(e.g. for the field bus connection of a robot control). However, the CrNi-Edition supports

a robot connection via robot interfaces ROB 4000 / 5000.

CMT Variants In addition to conventional welding processes, the CMT variants can also control the

CMT process. CMT (Cold Metal Transfer) is a special MIG short-arc process. Its special

features include low heat application and a controlled, low-current material transfer. CMT

is suitable for:

- Virtually spatter-free MIG soldering

- Welding on light-gauge sheet with minimal distortion

- Joining steel and aluminium (weld soldering)

Page 24: Fronius TPS Operating Instructions

8

TIME 5000 Digital Concept

As a universal power source, the TIME 5000 Digital is particularly suited for manual

applications. In addition to conventional welding processes, the TIME 5000 Digital also

supports high-performance welding processes. The TIME high-performance welding

process now has a welding system with digital technology.

Functional principle

Compared with conventional MIG/MAG processes, the following features bring about

faster welding speeds, with a 30 % increase in welding performance:

- Power module with high voltage reserves

- High-performance welding programs

- Specially selected shielding gases

- High-performance wirefeeder with water-cooled disk armature motor for wirefeed

speeds of up to 30 m/min

- TIME welding torch with dual circuit cooling system

Field of application

Anywhere where long seams, large weld cross-sections and controlled heat insertion are

required, e.g.:

- machine construction

- steel engineering

- crane construction

- shipbuilding

- boiler manufacture

The new TIME 5000 Digital power source can also be used in automated applications.

Material types

The high-performance welding process is especially suitable for

- unalloyed steels

- low-alloy steels EN 10027

- fine-grained structural steels up to 890 N/mm²

- steels resistant to low temperatures

Page 25: Fronius TPS Operating Instructions

9

System components

General remarks The power sources of the Digital Series can be run with various system components and

options. This makes it possible to optimize procedures and to simplify machine handling

and operation, as necessitated by the particular field of application for which the power

source is to be used.

Overview

FRONIUS

Wirefeeders

Interconnecting cables

“Human” hosepack boom

Trolley, and

gas-cylinder holders

Wirefeeder mount

Robot accessories

Fig.3 Overview of system components

Remote control unit

Welding torch

Power source

Cooling units

Grounding (earthing) cable

and electrode cable

Page 26: Fronius TPS Operating Instructions

10

Descriptions of the control panels

Standard control

panel

Important! On the “Standard” control panel, only the MIG/MAG standard synergic

welding process is available. The following processes and functions are not available

and cannot be retro-fitted:

- MIG/MAG pulse synergic welding process,

- Job Mode

- TIG welding

- Rod electrode (MMA) welding

- Spot welding

Any changes to the parameters “Welding current” and “Arc-length correction” have to be

made on the wirefeeder.

General remarks The functions on the control panels are all arranged in a very logical way. The various

parameters needed for welding are easy to select, by pressing the appropriate button,

and can easily be

- altered with buttons (“Standard”) or the adjusting dial (“Comfort”), and

- shown on the display during welding

Thanks to the “Synergic” function, whenever you alter any one parameter, suitable

adjustments will automatically be made to all the other parameters.

Note! Owing to software updates, you may find that your machine has certain

functions that are not described in these Operating Instructions, or vice-versa.

Also, certain illustrations may be very slightly different from the actual controls

on your machine. However, these controls function in exactly the same way.

Page 27: Fronius TPS Operating Instructions

11

“Standard”

control panel

(continued)

(23)(22)

(21) (20)

(14)(13)(12)(11) (9)(8)

(7) (6) (5)

(2)

Fig.4 “Standard” control panel

Warning! Operating the equipment incorrectly can cause serious injury and

damage. Do not use the functions described here until you have read and

completely understood all of the following documents:

- these Operating Instructions

- all operating instructions for the system components, especially the “Safety

rules”

Item Function

(2) Parameter selection button

for selecting the following parameters:

- sheet thickness

- welding current

- wirefeed speed

(5) Mode button(s)

for selecting the operating mode

2-step mode

4-step mode

special 4-step mode (aluminium welding start-up)

(6) Material button(s)

for selecting the filler metal and shielding gas to be used. Parameters SP1 and

SP2 are reserved for additional materials.

(7) Wire diameter button

for selecting the wire diameter to be used. Parameter SP is reserved for additional

wire diameters.

Page 28: Fronius TPS Operating Instructions

12

Standard control

panel

(continued)

(8) Welding current parameter

for selecting the welding current. Before the start of welding, the machine auto-

matically displays a guideline value based on the programmed parameters. During

welding, the actual value is displayed.

(9) Welding voltage parameter

for selecting the welding voltage. Before the start of welding, the machine auto-

matically displays a guideline value based on the programmed parameters. During

welding, the actual value is displayed.

(11) Sheet thickness parameter

for selecting the sheet thickness in mm or in. This automatically sets all the other

parameters as well.

(12) Wirefeed speed parameter

for selecting the wirefeed speed in m/min or ipm. Other parameters that are

dependent on this are also automatically adjusted accordingly.

(13) Overtemperature indicator

lights up if the power source overheats (e.g. because the duty cycle has been

exceeded). For more information on this, see the “Troubleshooting” section.

(14) HOLD indicator

every time a welding operation is finished, the actual values for welding current

and welding voltage are stored, and the “Hold” indicator lights up.

(20) Intermediate arc indicator

a spatter-prone “intermediate arc” occurs between the dip-transfer arc and the

spray arc. To alert you to this critical area - and help you avoid it - the intermediate

arc indicator lights up.

(21) Store button ... for accessing the Set-up menu

Important! If you press the Store button (21) and the “Material” button (6) at the

same time, the display shows the software version.

If you then press the “Material” button (6) on its own, the version number of the

welding database appears on the display (e.g.: 0 | 029 = M0029).

If you then press the “Material” button (6) a second time, the number of the wire-

feeder (A, or B in the case of twin-head mounts) and the software version n° of

the wirefeeder appear on the display (e.g.: A 1.5 | 0.23).

If you press the “Material” button (6) a third time, the operating time is displayed.

This registers the actual arc burning time since the initial start-up.

- Example: “654 | 32.1” = 65,432.1 h = 65,432 h | 6 min

Important! The operating time display is not suitable as a basis for calculating

hiring fees, guarantee, etc.

To exit, press the Store button (21).

(22) Gas-test button

to set the required quantity of gas at the pressure regulator.

After you press this button, gas will flow out for 30 s. Press the button again to

stop the gas test-flow before the end of this period.

Important! If you press the Store button (21) and the gas test button (22) at the

same time, the display shows the specified gas pre-flow time (e.g. “GPr | 0.1 s).

- You can alter the gas pre-flow time with the adjusting dial (1)

Page 29: Fronius TPS Operating Instructions

13

If you now press the “Process” button (4), the display gives you a read-out of the

pre-set gas post-flow time (e.g. “GPo | 0.5 s”)

- The gas post-flow time can be altered with the adjusting dial (1)

To exit, press the Store button (21).

(23) “Feeder inching” button

for feeding the welding wire into the torch hosepack with no accompanying flow of

gas or current

For information on the various wire inching sequences that are possible when the

welder presses and holds the “Feeder inching” button, see the section headed

“The Set-up Menu”.

- sub-section “Process parameters”, parameter “Fdi”.

Important! If you press the Store button (21) and the feeder inching button (23) at

the same time, the display gives a read-out of the pre-set feeder-inching speed

(e.g. Fdi | 10 m/min or Fdi | 393.70 ipm).

- You can alter the feeder inching speed with the “Material” buttons (6)

To exit, press the Store button (21).

Standard control

panel

(continued)

Page 30: Fronius TPS Operating Instructions

14

“Comfort” cont-

rol panel

(1)(24)

(23)

(22)

(21) (20)

(19)

(18)

(17)(16)

(15)

(14)

(13)

(12)(11)

(10) (9)(8)

(7) (6)

(5)

(4)

(3)(2)

(19)

Fig.5 “Comfort” control panel

Warning! Operating the equipment incorrectly can cause serious injury and

damage. Do not use the functions described here until you have read and

completely understood all of the following documents:

- these Operating Instructions

- all operating instructions for the system components, especially the “Safety

rules”

Item Function

(1) Adjusting dial

for changing parameters. If the indicator next to the adjusting dial is lit up, then the

selected parameter is one that can be altered.

(2) Parameter selection button

for selecting the following parameters

- “a”-dimension

- sheet thickness

- welding current

- wirefeed speed

- F1 indicator

- wirefeed-drive current-input indicator

If the indicator is lit up on the parameter selection button and on the adjusting dial,

then the indicated / selected parameter can be altered with the adjusting dial.

Page 31: Fronius TPS Operating Instructions

15

“Comfort” cont-

rol panel

(continued)

(3) Parameter selection button ... for selecting the following parameters:

- arc-length correction

- droplet-detachment / arc-force (dynamic) correction

- welding voltage

- welding speed

- job n°

- F3 indicator

If the indicator is lit up on the parameter selection button and on the adjusting dial,

then the indicated / selected parameter can be altered with the adjusting dial.

(4) Process button(s)

for selecting the welding process

MIG/MAG pulse synergic welding

MIG/MAG standard synergic welding

MIG/MAG standard manual welding

Job mode

TIG welding with touch-down ignition

rod electrode (MMA) welding

(5) Mode button(s)

for selecting the operating mode

2-step mode

4-step mode

special 4-step mode (aluminium welding start-up)

spot welding mode

operating Mode

(6) Material button(s)

for selecting the filler metal and shielding gas to be used. Parameters SP1 and

SP2 are reserved for additional materials.

(7) Wire diameter button

for selecting the wire diameter to be used. Parameter SP is reserved for additional

wire diameters.

(8) Welding current parameter

for selecting the welding current. Before the start of welding, the machine auto-

matically displays a guideline value based on the programmed parameters. During

welding, the actual value is displayed.

(9) Welding voltage parameter

for selecting the welding voltage. Before the start of welding, the machine auto-

matically displays a guideline value based on the programmed parameters. During

welding, the actual value is displayed.

Important! The power source has a pulsating open-circuit voltage. Where the

“Rod electrode (MMA) welding” process has been selected, the display indicates

an average welding-voltage value of 40 V before the start of welding (open circuit).

For welding start-up and the main welding operation itself, however, a welding

voltage of max. 50 V (TPS 2700) or 70 V (TS 4000 / 5000, TPS 3200 / 4000 /

5000) is available. Optimum ignition properties are ensured.

(10) “a”-dimension parameter

for selecting the „a“-dimension. The wirespeed and welding current/voltage are

calculated as a function of the specified welding speed.

Important! Before you select the “a”-dimension, the welding speed parameter

(17) must be set (recommended welding speed for manual welding: ~35 cm/min

or 13.78 ipm)

(11) Sheet thickness parameter

for selecting the sheet thickness in mm or in. This automatically sets all the other

parameters as well.

Page 32: Fronius TPS Operating Instructions

16

“Comfort” cont-

rol panel

(continued)

(12) Wirefeed speed parameter

for selecting the wirefeed speed in m/min or ipm. Other parameters that are

dependent on this are also automatically adjusted accordingly.

(13) Overtemperature indicator

lights up if the power source overheats (e.g. because the duty cycle has been

exceeded). For more information on this, see the “Troubleshooting” section

(14) HOLD indicator

every time a welding operation is finished, the actual values for welding current

and welding voltage are stored, and the “Hold” indicator lights up.

(15) Arc-length correction parameter

for correcting the arc length

- shorter arc length

0 neutral arc length

+ longer arc length

(16) Droplet detachment, arc force correction and arc force parameter

a different function depending on the process being used.

MIG/MAG standard synergic welding ... for influencing the short-circuiting dynamic

at the instant of droplet transfer

- harder, more stable arc

0 neutral arc

+ soft, low-spatter arc

MIG/MAG pulse synergic welding ... continuous correction facility for the droplet

detachment force

- lower droplet-detachment force

0 neutral droplet-detachment force

+ increased droplet-detachment force

MIG/MAG standard manual welding ... for influencing the short-circuiting dynamic

at the instant of droplet transfer

0 harder, more stable arc

10 soft, low-spatter arc

Rod electrode (MMA) welding ... for influencing the short-circuiting amperage at

the instant of droplet transfer

0 soft, low-spatter arc

100 harder, more stable arc

(17) Welding speed parameter

for selecting the welding speed. The wirespeed and welding current & voltage are

calculated as a function of the “a”-dimension parameter (10).

(18) JOB N° parameter

for retrieving parameter records/job numbers that were previously saved with the

“Store” button.

(19) F1/wirefeed drive current input/F3 indicators

for displaying defined parameters

(20) Intermediate arc indicator

between the dip-transfer arc and the spray arc, a spatter-prone “intermediate arc”

occurs. To alert you to this critical area - and help you avoid it - the intermediate

arc indicator lights up.

Page 33: Fronius TPS Operating Instructions

17

“Comfort” cont-

rol panel

(continued)

(21) „Store“ button

for accessing the Set-up menu or (in Job Mode) for storing parameter settings.

Important! If you press the Store button (21) and the “Material” button (6) at the

same time, the display shows the software version.

If you then press the “Material” button (6) on its own, the version number of the

welding database appears on the display (e.g.: 0 | 029 = M0029).

If you then press the “Material” button (6) a second time, the number of the wire-

feeder (A, or B in the case of twin-head mounts) and the software version n° of

the wirefeeder appear on the display (e.g.: A 1.5 | 0.23).

If you press the “Material” button (6) a third time, the operating time is displayed.

This registers the actual arc burning time since the initial start-up.

- Example: “654 | 32.1” = 65,432.1 h = 65,432 h | 6 min

Important! The operating time display is not suitable as a basis for calculating

hiring fees, guarantee, etc.

To exit, press the Store button (21).

(22) Gas-test button

to set the required quantity of gas at the pressure regulator. After you press this

button, gas will flow out for 30 s. Press the button again to stop the gas test-flow

before the end of this period.

Important! If you press the Store button (21) and the gas test button (22) at the

same time, the display shows the specified gas pre-flow time (e.g. “GPr | 0.1 s).

- You can alter the gas pre-flow time with the adjusting dial (1)

Now press the “Process” button (4) to display the specified gas post-flow time

(e.g. “GPo | 0.5 s”)

- The gas post-flow time can be altered with the adjusting dial (1)

To exit, press the Store button (21).

(23) “Feeder inching” button

for feeding the welding wire into the torch hosepack with no accompanying flow of

gas or current

For information on the various wire-inching sequences that are possible when the

welder presses and holds the “Feeder inching” button, see the section headed

“The Set-up Menu”,

- sub-section “Process parameters”, parameter “Fdi”.

Important! If you press the Store button (21) and the “Feeder inching” button (23)

at the same time, the display shows the specified feeder inching speed (e.g. “Fdi |

10 m/min” or “Fdi | 393.70 ipm”).

- You can alter the feeder-inching speed with the adjusting dial (1)

To exit, press the Store button (21).

Page 34: Fronius TPS Operating Instructions

18

“US” control

panel

(1)(24)

(23)

(19)

(18)

(16)

(15)

(14)

(13)

(12)(11)

(9)(8) (3)(2)

(19)

(22)

(21) (20)

(7) (6)

(5)

(4)

Fig.6 “US” control panel

Warning! Operating the equipment incorrectly can cause serious injury and

damage. Do not use the functions described here until you have read and

completely understood all of the following documents:

- these Operating Instructions

- all operating instructions for the system components, especially the “Safety

rules”

(24) Keylock switch (optional)

When the key is in the horizontal position, the following functions are disabled:

- selecting the welding process with the “Process” button(s) (4)

- selecting the operating mode with the “Mode” button(s) (5)

- selecting the filler metal with the “Material” button(s) (6)

- accessing the set-up menu with the “Store” button (21)

- accessing the job-correction menu (see the section headed “Job mode”)

Important! In this case, the functions available on the control panel of the system

components are then restricted in the same way as those of the control panel on

the power source.

“Comfort” control

panel

(continued)

Item Function

(1) Adjusting dial

for changing parameters. If the indicator next to the adjusting dial is lit up, then the

selected parameter is one that can be altered.

Page 35: Fronius TPS Operating Instructions

19

“US” control

panel

(continued)

(2) Parameter selection button

- sheet thickness

- welding current

- wirefeed speed

- F1 indicator

- wirefeed-drive current input indicator

If the indicator is lit up on the parameter selection button and on the adjusting dial,

then the indicated / selected parameter can be altered with the adjusting dial.

(3) Parameter selection button ... for selecting the following parameters:

- arc-length correction

- droplet-detachment / arc-force (dynamic) correction

- welding voltage

- job n°

- indicator F3

If the indicator is lit up on the parameter selection button and on the adjusting dial,

then the indicated / selected parameter can be altered with the adjusting dial.

(4) Process button(s)

for selecting the welding process

MIG/MAG pulse synergic welding

MIG/MAG standard synergic welding

MIG/MAG standard manual welding

Job mode

TIG welding with touch-down ignition

rod electrode (MMA) welding

(5) Mode button(s)

for selecting the operating mode

2-step mode

4-step mode

special 4-step mode (aluminium welding start-up)

spot welding mode

operating Mode

(6) Material button(s)

for selecting the filler metal and shielding gas to be used. Parameters SP1 and

SP2 are reserved for additional materials.

(7) Wire diameter button

for selecting the wire diameter to be used. Parameter SP is reserved for additional

wire diameters.

(8) Welding current parameter

for selecting the welding current. Before the start of welding, the machine auto-

matically displays a guideline value based on the programmed parameters. During

welding, the actual value is displayed.

(9) Welding voltage parameter

for selecting the welding voltage. Before the start of welding, the machine auto-

matically displays a guideline value based on the programmed parameters. During

welding, the actual value is displayed.

Important! The power source has a pulsating open-circuit voltage. Where the

“Rod electrode (MMA) welding” process has been selected, the display indicates

an average welding-voltage value of 40 V before the start of welding (open circuit).

For welding start-up and the main welding operation itself, however, a welding

voltage of max. 50 V (TPS 2700) or 70 V (TS 4000 / 5000, TPS 3200 / 4000 /

5000) is available. Optimum ignition properties are ensured.

Page 36: Fronius TPS Operating Instructions

20

“US” control

panel

(continued)

(11) Sheet thickness parameter

for selecting the sheet thickness in mm or in. This automatically sets all the other

parameters as well.

(12) Wirefeed speed parameter

for selecting the wirefeed speed in m/min or ipm. Other parameters that are

dependent on this are also automatically adjusted accordingly.

(13) Overtemperature indicator

lights up if the power source overheats (e.g. because the duty cycle has been

exceeded). For more information on this, see the “Troubleshooting” section.

(14) HOLD indicator

every time a welding operation is finished, the actual values for welding current

and welding voltage are stored, and the “Hold” indicator lights up.

(15) Arc length correction parameter ... for correcting the arc length

- shorter arc length

0 neutral arc length

+ longer arc length

(16) Droplet detachment, arc force correction and arc force parameter

a different function depending on the process being used.

MIG/MAG standard synergic welding ... for influencing the short-circuiting dynamic

at the instant of droplet transfer

- harder, more stable arc

0 neutral arc

+ soft, low-spatter arc

MIG/MAG pulse synergic welding ... continuous correction facility for the droplet

detachment force

- lower droplet-detachment force

0 neutral droplet-detachment force

+ increased droplet-detachment force

MIG/MAG standard manual welding ... for influencing the short-circuiting dynamic

at the instant of droplet transfer

0 harder, more stable arc

10 soft, low-spatter arc

Rod electrode (MMA) welding ... for influencing the short-circuiting amperage at

the instant of droplet transfer

0 soft, low-spatter arc

100 harder, more stable arc

(18) JOB N° parameter

for retrieving parameter records/job numbers that were previously saved with the

“Store” button.

(19) F1/wirefeed drive current input/F3 indicators

for displaying defined parameters

(20) Intermediate arc indicator

between the dip-transfer arc and the spray arc, a spatter-prone “intermediate arc”

occurs. To alert you to this critical area - and help you avoid it - the intermediate

arc indicator lights up.

Page 37: Fronius TPS Operating Instructions

21

“US” control

panel

(continued)

(21) „Store“ button

for accessing the Set-up menu or (in Job Mode) for storing parameter settings.

Important! If you press the Store button (21) and the “Material” button (6) at the

same time, the display shows the software version.

If you then press the “Material” button (6) on its own, the version number of the

welding database appears on the display (e.g.: “0 | 029” = M0029).

If you then press the “Material” button (6) a second time, the number of the wire-

feeder (A, or B in the case of twin-head mounts) and the software version n° of

the wirefeeder appear on the display (e.g.: A 1.5 | 0.23).

If you press the “Material” button (6) a third time, the operating time is displayed.

This registers the actual arc burning time since the initial start-up.

- Example: “654 | 32.1” = 65,432.1 h = 65,432 h | 6 min

Important! The operating time display is not suitable as a basis for calculating

hiring fees, guarantee, etc.

To exit, press the Store button (21).

(22) Gas-test button

to set the required quantity of gas at the pressure regulator. After you press this

button, gas will flow out for 30 s. Press the button again to stop the gas test-flow

before the end of this period.

If you press the Store button (21) and the gas test button (22) at the same time,

the display shows the specified gas pre-flow time (e.g. “GPr | 0.1 s”).

- You can alter the gas pre-flow time with the adjusting dial (1)

Now press the “Process” button (4) to display the specified gas post-flow time

(e.g. “GPo | 0.5 s”)

- The gas post-flow time can be altered with the adjusting dial (1)

To exit, press the Store button (21).

(23) “Feeder inching” button

for feeding the welding wire into the torch hosepack with no accompanying flow of

gas or current

For information on the various wire-inching sequences that are possible when the

welder presses and holds the “Feeder inching” button, see the section headed

“The Set-up Menu”,

- sub-section “Process parameters”, parameter “Fdi”.

Important! If you press the Store button (21) and the “Feeder inching” button (23)

at the same time, the display shows the specified feeder inching speed (e.g. “Fdi |

10 m/min” or 393.70 ipm).

- You can alter the feeder-inching speed with the adjusting dial (1)

To exit, press the Store button (21).

Page 38: Fronius TPS Operating Instructions

22

“US” control

panel

(continued)

(24) Keylock switch (optional)

When the key is in the horizontal position, the following functions are disabled:

- selecting the welding process with the “Process” button(s) (4)

- selecting the operating mode with the “Mode” button(s) (5)

- selecting the filler metal with the “Material” button(s) (6)

- accessing the set-up menu with the “Store” button (21)

- accessing the job-correction menu (see the section headed “Job mode”)

Important! In this case, the functions available on the control panel of the system

components are then restricted in the same way as those of the control panel on

the power source.

TIME 5000 Digital

control panelWarning! Operating the equipment incorrectly can cause serious injury and

damage. Do not use the functions described here until you have read and

completely understood all of the following documents:

- these Operating Instructions

- all operating instructions for the system components, especially the “Safety

rules”

(1)(24)

(23)

(22)

(21) (20)

(19)

(18)

(17)(16)

(15)

(14)

(13)

(12)(11)

(10) (9)(8)

(7) (6)

(5)

(4)

(3)(2)

(19)

Fig.7 TIME 5000 Digital control panel

Item Function

(1) Adjusting dial

for changing parameters. If the indicator next to the adjusting dial is lit up, then the

selected parameter is one that can be altered.

Page 39: Fronius TPS Operating Instructions

23

(2) Parameter selection button

for selecting the following parameters

- “a”-dimension

- sheet thickness

- welding current

- wirefeed speed

- F1 indicator

- wirefeed-drive current-input indicator

If the indicator is lit up on the parameter selection button and on the adjusting dial,

then the indicated / selected parameter can be altered with the adjusting dial.

(3) Parameter selection button ... for selecting the following parameters:

- arc-length correction

- droplet-detachment/arc-force (dynamic) correction

- welding voltage

- welding speed

- job n°

- F3 indicator

If the indicator is lit up on the parameter selection button and on the adjusting dial,

then the indicated / selected parameter can be altered with the adjusting dial.

(4) Process button(s)

for selecting the welding process

MIG/MAG pulse synergic welding

MIG/MAG standard synergic welding

MIG/MAG standard manual welding

Job mode

TIG welding with touch-down ignition

rod electrode (MMA) welding

(5) Mode button(s)

for selecting the operating mode

2-step mode

4-step mode

special 4-step mode (aluminium welding start-up)

spot welding mode

operating Mode

(6) Material button(s)

for selecting the filler metal and shielding gas to be used. Parameters SP1 and

SP2 are reserved for additional materials.

(7) Wire diameter button

for selecting the wire diameter to be used. Parameter SP is reserved for additional

wire diameters.

(8) Welding current parameter

for selecting the welding current. Before the start of welding, the machine auto-

matically displays a guideline value based on the programmed parameters. During

welding, the actual value is displayed.

(9) Welding voltage parameter

for selecting the welding voltage. Before the start of welding, the machine auto-

matically displays a guideline value based on the programmed parameters. During

welding, the actual value is displayed.

Important! The power source has a pulsating open-circuit voltage. Where the

“Rod electrode (MMA) welding” process has been selected, the display indicates

an average welding-voltage value of 40 V before the start of welding (open circuit).

For welding start-up and the main welding operation itself, however, a welding

voltage of max. 50 V (TPS 2700) or 70 V (TS 4000 / 5000, TPS 3200 / 4000 /

5000) is available. Optimum ignition properties are ensured.

TIME 5000 Digital

control panel

(continued)

Page 40: Fronius TPS Operating Instructions

24

(10) “a”-dimension parameter

for selecting the „a“-dimension. The wirespeed and welding current/voltage are

calculated as a function of the specified welding speed.

Important! Before you select the “a”-dimension, the welding speed parameter

(17) must be set (recommended welding speed for manual welding: ~35 cm/min

or 13.78 ipm)

(11) Sheet thickness parameter

for selecting the sheet thickness in mm or in. This automatically sets all the other

parameters as well.

(12) Wirefeed speed parameter

for selecting the wirefeed speed in m/min or ipm. Other parameters that are

dependent on this are also automatically adjusted accordingly.

(13) Overtemperature indicator

lights up if the power source overheats (e.g. because the duty cycle has been

exceeded). For more information on this, see the “Troubleshooting” section.

(14) HOLD indicator

every time a welding operation is finished, the actual values for welding current

and welding voltage are stored, and the “Hold” indicator lights up.

(15) Arc-length correction parameter

for correcting the arc length

- shorter arc length

0 neutral arc length

+ longer arc length

(16) Droplet detachment, arc force correction and arc force parameter

a different function depending on the process being used.

MIG/MAG standard synergic welding ... for influencing the short-circuiting dynamic

at the instant of droplet transfer

- harder, more stable arc

0 neutral arc

+ soft, low-spatter arc

MIG/MAG pulse synergic welding ... continuous correction facility for the droplet

detachment force

- lower droplet-detachment force

0 neutral droplet-detachment force

+ increased droplet-detachment force

MIG/MAG standard manual welding ... for influencing the short-circuiting dynamic

at the instant of droplet transfer

0 harder, more stable arc

10 soft, low-spatter arc

Rod electrode (MMA) welding ... for influencing the short-circuiting amperage at

the instant of droplet transfer

0 soft, low-spatter arc

100 harder, more stable arc

(17) Welding speed parameter

for selecting the welding speed. The wirespeed and welding current & voltage are

calculated as a function of the “a”-dimension parameter (10).

TIME 5000 Digital

control panel

(continued)

Page 41: Fronius TPS Operating Instructions

25

(18) JOB N° parameter

for retrieving parameter records/job numbers that were previously saved with the

“Store” button.

(19) F1/wirefeed drive current input/F3 indicators

for displaying defined parameters

(20) Intermediate arc indicator

between the dip-transfer arc and the spray arc, a spatter-prone “intermediate arc”

occurs. To alert you to this critical area - and help you avoid it - the intermediate

arc indicator lights up.

(21) „Store“ button

for accessing the Set-up menu or (in Job Mode) for storing parameter settings.

Important! If you press the Store button (21) and the “Material” button (6) at the

same time, the display shows the software version.

If you then press the “Material” button (6) on its own, the version number of the

welding database appears on the display (e.g.: 0 | 029 = M0029).

If you then press the “Material” button (6) a second time, the number of the wire-

feeder (A, or B in the case of twin-head mounts) and the software version n° of

the wirefeeder appear on the display (e.g.: A 1.5 | 0.23).

If you press the “Material” button (6) a third time, the operating time is displayed.

This registers the actual arc burning time since the initial start-up.

- Example: “654 | 32.1” = 65,432.1 h = 65,432 h | 6 min

Important! The operating time display is not suitable as a basis for calculating

hiring fees, guarantee, etc.

To exit, press the Store button (21).

(22) Gas-test button

to set the required quantity of gas at the pressure regulator. After you press this

button, gas will flow out for 30 s. Press the button again to stop the gas test-flow

before the end of this period.

Important! If you press the Store button (21) and the gas test button (22) at the

same time, the display shows the specified gas pre-flow time (e.g. “GPr | 0.1 s).

- You can alter the gas pre-flow time with the adjusting dial (1)

If you now press the “Process” button (4), the display gives you a read-out of the

pre-set gas post-flow time (e.g. “GPo | 0.5 s”)

- The gas post-flow time can be altered with the adjusting dial (1)

To exit, press the Store button (21).

TIME 5000 Digital

control panel

(continued)

Page 42: Fronius TPS Operating Instructions

26

(23) “Feeder inching” button

for feeding the welding wire into the torch hosepack with no accompanying flow of

gas or current

For information on the various wire-inching sequences that are possible when the

welder presses and holds the “Feeder inching” button, see the section headed

“The Set-up Menu”,

- sub-section “Process parameters”, parameter “Fdi”.

Important! If you press the Store button (21) and the “Feeder inching” button (23)

at the same time, the display shows the specified feeder inching speed (e.g. “Fdi |

10 m/min” or “Fdi | 393.70 ipm”).

- You can alter the feeder-inching speed with the adjusting dial (1)

To exit, press the Store button (21).

(24) Keylock switch (optional)

When the key is in the horizontal position, the following functions are disabled:

- selecting the welding process with the “Process” button(s) (4)

- selecting the operating mode with the “Mode” button(s) (5)

- selecting the filler metal with the “Material” button(s) (6)

- accessing the set-up menu with the “Store” button (21)

- accessing the job-correction menu (see the section headed “Job mode”)

Important! In this case, the functions available on the control panel of the system

components are then restricted in the same way as those of the control panel on

the power source.

TIME 5000 Digital

control panel

(continued)

Page 43: Fronius TPS Operating Instructions

27

(28)

(27)

(26)

(25)

Fig.8 “Remote” operating panel

“Remote” opera-

ting panel

The “Remote” operating panel goes with the “Remote” power source. The “Remote”

power source is designed for use with automatic welders and robots, and is controlled

via the LocalNet only.

The “Remote” power source can be operated via the following system add-ons:

- Remote control units

- Robot interfaces

- Field bus coupler

Item Function

(25) Error indicator

lights up if an error has occurred. All the units which are connected to the Local-

Net, and which have a digital display, support the display of the relevant error

message.

The error messages displayed are described in the section headed “Troubleshoo-

ting”.

(26) Robot interface indicator

glows as long as the power source is switched on and a robot interface or a field-

bus coupler is connected to the LocalNet.

(27) Power source ON indicator

glows as long as the mains cable is plugged into the mains and the mains switch

is in the “I” position

(28) Operating instructions symbol

Observe all the safety, operating, care and maintenance instructions in the “Ope-

rating instructions” manual

Page 44: Fronius TPS Operating Instructions

28

The CMT operating panel is part of the CMT power source. The CMT power source is

designed for use with automatic welders and robots, and is controlled solely via the

LocalNet.

The “Remote” power source can be operated via the following system add-ons:

- RCU 5000i remote control unit

- ROB 5000 robot interface

- Field bus systems

CMT control

panel

Fig.9 CMT control panel

(28)

(27)

(26)

(25)

(29)

Item Function

(25) Error indicator

lights up if an error has occurred. All the units which are connected to the Local-

Net, and which have a digital display, support the display of the relevant error

message.

The error messages displayed are described in the section headed “Troubleshoo-

ting”.

(26) Robot interface indicator

glows as long as the power source is switched on and a robot interface or a field-

bus coupler is connected to the LocalNet.

(27) Power source ON indicator

glows as long as the mains cable is plugged into the mains and the mains switch

is in the “I” position

(28) Operating instructions symbol

Observe all the safety, operating, care and maintenance instructions in the “Ope-

rating instructions” manual

Page 45: Fronius TPS Operating Instructions

29

Connections - switches - mechanical components

TPS 2700 power

sourceRear view

Fig.10 TPS 2700 power source

Side viewFront view

(L)(K)

(J)

(I) (H)

(G)

(F)

(E)

(D)

(C)

(B)(A)

Item Function

(A) Central torch connector **)

for connecting the welding torch

(B) (-) - current socket with bayonet latch

used

- for connecting the grounding (earthing) cable in MIG/MAG welding

- for the current connection on the TIG welding torch

- for connecting the electrode (or grounding/earthing) cable in rod electrode

(MMA) welding, depending on the type of electrode being used

(C) (+) - current socket with bayonet latch

used

- for connecting the grounding (earthing) cable in TIG welding

- for connecting the electrode (or grounding/earthing) cable in rod electrode

(MMA) welding, depending on the type of electrode being used

(D) Torch control connection socket

for connecting the torch control plug

(E) LocalNet connection socket

standardised connection socket for system extensions (e.g. remote control,

JobMaster torch, etc.)

(F) Blanking cover

(G) Mains switch

for switching the power source on and off.

(H) Shielding gas connection socket

(I) Mains cable with strain-relief device

(J) Blanking cover

intended for LocalNet connection socket

(K) Wirespool holder with braking device

for holding standard welding wire spools weighing up to 16 kg (35.27 lbs) and with

a max. diameter of 30.00 cm (11.81 in)

(L) 4-roller drive

**) Connections, switches and mechanical components are denoted with capital letters, e.g.: (F)

Page 46: Fronius TPS Operating Instructions

30

TS 4000 / 5000,

TPS 3200 / 4000 /

5000 power

sources

Fig.11 TS 4000 / 5000, TPS 3200 / 4000 / 5000 power sources

(M)(J)

(I)(G) (F)(C)(B)

Front view Rear view

(J) (N)

Item Function

(B) (-) - current socket with bayonet latch

- for connecting the grounding (earthing) cable in MIG/MAG welding

- for the current connection on the TIG welding torch

- for connecting the electrode (or grounding/earthing) cable in rod electrode

(MMA) welding, depending on the type of electrode being used

(C) (+) - current socket with bayonet latch

- for connecting the interconnecting hosepack in MIG/MAG welding

- for connecting the grounding (earthing) cable in TIG welding

- for connecting the electrode (or grounding/earthing) cable in rod electrode

(MMA) welding, depending on the type of electrode being used

(F) Second (-) current socket with bayonet latch (optional)

- for connecting the interconnecting hosepack in MIG/MAG welding for polarity

reversal (e.g. for innershield and flux-core wire welding)

- specially for automated and robot applications where the interconnecting

hosepack and grounding/earthing cable are to be connected to one side of

the power source (e.g. in a control cubicle)

Second (+) current socket with bayonet latch (optional)

- for connecting a second current cable

Blanking cover

- for use where the optional second current socket with bayonet latch has not

been selected

(G) Mains switch

for switching the power source on and off.

(I) Mains cable with strain-relief device

(J) Blanking cover

intended for LocalNet or LHSB (Local High-Speed Bus) connection socket

(M) LocalNet connection socket

Interconnecting hosepack

(N) Blanking cover

intended for LHSB (Local High-Speed Bus) connection socket

Page 47: Fronius TPS Operating Instructions

31

Minimum equipment needed for welding

Depending on which weld process you intend to use, a certain minimum level of equip-

ment will be needed in order to work with the power source.

This section contains lists of the minimum equipment levels required for welding with

each of the weld processes.

General remarks

- Power source

- Grounding (earthing) cable

- Electrode holders

- Rod electrodes

- Power source

- Grounding (earthing) cable

- TIG gas-valve torch

- Gas connection (for supplying the machine with shielding gas)

- Filler metal (depending on the application)

- Power source

- Grounding (earthing) cable

- MIG/MAG welding torch

- Gas connection (for supplying the machine with shielding gas)

- Wirefeeder (TS 4000 / 5000, TPS 3200 / 4000 / 5000 only)

- Interconnecting hosepack (only on TS 4000/5000, TPS 3200/4000/5000)

- Welding wire

MIG/MAG wel-

ding

TIG-DC welding

Rod electrode

(MMA) welding

Page 48: Fronius TPS Operating Instructions

32

Before commissioning

General remarks

The power source may only be used for MIG/MAG, rod electrode (MMA) and TIG wel-

ding.

Utilisation for any other purpose, or in any other manner, shall be deemed to be “not in

accordance with the intended purpose”. The manufacturer shall not be liable for any

damage resulting from such improper use.

Utilisation in accordance with the “intended purpose” also comprises

- following all the instructions given in this manual

- performing all stipulated inspection and servicing work.

Utilisation for

intended purpose

only

Machine set-up

regulations

Mains connection

The machine is tested to “Degree of protection IP23”, meaning:

- Protection against penetration by solid foreign bodies with diameters greater than 12

mm (0.49 in.)

- Protection against direct sprays of water up to 60° from the vertical

The machine can be set up and operated outdoors in accordance with IP23. However,

direct wetting (e.g. from rain) should be avoided.

The equipment is designed to run on the mains voltage given on the respective rating

plates. If your version of the machine does not come with the mains cables and plugs

ready-mounted, these must be mounted in accordance with your national regulations

and Standards. For details of fuse protection of the mains supply lead, please see the

Technical Data.

Note! Inadequately dimensioned electrical installations can lead to serious

damage. The mains lead, and its fuse protection, must be dimensioned in

accordance with the local power supply. The technical data shown on the rating

plate shall apply.

Applies to TIME 5000 Digital power source: The standard mains plug allows the

user to operate with a mains voltage of up to 400 V. For mains voltages up to

460 V, fit an approved mains plug or install the mains supply directly.

Warning! Operating the equipment incorrectly can cause serious injury and

damage. Do not use the functions described here until you have read and

completely understood all of the following documents:

- these Operating Instructions

- all operating instructions for the system components, especially the “Safety

rules”

The venting duct is a very important safety feature. When choosing the machine locati-

on, make sure that it is possible for the cooling air to enter and exit unhindered through

the louvres on the front and back of the machine. Any electroconductive metallic dust

from e.g. grinding-work must not be allowed to get sucked into the machine.

Warning! A machine that topples over or falls from its stand can easily kill

someone. Place equipment on an even, firm floor in such a way that it stands

firmly.

Page 49: Fronius TPS Operating Instructions

33

Connecting up the mains cable on US power sources

Safety

1. Remove the left side panel of the power source

2. Strip about 100 mm (4 in.) of insulation from the end of the mains cable.

Important! The PE conductor (green, or green with yellow stripes) should be approx. 10

- 15 mm (0.4 - 0.6 in.) longer than the phase conductors.

3. Fit wire end ferrules to phase conductors and PE conductors of the mains cable;

crimp ferrules with pliers

Note! If wire end ferrules are not used, there is a risk of short circuits between

the phase conductors or between phase conductors and the PE conductor. Fit

wire end ferrules to all phase conductors and the PE conductor of the stripped

mains cable.

Connecting up

the mains cable

Stipulated mains

cables and strain

relief devices

Power source Mains voltage Cable cross-section

TS 4000/5000, TPS 4000/5000 3 x 460 V AWG 10

3 x 230 V AWG 6

TPS 3200 3 x 460 V AWG 10

3 x 230 V AWG 8

AWG ... American wire gauge

General remarks The US power sources are supplied without mains cable. A mains cable appropriate for

the connection voltage must be fitted prior to putting the unit into service.

A strain relief device for a cable cross-section AWG 10 is installed on the power source.

Strain relief devices for larger cable cross-sections must be designed accordingly.

4. Undo the screws (2x) and clamping

nut (width-across 30) on the strain

relief device

Fig.12 Undoing the screws and clamping nut

Warning! Operating the equipment incorrectly can cause serious injury and

damage. The following activities must only be carried out by Fronius-trained

qualified personnel! Pay particular attention to the “Safety rules” section.

Page 50: Fronius TPS Operating Instructions

34

2

3

24

4

PE

W1

V1

U1

5

7

8

6

Connecting up

the mains cable

(continued)

5. Insert the mains cable into the strain

relief device

Important! Push the mains cable in far

enough to make it possible to connect the

PE conductor and the phase conductors to

the block terminal properly.

6. Tighten the clamping nut (width-

across 30)

7. Tighten the screws (2x)

8. Connect the mains cable to the block

terminal properly:

- PE conductor (green, or green with

yellow stripes) to the PE connec-

tion

- phase conductors to connections

L1 - L3

9. Replace the left side panel of the

power source

Fig.13 Connecting up the mains cable

Exchanging the

strain relief

device

Fig.15 How to fit the large strain relief device

together

1. Remove the left side panel of the

power source

2. Remove the screws (2x) from the old

strain relief device

3. Pull the old strain relief device for-

wards to detach it

4. Remove the screws for the adapter

plate, and remove the adapter plate

5. Fit the large strain relief device

together:

- Insert the hexagon nut (width-

across 50) into the holding plate

Important! The points of the hexagon

nut must point towards the holding

plate for a reliable earth connection to

the power source housing.

- Screw the front of the large strain

relief device into the hexagon nut

(width-across 50).

The hexagon nut (width-across 50)

now bites into the holding plate

Fig.14 Removing an existing strain relief device

Page 51: Fronius TPS Operating Instructions

35

6

7

7

6. Slot the large strain relief device into

the housing and fasten it with 2

screws

7. Connecting up the mains cable

8. Replace the left side panel of the

power source

Fig.16 Fitting a large strain relief device

Exchanging the

strain relief

device

(continued)

Page 52: Fronius TPS Operating Instructions

36

Commissioning

We recommend using an FK 4000 R cooling unit for the following applications and

situations:

- TS 4000 / 5000, TPS 3200 / 4000 / 5000 power sources

- Jobmaster welding torches

- Push-Pull welding torches

- Robot welding

- Hosepacks over 5 m long

- MIG/MAG pulse synergic welding

- In general, where welding is performed in higher power ranges

The cooling unit is powered from the power source. As soon as the mains switch (G) of

the power source is switched to the “I” position, the cooling unit will be ready for use.

General remarks

Remarks on the

cooling unit

Warning! An electric shock can be fatal. If the machine is plugged into the

mains electricity supply during installation, there is a high risk of very serious

injury and damage. Only carry out work on the machine when

- the mains switch is in the “O” position,

- the machine is unplugged from the mains.

The section on commissioning deals with the following activities:

- Installation of the system components

- Fixing strain relief device in place and connecting interconnecting hosepack

- Connecting gas cylinder and making a ground (earth) connection

- Fitting the welding torch and putting the cooling unit into service

Important! Please refer to the relevant wirefeeder’s operating instructions for informati-

on regarding fitting and adjusting the wirefeeder.

- inserting/replacing feed rollers

- Inserting the wirespool/inserting the basket-type spool

- Feeding in the welding wire

- Adjusting the brake

Overview

Page 53: Fronius TPS Operating Instructions

37

Note! The diagram below is intended to show you how to put the power source

into service.

See the instructions for the relevant system components for detailed information

relating to the individual steps.

Installation of the

system compon-

ents (overview)

Fig.18 Installation of the system components

Installation of the system components

Page 54: Fronius TPS Operating Instructions

38

2

1

1

2

Fig.19 Fixing the strain relief device to the trolley

1. Fit the strain relief device of the

interconnecting hosepack to the

trolley

Important! Where the strain relief device

is subjected to heavy loads, it must be

screwed to the floor of the trolley. A strain

relief device is not provided in the case of

1.2 m (4 ft.) interconnecting hosepacks.

Fig.20 Fitting the strain relief device to the

wirefeeder

Fixing the strain

relief device in

place

2. Fit the strain relief device of the

interconnecting hosepack to the

wirefeeder

Fixing strain relief device in place and connecting

interconnecting hosepack

Page 55: Fronius TPS Operating Instructions

39

Fig.21 Connecting interconnecting hosepack - overview

Connecting

interconnecting

hosepack

1. Connect interconnecting hosepack to the power source:

- Plug the welding potential bayonet plug (a) of the interconnecting hosepack to

the socket (C), and turn it to fasten it

- Plug the LocalNet connector (b) of the interconnecting hosepack into the Local-

Net connection socket (M) and fix by turning the swivel nut

- For CMT power sources only: Plug LHSB plug (c) into LHSB connection socket

(J)

2. Connect interconnecting hosepack to cooling unit with these connections:

- Water flow (d) - blue

- Water return (e) - red

3. Connect shielding gas hose (f) to pressure regulator on the gas cylinder

Important! There is no cooling device present in the case of gas-cooled systems. There

is no need to attach the water connections in the case of gas-cooled systems.

Red

Blue

Power source

Cooling unit

Gas cylinder /pressureregulator

(M)

(C)(b)

(a)

(f)

(J)

(c)

(d)

(e)

Fig.22 Wirefeeder

3. Connecting interconnecting hosepack

to wirefeeder

Page 56: Fronius TPS Operating Instructions

40

1. Stand the gas cylinder on the floor of

the trolley and secure it by fixing the

cylinder strap around a point in the top

third of the cylinder - but never around

the neck of the cylinder

2. Connect the gas cylinder:

- Take the protective cap off the gas

cylinder

- Briefly turn the gas-cylinder valve

anticlockwise, to blow off any dust

and dirt

- Inspect the seal on the pressure

regulator

- Screw the pressure regulator onto

the gas cylinder and tighten it

- TS 4000/5000, TPS 3200/4000/

5000:

Connect the shielding-gas connec-

tor (on the end of the gas hose of

the interconnecting hosepack) to

the pressure regulator

- TPS 2700:

Connect the shielding-gas connec-

tor (H) (on the end of the gas

hose) to the pressure regulator

Connecting up

the gas cylinder

Fig.23 Fixing the gas cylinder on the trolley

Note! Where a gas adapter is being used for the gas hose, glue in and seal the

adapter and test to ensure that it is gas-tight.

Connecting gas cylinder and making a ground

(earth) connection

1. Plug the grounding (earthing) cable

(c) into the current socket (B) and turn

it to fasten it

2. With the other end of the grounding

(earthing) cable, establish a connec-

tion to the workpiece

Fig.24 Plugging in the grounding (earthing) cable

(B)

(c)

Making an earth

connection

Page 57: Fronius TPS Operating Instructions

41

Fig.25 Central torch connector and torch-control

connection point on the VR 4000

(D)

(A)

1. Switch the mains switch (G) to the “0”

position

2. Check that the torch is correctly and

completely tooled up. Insert it - infeed

tube first - into the central torch

connector (A)

3. Tighten the swivel nut by hand to fix

the torch in place

4. Plug the control plug of the welding

torch onto the torch control connec-

tion (D) and turn it to fasten it

Important!

- On the TPS 2700, water-cooled torches can only be used with an external water

connection.

- On the TPS 2700, the central torch connector (A) and the torch-control connection

point (D) are located at the front of the power source.

The cooling unit is powered from the power source. As soon as the mains switch (G) of

the power source is switched to the “I” position, the cooling unit will be ready for use.

Note! Before starting up the cooling unit, check the level and purity of the

coolant.

Mounting the

welding torch

Putting the

cooling unit into

service

Mounting the welding torch and putting the cooling

unit into service

Page 58: Fronius TPS Operating Instructions

42

MIG/MAG operating modes

For information on settings, setting range and units of measurement, please see the

section headed “Set-up Menu: Level 1”.

Press the torch trigger Hold the torch trigger Release the torch trigger

Fig.26 “Press torch trigger”

symbol

Fig.27 “Hold torch trigger”

symbol

Fig.28 “Release torch trigger”

symbol

GPr....... Gas pre-flow time

I-S ......... Starting-current phase: The base metal is heated up rapidly, despite the high

thermal dissipation that occurs at the start of welding

SL ......... Slope: The starting current is continuously lowered down as far as the welding

current or the welding current as far as the crater-fill current

I ............ Welding-current phase: Uniform thermal input into the base metal, whose

temperature is raised by the advancing heat

I-E ......... Crater-fill phase: To prevent any local overheating of the base metal due to

heat build-up towards the end of welding. This eliminates any risk of weld drop-

through.

SPt ....... Spot-welding time

GPo ...... Gas post-flow time

General remarks

Symbols and

abbreviations

Warning! Operating the equipment incorrectly can cause serious injury and

damage. Do not use the functions described here until you have read and

completely understood all of the following documents:

- these Operating Instructions

- all operating instructions for the system components, especially the “Safety

rules”

Page 59: Fronius TPS Operating Instructions

43

4-step mode “4-step mode“ is suitable for longer weld seams.

Fig.30 4-step mode

t

I

+

IGPr GPo

+

“2-step mode“ is suitable for

- tacking-work

- short seams

- automatic-welder and robot welding

2-step mode

Fig.29 2-step mode

t

I

+

IGPr GPo

Page 60: Fronius TPS Operating Instructions

44

The welding operation can be aborted by pressing the torch trigger a second time.

Fig.32 Spot welding

t

I

+

SPtGPr GPo

+

The “Special 4-step (aluminium welding start-up)” mode is particularly suitable for wel-

ding aluminium materials. The special pattern of the welding-current curve takes account

of the high thermal conductivity of aluminium:

Special 4-step

mode (aluminium

welding start-up)

Fig.31 Special 4-step mode

I

tIGPr GPoI-S SL I-ESL

+ +

The “Spot welding” mode is suitable for welding joins on overlapped sheets.

Step-by-step guide to welding a spot:

1. Hold the welding torch in the vertical

2. Press and release the torch trigger

3. Keep the torch in the same position

4. Wait until the end of the gas post-flow time

5. Lift the torch off the workpiece

Spot welding

Page 61: Fronius TPS Operating Instructions

45

MIG/MAG wel-

ding

MIG/MAG welding

1. Plug the grounding (earthing) cable into current socket (B) and latch it

2. With the other end of the grounding (earthing) cable, establish a connection to the

workpiece

3. Plug the torch into the central torch connector (A)

(see also “Putting the power source into service / Fitting the welding torch”)

4. Only where a cooling unit and water-cooled torch are used:

- TS 4000/5000, TPS 3200/4000/5000 with water cooling: Plug the water hoses of

the welding torch to the correct plug-type connectors on the wirefeeder

- TPS 2700 with water cooling: Plug the water hoses of the welding torch to the

correct plug-type connectors on the cooling unit

5. Plug in the mains plug

Caution! Risk of injury and damage from electric shock and from welding wire

emerging at speed from the torch. When you press the torch trigger:

- hold the torch so that it points away from your face and body

- do not point the welding torch at people

- make sure that the welding wire does not touch any electrically conducting

or earthed (grounded) parts, such as the housing, etc.

Warning! An electric shock can be fatal. If the machine is plugged into the

mains electricity supply during installation, there is a high risk of very serious

injury and damage. Only carry out work on the machine when

- the mains switch is in the “O” position,

- the machine is unplugged from the mains.

Warning! Operating the equipment incorrectly can cause serious injury and

damage. Do not use the functions described here until you have read and

completely understood all of the following documents:

- these Operating Instructions

- all operating instructions for the system components, especially the “Safety

rules”

6. Switch the mains switch (G) to the “I” position - all the indicators on the control panel

now briefly light up

Note! If the flow of coolant water is insufficient, damage may result. Check the

coolant flow at regular intervals while the machine is in operation - it must be

possible to see that coolant is flowing properly.

7. With the “Process” button (4), select the desired welding process:

- MIG/MAG pulse synergic welding

- MIG/MAG standard synergic welding

- MIG/MAG standard manual welding

8. With the “Material” button (6), select which filler metal and shielding gas are to be

used

9. With the “Wire diameter” button (7), select the diameter of the wire

10. With the “Mode” button (5), select the desired operating mode:

- 2-step mode

- 4-step mode

- Special 4-step mode (aluminium welding start-up)

- Spot welding

For details of how to set the parameters for the “Special 4-step” mode and the “Spot

welding” mode please see the section headed “The set-up menu”.

Page 62: Fronius TPS Operating Instructions

46

MIG/MAG wel-

ding

(continued)

The power source has an “Ignition time-out” function. This function is not factory-activa-

ted as standard.

To activate the ignition time-out:

- Launch “Set-up menu: Level 2“

- Set a value of between 5 mm and 100 mm, or between 0.20 in and 3.94 in. (ito | 5 ...

100 or

ito | 0.20 ... 3,94)

Please see the section headed “Set-up menu: Level 2” (“Parameters 2nd”) for more

details regarding the settings, setting range and units of measurement of the “Ignition

time-out” parameter (ito).

Once the torch trigger is pressed, gas pre-flow begins immediately. Wire inching then

begins, followed by ignition. If no current starts flowing before the length of wire specified

in the set-up menu has been fed, the power source cuts out automatically. The service

code “no | IGn“ appears on the control panel.

“E55” is displayed on the JobMaster torch and on the field-bus module.

To make another attempt to achieve ignition, press the torch trigger again.

Ignition time-out

function

Important! Parameters that have been set on one control panel (e.g. wire feeder or

remote control unit) might not be able to be changed on another control panel (e.g.

power source).

11. Specify the desired welding power with reference to any of the following parameters:

- a-dimension (10)

- Sheet thickness (11)

- Welding current (8)

- Wirefeed speed (12)

Important! The parameters “a”-dimension (10), sheet thickness (11), welding current (8)

and wirefeed speed (12) are directly interlinked. It is only necessary to alter one of the

parameters, as the other parameters are immediately adjusted to match.

Before you select the “a”-dimension, the welding-speed parameter (17) must be set

(recommended welding speed for manual welding: approx. 35 cm/min or 13.78 ipm).

12. Open the gas-cylinder valve

13. Set the gas-flow rate:

- Press the “Gas-test” button (22)

- Turn the adjusting-screw on the underside of the pressure regulator until the

manometer indicates the desired shielding gas flow-rate

14. Press the torch trigger and start welding

All parameter command values that have been set by means of either the adjusting dial

(1) or the buttons on the torch will remain stored until the next time they are changed.

This is true even if the power source is switched off and on again in the meantime.

In order to achieve an optimum welding result, it is necessary in some cases to make

corrections to the arc-length correction and droplet-detachment / arc-force correction

parameters as well as to background parameters such as gas pre-flow, gas post-flow

and/or soft-start (feeder creep). For details of how to set the background parameters gas

pre-flow, gas post-flow and soft-start (feeder creep), please see “Set-up menu: Level 1”.

Important! It is not possible to correct the arc-length on the “Standard” control panel.

However, you can set the arc-force correction as a background parameter in the Set-up

Menu.

Page 63: Fronius TPS Operating Instructions

47

The ‘Standard manual welding’ process is a MIG/MAG standard synergic welding pro-

cess with no synergic function. In the same way as where the synergic function is active,

the user selects the welding program (by way of the filler metal, shielding gas and wire

diameter) and the operating mode, and then sets the parameters. However, changing

one parameter does not result in any automatic adjustments to the other parameters. All

of the variable parameters must thus be adjusted individually, as dictated by the welding

process in question.

Important! As long as the “Standard manual welding” process is selected, the “Synchro-

Puls” option is not supported.

In the “Standard manual welding” process, the following parameters are available:

- Wirefeed speed (12) ... 0.5 m/min - maximum wirefeed speed (e.g. 22.0 m/min) or

19.69 ipm. - maximum wirefeed speed (e.g. 866.14 ipm.)

- Welding voltage (9) ... 10.0 - 40.0 V (TPS 2700: 10.0 - 34.0 V)

- Arc force (dynamic) correction (16) ... for influencing the short-circuiting dynamic at

the instant of droplet transfer

0,0 harder, more stable arc

10,0 soft, low-spatter arc

- Welding current (8) - only displayed as actual value

1. Switch the mains switch (G) to the “I” position (all the indicators on the control panel

briefly light up)

2. Select the “Standard manual welding” process with the Process button (4)

3. With the “Material” button (6), select which filler metal and shielding gas are to be

used

4. With the “Wire diameter” button (7), select the diameter of the wire

Important! In the “Standard manual welding” process, the “Special 4-step” mode

only corresponds to conventional 4-step operation.

Standard manual

welding

In the factory settings, the arc break watchdog function (Arc) is set to OFF.

To activate the arc break watchdog function:

- Launch “Set-up menu: Level 2“

- Set a value of between 0.01 s and 2 s (Arc | 0.01 ... 2)

To deactivate the arc break watchdog function:

- Launch “Set-up menu: Level 2“

- Set it to OFF (Arc | OFF)

See the section headed “Set-up menu: Level 2” (“Parameters 2nd”) for information on

setting the arc break watchdog parameter (Arc).

If the arc breaks and no current starts to flow again within the time defined in the set-up

menu, the machine cuts out automatically. The service code “no | Arc“ appears on the

control panel.

To start welding again, press the torch trigger again.

Note! At maximum welding current and very low arc length it is possible that the

arc will break without the service code “no | Arc” appearing. If the arc is reduced

significantly, the welding current would have to be increased to more than the

maximum current in order to be able to maintain the requested welding power.

As this is not acceptable, the power source switches off for safety reasons.

Arc break watch-

dog function

Page 64: Fronius TPS Operating Instructions

48

“Spatter-free

ignition” optionImportant! External enabling of the “spatter-free ignition” option is possible from softwa-

re version 2.70.1 (power source) upwards. At present, this option only supports alumini-

um wires of diam.

- 0.8 mm, 1.0 mm, 1.2 mm and 1.6 mm.

- USA: 0.9 mm (0.035 in.), 1.2 mm (0.045 in.) and 1.6 mm (1/16

in.)

Note! Optimum functioning of the “spatter-free ignition” option can only be

ensured in conjunction with Fronius push-pull wirefeed systems.

System requirements:

- Software version 2.60.1 (power source)

- Software version 1.40.15 (wirefeeder)

The Spatter Free Ignition option (SFi) makes it possible to ignite the arc with practically

no spatter. At the beginning of welding, the wire is slowly fed as far as the surface of the

workpiece and then stopped as soon as it touches down. Next, the welding current is

activated and the wire is pulled back. Once the correct arc length has been reached, the

wire starts being fed at the speed specified for this weld process.

Important! There is a sticker showing a program table on the power source. The stored

welding programs are listed in this table. Not all of these welding programs support the

SFI function. SFI is automatically deactivated on changing to a program that does not

support the SFI function. SFI must be re-activated on changing back to a program that

supports the SFI function.

To activate the SFi option:

- Select your welding program

- Select SFi (parameter Fdc - feeder creep) in the set-up menu

- Exit from the set-up menu

5. With the “Mode” button (5), select the desired operating mode

Important! Parameters that have been set on one control panel (e.g. wire feeder or

remote control unit) might not be able to be changed on another control panel (e.g.

power source).

Note! If the machine does not reach the specified welding voltage, the power

source delivers the highest voltage that is possible at that time.

6. Set the parameters “Wirefeed speed” (12), “Welding voltage” (9) and “Arc-force

correction” (16) separately

7. Open the gas-cylinder valve

8. Set the gas-flow rate:

- Press the “Gas-test” button (22)

- Turn the adjusting-screw on the underside of the pressure regulator until the

manometer indicates the desired shielding gas flow-rate

9. Press the torch trigger and start welding

All parameter command values that have been set by means of either the adjusting dial

(1) or the buttons on the torch will remain stored until the next time they are changed.

This is true even if the power source is switched off and on again in the meantime.

Standard manual

welding

(continued)

Page 65: Fronius TPS Operating Instructions

49

SynchroPuls

option

Important! External enabling of the “SynchroPuls” option is possible from software

version 2.70.1 (power source) upwards. This option only supports Fronius manual push-

pull and Robacta Drive push-pull (slave) wirefeed systems.

System requirements:

- Software version 2.60.4 (power source)

- Software version 1.40.15 (wirefeeder)

The “SynchroPuls” option is recommended for welds using aluminium alloys where you

want to give the weld-seams a rippled appearance. This effect is achieved by having the

welding power alternate between two operating points.

For details on setting the available parameters, please see the section headed “Set-up

menu: Level 1”.

F ........... Frequency (SynchroPuls) ... OFF ... 0.5 - 5 Hz

Factory setting: OFF

dFd ....... Offset welding output (SynchroPuls) ... 0.0 - 2.0 m/min or 0.0 - 78.74 ipm.

Factory setting: 2.0 m/min or 78.74 ipm.

Al.2 ....... Arc-length correction (SynchroPuls) ... +/- 30 % of welding voltage

Factory setting: 0

- The two operating points result from the welding output being changed - positively

and negatively - by a value dFd (Welding-output offset: 0.0 - 2.0 m/min or 0.0 -78.74

ipm) that can be adjusted in the Set-up menu.

- The frequency F of the alternation (OFF ... 0.5 - 5 Hz) between the two operating

points can also be specified in the Set-up menu

- The arc-length correction for the lower of the two operating points is made by way of

the arc-length correction parameter (15) - see “Description of the control panel”.

- The arc-length correction for the higher of the two operating points must be made in

the Set-up menu, by way of the parameter Al.2 (+/- 30 %).

Note! In order to activate SynchroPuls, you must (as a minimum) change the

value of the parameter F (frequency) from OFF to a value of between 0.5 Hz

and 5 Hz.

The graph below shows how SynchroPuls functions, in this case when used with the

“Special 4-step” mode (I-S = Starting-current phase, SL = Slope,

I-E = Crater-fill phase):

Fig.33 SynchroPuls - Mode of functioning

I

t

vD

Wir

efe

ed

sp

ee

d

Al.2

I-S

SL

I-E

SL

+ +

dFd

dFd

1/F

Page 66: Fronius TPS Operating Instructions

50

Robot signal

0

1

Welding offWelding on

I

I-S

I-E

t-S SL SL t-E

we

ldin

g c

urr

en

t

t

t

Fig.34 Mode of functioning of “Special 2-step mode”

The Special 2-step mode for robot interface is available when a robot interface or a field

bus coupler for robot control is connected to the LocalNet.

Important! As soon as a ROB 4000/5000 robot interface or a field-bus coupler is con-

nected to the LocalNet, 2-step mode is automatically selected. After this, it is only pos-

sible to exit from 2-step mode (by pressing the “Mode” button (5) ) once the robot inter-

face has been disconnected from the LocalNet.

If a ROB 3000 robot interface is connected, it is possible to select any of the modes (2-

step mode, 4-step mode, Special 4-step mode, ...).

Please see the section headed “Set-up menu: Level 1” for details on the settings, setting

range and units of measurement of the available parameters.

The parameters for the “Special 2-step mode for robot interface” can only be selected in

“Set-up menu: Level 1“ (“Mode” parameter) when a robot interface, or a field bus coupler

for robot control, is connected to the LocalNet.

The graph below illustrates the mode of functioning of the “Special 2-step mode” (I-S =

Starting-current phase, SL = Slope, I-E = Crater-fill phase, t-S = Starting-current duration,

t-E = Final-current duration):

Special 2-step

mode for robot

interface

Page 67: Fronius TPS Operating Instructions

51

“Wire-stick control” function

The “Wire-stick control” function is available when a robot interface, or a field bus

coupler for robot control, is connected to the LocalNet.

Important! The standard factory setting is that the “Wire-stick control” function is not

activated. Where needed, activate the “Wire-stick control” function in the “Set-up menu:

Level 2” (“Stc | ON”).

After the end of welding, the “Wire-stick control” function detects any “sticking” of the

wire in the solidifying weld pool. If a sticking wire-tip is detected within 750 ms after the

end of welding, the error message “Err | 054” will be output.

Special 2-step

mode for robot

interface

(continued)

Warning! A welding process that starts automatically can pose a risk to life.

The “Arc on” signal must not be set while the error is being rectified, otherwise

welding will start as soon as the error is rectified.

- Cut off the sticking wire-tip

Important! The error message “Err | 054” does not need to be acknowledged.

- The power source is now ready for operation.

Page 68: Fronius TPS Operating Instructions

52

TIG welding

Preparations

General remarks

TIG welding

1. Switch the mains switch (G) to the “O” position

2. Unplug the machine from the mains

3. Dismount the MIG/MAG welding torch

4. Plug the grounding (earthing) cable into current socket (C) and latch it in firmly

5. With the other end of the grounding (earthing) cable, establish a connection to the

workpiece

6. Plug the welding cable of the TIG gas-valve welding torch into current socket (B)

and latch it by turning it clockwise

7. Screw the pressure regulator onto the (argon) shielding-gas cylinder and tighten it

8. Attach the gas hose to the pressure regulator

9. Plug in the mains plug

1. Switch the mains switch (G) to the “I” position - all the indicators on the control panel

will now briefly light up

2. With the “Process” button (4), select the TIG welding process - the welding voltage

to the welding socket is switched on after a 3 s timelag.

Important! Parameters that have been set on one control panel (e.g. wire feeder or

remote control unit) might not be able to be changed on another control panel (e.g.

power source).

3. Press the “Parameter selection” button (2) (indicator on the button must light up)

4. Set the desired amperage, using the adjusting dial (1) (value can be read off from

the left-hand indicator)

5 Open the gas cut-off valve on the TIG gas-valve torch and set the desired shielding-

gas flow rate on the pressure regulator

6. Start welding

Warning! An electric shock can be fatal. If the machine is plugged into the

mains electricity supply during installation, there is a high risk of very serious

injury and damage. Only carry out work on the machine when

- the mains switch is in the “O” position,

- the machine is unplugged from the mains.

Warning! Operating the equipment incorrectly can cause serious injury and

damage. Do not use the functions described here until you have read and

completely understood all of the following documents:

- these Operating Instructions

- all operating instructions for the system components, especially the “Safety

rules”

Caution! Risk of injury and damage from electric shock. As soon as the mains

switch is in the “I” position, the tungsten electrode of the welding torch is LIVE.

Make sure that the tungsten electrode does not touch any persons or electrical-

ly conducting or earthed parts (e.g. housing etc.)

The TIG welding process is only possible

- in conjunction with the “Comfort” or the “US” control panel

- with a TIG gas-valve torch

Page 69: Fronius TPS Operating Instructions

53

Fig.36 Arc ignites when electrode is touched down

on workpiece

3. Raise the torch and pivot it into the

normal position - the arc ignites

4. Start welding

Fig.37 Arc ignited - welding commences

1. Lift the TIG gas-valve torch away from the workpiece until the arc goes out.

2. After the end of welding and a suitable gas post-flow time, close the gas shut-off

valve on the TIG gas-valve torch

All parameter command values that have been set by means of the adjusting dial (1) will

remain stored until the next time they are changed. This is true even if the power source

is switched off and on again in the meantime.

Finishing welding

Igniting the arc

Fig.35 Placing the gas nozzle down

Ignition of the welding arc is effected by touching down the tungsten electrode onto the

workpiece.

1. Place the gas nozzle on the ignition

location so that there is a gap of 2 - 3

mm (0.08 - 0.12 in.) between the

tungsten tip and the workpiece

2. Gradually tilt up the welding torch until

the tungsten tip touches the workpi-

ece

Page 70: Fronius TPS Operating Instructions

54

TIG-Comfort-Stop

option

Fig.38 Welding

1. Welding

Fig.39 Raising torch

2. During welding, briefly raise torch

- The arc length is increased signifi-

cantly

If desired, the power source can also be fitted with the optional “TIG Comfort Stop”.

System requirements:

- Software version 3.00.2 (power source)

At the end of the welding operation, the welding current is switched off automatically if

the length of the arc increases by more than a defined amount.

This prevents the arc being unnecessarily elongated when the TIG gas-valve torch is

lifted off the workpiece.

Important! For details of how to activate and make settings for the optional “TIG Com-

fort Stop” function, please refer to the section headed “CSS parameter”.

The standard factory setting is that the optional “TIG Comfort Stop” function of the power

source is deactivated.

Page 71: Fronius TPS Operating Instructions

55

3. Lower the welding torch

- The arc length is decreased

significantly

- the optional TIG Comfort Stop

function is triggered

Fig.40 Lowering the torch

TIG-Comfort-Stop

option

(continued)

Fig.41 Keeping the torch at the same height and

then removing it

4. Keep the welding torch at the same

height:

- the welding current is continuously

decreased (downslope) and

- the arc goes out.

Important! The downslope is pre-set

and cannot be adjusted.

5. Raise the torch from the workpiece.

Page 72: Fronius TPS Operating Instructions

56

I

Fig.42 TIG welding process with the optional TIG Comfort Stop function activated

t

Pre-set welding current

TIG welding with

TIG Comfort Stop

TIG welding: the following diagram shows the welding current sequence when the

optional TIG Comfort Stop function is activated.

Downslope

The “TIG Comfort Stop” function is activated and set by means of the CSS parameter.

The CSS parameter is located in the “Set-up Menu - Level 2”, “TIG welding”.

For more detailed information on how to access the Set-up menu and set the parame-

ters, please refer to the section headed “Set-up Menu - Level 2” in the User Manual.

CSS parameter

Page 73: Fronius TPS Operating Instructions

57

1. Switch the mains switch (G) to the “I” position - all the indicators on the control panel

will now briefly light up

2. With the “Process” button (4), select the rod electrode (MMA) welding process - the

welding voltage to the welding socket is switched on after a 3 s timelag.

Important! Parameters that have been set on one control panel (e.g. wire feeder or

remote control unit) might not be able to be changed on another control panel (e.g.

power source).

3. Press the “Parameter selection” button (2) (indicator on the button must light up)

4. Set the desired amperage, using the adjusting dial (1) (value can be read off from

the left-hand indicator)

5. Press the “Parameter selection” button (3) (indicator on the button must light up)

6. Set the desired arc-force dynamic, using the adjusting dial (1) (value can be read off

from the right-hand indicator)

7. Start welding

Rod electrode (MMA) welding

1. Unplug the machine from the mains

2. Switch the mains switch (G) to the “O” position

3. Dismount the MIG/MAG welding torch

4. Plug the grounding (earthing) cable into either current socket (B) or (C), depending

upon which type of electrode is to be used, and latch it in firmly

5. With the other end of the grounding (earthing) cable, establish a connection to the

workpiece

6. Plug the welding cable into either current socket (B) or (C), depending upon which

type of electrode is to be used, and latch it by turning it clockwise

7. Plug in the mains plug

General remarks

Preparations

Rod electrode

(MMA) welding

The “Rod electrode (MMA) welding” process is only possible in conjunction with the

“Comfort” und “US” control panels.

If the rod electrode (MMA) welding process is selected, any cooling device present is

automatically deactivated. It is not possible to switch it on.

Warning! An electric shock can be fatal. If the machine is plugged into the

mains electricity supply during installation, there is a high risk of very serious

injury and damage. Only carry out work on the machine when

- the mains switch is in the “O” position,

- the machine is unplugged from the mains.

Warning! Operating the equipment incorrectly can cause serious injury and

damage. Do not use the functions described here until you have read and

completely understood all of the following documents:

- these Operating Instructions

- all operating instructions for the system components, especially the “Safety

rules”

Caution! Risk of injury and damage from electric shock. As soon as the mains

switch is in the “I” position, the rod electrode in the electrode holder is LIVE.

Make sure that the rod electrode does not touch any persons or electrically

conducting or earthed parts (e.g. the housing etc.)

Page 74: Fronius TPS Operating Instructions

58

I (A)

t (s)

0,5 1 1,5

Hti

IH

HCU

200

300

Fig.43 Example of “Hot-Start” function

Legend

Hti ...... Hot-current time,

0-2 s, factory setting: 0.5 s

HCU .. Hot-start current, 0-100%, factory

setting: 50 %

IH

........ Main current = Pre-set welding

current

Mode of functioning

During the specified hot-current time (Hti),

the welding current is increased to a

certain value. This value (HCU) is 0-100%

higher than the selected welding current

(IH).

Hot-Start func-

tion

All parameter command values that have been set by means of the adjusting dial (1) will

remain stored until the next time they are changed. This is true even if the power source

is switched off and on again in the meantime.

In order to obtain optimum welding results, it will sometimes be necessary to set or

adjust the Hot-Start function:

Advantages:

- Improved ignition, even when using electrodes with poor ignition properties

- Better fusion of the base metal in the start-up phase, meaning fewer cold-shut

defects

- Largely prevents slag inclusions

For details on setting the available parameters, please see the section headed “Set-up

menu: Level 2”.

Rod electrode

(MMA) welding

(continued)

Example: A welding current (IH)

of 200 A has been set. For the hot-start current (HCU), a

value of 50 % has been selected. During the hot-current time (Hti, e.g. 0.5 s), the actual

welding current will be 200 A + (50 % of 200 A) = 300 A.

The anti-stick function can be activated and deactivated in the “Set-up menu: Level 2”

(see the section headed: “Set-up menu: Level 2”).

As the arc becomes shorter, the welding voltage may drop so far that the rod electrode

will tend to “stick”. This may also cause “burn-out” of the rod electrode.

Electrode burn-out is prevented if the anti-stick function has been activated. If the rod

electrode begins to stick, the power source immediately switches the welding current off.

After the rod electrode has been detached from the workpiece, the welding operation

can be continued without difficulty.

Anti-stick func-

tion

Page 75: Fronius TPS Operating Instructions

59

“Job Mode” enhances the quality of welding-engineering fabrication, both in manual

welding and also in semi-automatic and fully automated operation.

The traditional way of reproducing often-needed jobs (operating points) has been to

document the required parameters by hand. In Job Mode, it is now possible to create,

copy, delete and retrieve up to 100 different jobs.

Important! Job Mode is only available on power sources equipped with either the

“Comfort” or “US” control panels.

Important! If using the TR 2100 TIME remote control unit and VR 4000-30 TIME wire-

feeder, the „Job mode“ function is not available. Once the remote control unit or wirefee-

der is connected, the MIG/MAG pulse synergic welding process is automatically se-

lected. No other process can be selected on the power source.

The following syntax is used in Job Mode, on the left-hand indicator:

- - - ........ No job in this program location (only when you try to retrieve a job from this

location, otherwise nPG)

nPG ...... No job in this program location

PrG ....... There is a job in this program location

Pro ........ Job is being created / copied in this program location

dEL ....... Job is being deleted from this program location

Job mode

General remarks

The machine comes with no jobs pre-programmed. A job has to be created before it can

be retrieved.

To create a job, proceed as follows:

2. Briefly press the Store button (21) to

change to the job menu. The first

vacant program location for the job is

now indicated.

3. Select the desired program location

with the adjusting dial (1), or else

leave the suggested program location

unchanged.

4. Press and hold the Store button (21).

The left-hand display reads “Pro” - the

job is stored in the program location

you have just selected.

Creating a job

1. Set the desired welding parameters

that you want to store as a “Job”.

Page 76: Fronius TPS Operating Instructions

60

You can copy a job that has already been stored in one program location to any other

program location. To copy a job, proceed as described below:

Important! The parameters in the set-up menu are stored automatically with every job -

except for the functions “PushPull Unit”, “Cooling-unit cut-out”, “Welding-circuit resis-

tance measurement” and “Welding-circuit inductivity”

Creating a job

(continued)

Copying/overwri-

ting a job

2. Use the adjusting dial (1) to select

which job you want to copy

3. Briefly press the Store button (21) to

change to the job menu. The first

vacant program location for the job to

be copied is now indicated.

4. Select the desired program location

with the adjusting dial (1), or else

leave the suggested program location

unchanged.

5. Press and hold the Store button (21).

The left-hand display reads “Pro” - the

job is copied to the program location

you have just selected.

6. “PrG” appears on the left-hand display

to indicate that the job is now stored.

Release the Store button (21).

7. Briefly press the Store button (21) to

exit from the job menu

1. With the “Process” button (4), select

“Job Mode” as the process. The

display now shows the last job to be

used.

Important! If the selected program location already has a job stored in it, then this

existing job will be overwritten with the new job. This action cannot be undone.

5. “PrG” appears on the left-hand display

to indicate that the job is now stored.

Release the Store button (21).

6. Briefly press the Store button (21) to

exit from the job menu

Important! If the selected program location already has a job stored in it, then this

existing job will be overwritten with the new job. This action cannot be undone.

Page 77: Fronius TPS Operating Instructions

61

A job that has been stored to a program location can also be deleted again. To delete a

job, proceed as described below:

Deleting a job

1. Briefly press the Store button (21) to

change to the job menu. The first

vacant program location is indicated.

2. With the adjusting dial (1), select the

job to be deleted the “DEL” symbol

lights up on the “Wire diameter”

button (7).

3. Press and hold the “Wire diameter”

button “DEL” (7). The left-hand

display reads “dEL” - the job is dele-

ted.

4. “nPG” appears on the left-hand

display to indicate that the job is now

deleted. Release the Wire diameter

“DEL” button (7).

5. Briefly press the Store button (21) to

exit from the job menu

Retrieving a job

1. With the “Process” button (4), select

“Job Mode” as the process - the last

job used is displayed. To view the

settings programmed in this job, use

the “Parameter selection” buttons (2)

and (3). The process and operating

mode of the stored job are also

displayed.

2. With the adjusting dial (1), select the

desired job

The job can also be selected from the

JobMaster or Up/Down torch.

Important! When you retrieve a job directly from the power source, you can also select

vacant program locations (symbolised by “- - -”). From the JobMaster or Up/Down

torches, on the other hand, you can only select program locations that have already

been programmed.

3. Start welding - during welding you can

always change to another job without

interruption.

4. When you change to another process,

this finishes Job Mode.

Once programmed, all jobs can be retrieved in Job Mode. To retrieve a job, proceed as

follows:

Page 78: Fronius TPS Operating Instructions

62

Job correction

The “Job correction” function allows the user to tailor the set-up parameters to suit

individual jobs.General remarks

(2)(21)

(4)

(4)

(4)

(4)

(1)

(1)

(1)

Accessing the

job correction

menu

Changing a

parameter

Fig.44 Selection menu for the special function: “Job correction”

(21)

1. Use the “Process” button (4) to select the desired parameter

2. Use the adjusting dial (1) to alter the value of this parameter

The selection menu can be accessed from:

- the power-source control panel

- the RCU 4000 and RCU 5000i remote-control panels

- Win RCU (JobExplorer software)

- ROB 4000 / 5000 robot interface

1. Press and hold the Store button (21)

2. Press the parameter selection button (2)

3. Release the Store button (21).

The power source is now in the job correction selection menu - the first parameter, “Job”

(for selecting the job whose parameters are to be adjusted), is now displayed.

Page 79: Fronius TPS Operating Instructions

63

Exiting the job

correction menu

Available parame-

ters

subsequently correctable parameters ...

- with boundary values for which an

adjusting range can be defined

- Within this setting range, these

parameters can be corrected from the

following control elements:

- “Comfort” control panel

- “US” control panel

- JobMaster welding torch

- RCU 4000 remote control unit

- Win RCU (JobExplorer software)

Permanently

settable parame-

ters

1. Press the Store button (21)

Important! Any alterations are saved by exiting from the “Job correction” menu.

The available parameters are listed below:

permanently settable parameters ...

- cannot be altered apart from in the

“Job correction“ menu.

- can only be corrected in the “Job

correction” menu.

Job

Job whose parameters are to be adjusted

unit -

setting range 0-99 = numbers of the programmed jobs, n = memory location

vacant

factory setting -

P

Power correction - Correction of the welding power as defined by the wirefeed speed

unit m/min ipm.

setting range e.g.: 5 - 22 e.g.: 0.2 - 866.14

(setting range depends upon which job has been selected)

factory setting -

AL.1

Arc Length correction.1 - general

unit % of the welding voltage

setting range +/- 30

factory setting -

Important! When the SynchroPuls option is enabled, AL.1 is the arc length correction

for the lower operating point of the pulsed welding power.

The arc-length correction for the upper operating point is made using Parameter AL.2.

“Min.” and “max.” are used for setting ranges that differ according to power source, wire

feed, welding program etc.

Page 80: Fronius TPS Operating Instructions

64

Permanently

settable parame-

ters

(continued)

dYn

dynamic - Arc force dynamic correction (standard arc) or pulse correction (pulsed arc),

(functionality is analogous to the parameter “Arc force dynamic correction” or “Arc force

dynamic” - see the section headed “Description of the control panel”)

unit 1

setting range +/- 5

factory setting -

GPr

Gas pre-flow time

Unit s

Setting range 0 - 9,9

Factory setting 0,1

GPo

Gas post-flow time

Unit s

Setting range 0 - 9,9

Factory setting 0,5

Fdc

Feeder creep

unit m/min ipm.

setting range AUT, OFF, 0.5 - max. AUT, OFF, 19.69 - max.

Additional possible setting with SFi option: SFi

factory setting AUT AUT

Important! If Fdc is set to AUT, the value from the welding program database will be

used. If Fdc values are set manually and these values are faster than the wirefeed

speed that was set for the welding operation

Feeder-creep speed = the wirefeed speed that was set for the welding operation

Fdi

Feeder inching

unit m/min ipm.

setting range 1 - max. 39.37 - max.

factory setting 10 393.70

bbc

burn-back time correction

unit s

setting range +/- 0,20

factory setting 0

I-S

I (current) - Starting

unit % of starting current

setting range 0 - 200

factory setting 135

Page 81: Fronius TPS Operating Instructions

65

SL

Slope

unit s

setting range 0,1 - 9,9

factory setting 1,0

I-E

I (current) - End

unit % of welding current

setting range 0 - 200

factory setting 50

Important! The parameters “Starting-current duration” (t-S) and “Final-current duration”

(t-E) are available when a robot interface, or a field bus coupler for robot control, is

connected to the LocalNet.

t-S

time - Starting current

unit s

setting range OFF, 0.1 - 9.9

factory setting OFF

t-E

time - End current

unit s

setting range OFF, 0.1 - 9.9

factory setting OFF

Important! The parameters above are illustrated by a graph in the section headed “MIG/

MAG welding”.

SPt

Spot-welding time ... Spot-welding time

unit s

setting range 0,1 - 5,0

factory setting 1,0

F

Frequency - for SynchroPuls option

unit Hz

setting range 0,5 - 5

factory setting OFF

dFd

delta Feeder - Welding power offset for the SynchroPuls option (defined by the wirefeed

speed)

unit m/min ipm.

setting range 0,0 - 2,0 .0 - 78.74

factory setting 2 78.74

Permanently

settable parame-

ters

(continued)

Page 82: Fronius TPS Operating Instructions

66

Parameters that

can be corrected

at a later time

Important! A correction of the welding power (defined by the wire feed speed) and the

arc length - also during welding - can only be carried out from the

- Comfort control panel

- “US” control panel

- JobMaster welding torch

- RCU 4000 remote control unit

- Win RCU (JobExplorer software)

- within the defined boundaries (listed below for the parameters PcH, PcL and AL.c)

As long as the power source is switched on, the corrected parameter values remain

saved. After the power source has been switched on again, the parameters are reset to

the permanently settable values.

“Min.” and “max.” are used for setting ranges that differ according to power source, wire

feed, welding program etc.

PcH

Power correction High ... Correction boundary (high) for the welding power

unit % of the value set for P (see section “permanently settable parame-

ters”)

setting range 0 - 20

factory setting 0

AL.2

Arc-Length correction0.2 - for the upper operating point of the pulsed welding power

where the SynchroPuls option is enabled:

unit %

setting range +/- 30 of the welding voltage

factory setting 0

Important! The arc-length correction for the lower operating point is made using Para-

meter AL.1.

tri

Trigger - subsequent correction of operating mode: 2-step, 4-step, special 2-step,

special 4-step and spot-welding

unit -

setting range 2-step, 4-step, special 4-step, spot-welding

factory setting 2-step

Permanently

settable parame-

ters

(continued)

Page 83: Fronius TPS Operating Instructions

67

Parameters that

can be corrected

at a later time

(continued)

Job

t (s)

Job 1

Job

(2)

Job 1

JSL = OFF

Job 1

JSL = 0.1 - 9.9 s

JSL

Fig.45 Job Slope

The value that has been set for Job Slope is stored along with the Job currently se-

lected.

Job

(2)

PcL

Power correction Low - Correction boundary (low) for the welding power

unit % of the value set for P (see section “permanently settable parame-

ters”)

setting range 0 - 20

factory setting 0

Important! The parameter P can be decreased by means of the wirefeed speed para-

meter (e.g. from the JobMaster welding torch). The maximum such decrease is by the

value set for PcL.

AL.c

Arc Length.correction - correction boundary for arc length high and low

unit % of the value set for AL.1 (see section “permanently settable

parameters”)

setting range 0 - 30

factory setting 0

Important! The parameter AL.c can be increased or decreased by means of the para-

meter arc length correction (e.g. from the JobMaster welding torch). The maximum such

correction is by the value set for AL.1.

JSL

Job Slope - defines the time between the currently selected job and the next one

unit s

setting range OFF or 0.1 - 9.9

factory setting OFF

Page 84: Fronius TPS Operating Instructions

68

The shielding gas set-up menu offers easy access to the shielding gas settings.

Shielding gas set-up menu

General remarks

Standard control

panel: AccessingAccessing the shielding gas set-up menu

1. Plug in the mains plug

2. Switch the mains switch (G) to the “I” position

3. Press and hold the store button (21)

4. Press the gas-test button (22)

5. Release the store button (21).

Changing a parameter

6. Use the “Material” button (6) to select the required parameter

7. Use the “Mode” button (5) to alter the value of the parameter

Exiting the set-up menu

8. Press the store button (21)

Accessing the shielding gas set-up menu

1. Plug in the mains plug

2. Switch the mains switch (G) to the “I” position

3. Press and hold the store button (21)

4. Press the gas-test button (22)

5. Release the store button (21).

The power source is now in the shielding gas setup menu - the first parameter GPr (gas

pre-flow time) is displayed.

Changing the parameters

7. Use the “Process” button (4) to select the desired parameter

8. Use the adjusting dial (1) to alter the value of this parameter

Exiting from the Set-up menu

9. Press the store button (21)

“Comfort”/“US”

control panel:

Accessing

Fig.46 “Comfort” control panel: Shielding gas set-up menu

1. Plug in the mains plug

2. Switch the mains switch (G) tothe “I” position

3. Press and hold the store button (21)

4. Press the gas-test button (4)5. Release the Store button (21) ...

... the last parameter to be

selected is displayed

7. Use the adjusting dial (1) to alter the

values of the parameters

8. Press the store button (21)

6. Use the “Process”button (4) to

select the desired

parameter

Page 85: Fronius TPS Operating Instructions

69

Gas test parame-

ter

GPr

Gas pre-flow time

Unit s

Setting range 0 - 9,9

Factory setting 0,1

GPo

Gas post-flow time

Unit s

Setting range 0 - 9,9

Factory setting 0,5

GPU

Gas Purger

Unit min

Setting range OFF, 0.1 -10.0

Factory setting OFF

Purging of the shielding gas begins as soon as GPU is allocated a value.

For safety reasons, purging of the shielding gas cannot be restarted until a new GPU

value is entered.

Important! Purging with shielding gas is necessary if condensation forms when the

device is left unused in a cold environment for a prolonged period. Long hosepacks are

most affected.

“Min.” and “max.” are used for setting ranges that differ according to power source, wire

feed, welding program etc.

Page 86: Fronius TPS Operating Instructions

70

The digital power sources come with a wealth of expert knowledge already built in! You

can retrieve and use any of the optimised parameters stored in the machine whenever

you wish.

The set-up menu provides simple access to this expert knowledge plus some additional

functions. It enables the parameters to be easily adapted to the various tasks.

Set-up menu: Level 1

General remarks

Standard control

panel: Accessing

Standard control

panel: Parame-

ters

Important! The number of parameters available for the “Standard” control panel, and the

order in which they are arranged, is not the same as in the extended set-up menu

structure found on the “Comfort” and “US” control panels.

SFi Spatter Free Ignition option (only where a Push-Pull unit is plugged in and where

the SFI option has been enabled)

****) A complete description of the parameters may be found in the section headed “Process parameters”.*****) A complete description of the parameters may be found in the section headed “Operating mode

parameters”.

Options:

- SFI

- tS *****)

- tE *****)

- GPr ****)

- GPo ****)

- Fdc ****)

- Fdi ****)

- bbc ****)

- dYn ****)

- I-S *****)

- SL *****)

- I-E *****)

- FAC ****)

- 2nd ****)

Accessing the Set-up menu: Level 1

1. Plug in the mains plug

2. Switch the mains switch (G) to the “I” position

3. Press and hold the Store button (21)

4. Press the “Mode” button (5)

5. Release the Store button (21).

Changing a parameter

6. Use the “Material” button (6) to select the required parameter

7. Use the “Mode” button (5) to alter the value of the parameter

Exiting from the Set-up menu

8. Press the Store button (21)

Accessing the Set-up menu for “Process” parameters

The mode of functioning is explained here with reference to the “MIG/MAG standard

synergic welding” process. The procedure for changing other “Process” parameters is

identical.

1. Plug in the mains plug

2. Switch the mains switch (G) to the “I” position

3. Use the “Process” button (4) to select the “MIG/MAG standard synergic welding”

process

4. Press and hold the Store button (21)

5. Press the “Process” button (4)

6. Release the Store button (21).

“Comfort”/“US”

control panel:

Accessing

Page 87: Fronius TPS Operating Instructions

71

“Comfort” / “US”

control panel:

Accessing

(continued)

Fig.47 “Comfort” control panel: Example with the “MIG/MAG standard synergic welding” process

3. With the “Process” button (4) ...

9. Press the store button (21)

... the last parameter to be

selected is displayed

Accessing the Set-up menu for “Mode” parameters

The mode of functioning is explained here with reference to the “Special 4-step” mode.

The procedure for changing other “Mode” parameters is identical.

1. Plug in the mains plug

2. Switch the mains switch (G) to the “I” position

3. Use the “Process” button (4) to select the “MIG/MAG standard synergic welding” or

“MIG/MAG pulse synergic welding” process

4. With the “Mode” button (5), select the “Special 4-step” mode

5. Press and hold the store button (21)

The power source is now in the set-up menu for the “MIG/MAG standard synergic

welding” process, and the first parameter GPr (gas pre-flow time) is displayed.

Changing the parameters

7. Use the “Process” button (4) to select the desired parameter

8. Use the adjusting dial (1) to alter the value of this parameter

Exiting from the Set-up menu

9. Press the Store button (21)

1. Plug in the mains plug2. Switch the mains switch (G) to the “I” position

... select the “MIG/MAG standard synergic welding” process

4. Press and hold the Store button (21)5. Press the “Process” button (4)

6. Release the Store button (21) ...

7. Use the

“Process”

button (4) to

select the

desired

parameter8. Use the adjusting dial (1) to alter the values of the

parameters

Page 88: Fronius TPS Operating Instructions

72

6. Press the “Mode” button (5)

7. Release the Store button (21).

The power source is now in the set-up menu for the “Special 4-step” mode, and the first

parameter I-S (starting current) is displayed.

Changing a parameter

8. Use the “Mode” button (5) to select the desired parameter

9. Use the adjusting dial (1) to alter the value of this parameter

Exiting from the Set-up menu

10. Press the Store button (21)

“Comfort” / “US”

control panel:

Accessing

(continued)

“Comfort”/“US”

control panel:

Parameters

The parameters of the “Set-up menu: Level 1” are described in the following sections:

“Process parameters” and “Operating mode parameters”.

5. Press and hold the Store button (21)

6. Press the “Mode” button (5)

7. Release the Store button (21).

10. Press the store button (21)

Fig.48 “Comfort” control panel: Example with the “Special 4-step” process

1. Plug in the mains plug2. Switch the mains switch (G) to the “I” position

3. With the “Process” button (4) ...

... select “MIG/MAG standard synergicwelding” or ...

... “MIG/MAG pulse synergic welding”.

4. With the “Mode” button (5) ...

... select the “Special 4-step” mode

9. Use the adjusting dial (1) to

alter the values of the

parameters8. Use the “Mode” button

(5) to select the desired

parameter

Page 89: Fronius TPS Operating Instructions

73

Process parameters

MIG/MAG stan-

dard synergic/

pulse synergic

welding

Wirefeed speed

(m/min or ipm)

t (s)

1 2 3 4 52,5

1

Fdi(e.g. 22)

“Feeder inching” button

- Hold down the button for up to one

second ... Irrespective of what value

has been set, the wire speed remains

at 1 m/min or 39.37 ipm for the first

second.

- Hold down the button for up to 2.5

seconds ... After the end of a 1-

second period, the wire speed increa-

ses at a uniform rate over the next 1.5

seconds.

- Hold down the button for longer than

2.5 seconds ... After a total of 2.5

seconds, the wire starts to be inched

at a constant rate equal to the speed

set for the parameter “Fdi”.

GPr

Gas pre-flow time

unit s

setting range 0 - 9,9

factory setting 0,1

GPo

Gas post-flow time

unit s

setting range 0 - 9,9

factory setting 0,5

Fdc

Feeder creep - with SFi option

unit m/min ipm.

setting range AUT, OFF, ON, 0.5 - max. AUT, OFF, ON, 19.69 - max.

factory setting AUT AUT

Important! If Fdc is set to AUT, the value from the welding program database will be

used. If Fdc values are set manually and these values are faster than the wirefeed

speed that was set for the welding operation

Feeder-creep speed = the wirefeed speed that was set for the welding operation

Fdi

Feeder inching

unit m/min ipm.

setting range 1 - max. 39.37 - max.

factory setting 10 393.70

Important! To facilitate exact positioning of the welding wire, the following sequences

are possible when the welder presses and holds the feeder inching button (23):

Fig.49 Time-path of the wirespeed when the feeder

inching button is pressed and held down

“Min.” and “max.” are used for setting ranges that differ according to power source, wire

feed, welding program etc.

Page 90: Fronius TPS Operating Instructions

74

MIG/MAG stan-

dard synergic/

pulse synergic

welding

(continued)

If you release the feeder inching button (23) and press it again before the end of a 1-

second period, the sequence starts again from the beginning. This makes it possible to

position the wire continuously at the low wirespeed of 1 m/min or 39.37 ipm when nee-

ded.

bbc

burn-back time correction

unit s

setting range +/- 0,20

factory setting 0

F

Frequency ... Frequency for the SynchroPuls option:

unit Hz

setting range OFF, 0.5 -5

factory setting OFF

Note! In order to activate SynchroPuls, you must (as a minimum) change the

value of the parameter F (frequency) from OFF to a value of between 0.5 Hz

and 5 Hz.

The parameters and the mode of functioning of SynchroPuls are explained in more detail

in the section headed “MIG/MAG welding”.

dFd

delta Feeder - Welding power offset for the SynchroPuls option (defined by the wirefeed

speed)

unit m/min ipm.

setting range 0,0 - 2,0 .0 - 78.74

factory setting 2 78.74

AL.2

Arc Length correction0.2 - for the upper operating point of the pulsed welding power

where the SynchroPuls option is enabled

unit % of the welding voltage

setting range +/- 30

factory setting 0

Important! The arc-length correction for the lower operating point is made using the arc-

length correction parameter (15) (see the section headed “Descriptions of the control

panels”)

dYn

dynamic - arc force correction (only on „Standard“ control panel)

unit 1

setting range +/- 5

factory setting 0

ALS

Arc Length Start - increased welding voltage as striking voltage at welding start-up, for

MIG/MAG standard synergic welding. In conjunction with the Alt parameter explained

below, ALS makes an optimised ignition sequence possible.

unit % of the welding voltage

setting range 0 - 100

factory setting 0

Example:

- ALS = 100 %

- welding voltage currently set: 13 V

- Striking voltage: 13 V + 100 % = 26 V

Page 91: Fronius TPS Operating Instructions

75

ALt

Arc Length time - time of the arc length increased by ALS. During the ALt time there is a

continuous decrease in the arc length to the currently set value.

unit s

setting range 0 - 5

factory setting 0

FAC

Factory - for resetting the welding machine to factory settings

Press and hold the Store button (21) for 2 s to reset the machine to its original (i.e.

factory) settings. If the display reads “PrG”, then the welding machine has been reset

Important! When the welding machine is reset, all the personal settings in Level 1 of the

set-up menu are lost.

When the welding machine is re-set, jobs are not deleted, but continue to be stored in

the memory. The functions in the second level of the set-up menu (2nd) are not deleted

either. Exception: The “Ignition time-out” parameter (ito).

2nd

Second level of the Set-up menu (see: “Set-up menu: Level 2”)

MIG/MAG stan-

dard synergic/

pulse synergic

welding

(continued)

TIG welding

Rod electrode

(MMA) weldingImportant! When you re-set the welding machine with the “Factory” (FAC) parameter

(Set-up menu: Level 1), the parameters Hot current time (Hti) and Hot start current

(HCU) will also be re-set.

Hti

Hot-current time

unit s

setting range 0 - 2,0

factory setting 0,5

HCU

Hot-start current

unit %

setting range 0 - 100

factory setting 50

2nd

Second level of the Set-up menu (see: “Set-up menu: Level 2”)

2nd

Second level of the Set-up menu (see: “Set-up menu: Level 2”)

Page 92: Fronius TPS Operating Instructions

76

Operating-mode parameters

The parameters for the “Special 2-step mode for robot interface” are available when a

robot interface or a field bus coupler for robot control are connected to the LocalNet.

I-S

I (current) - Starting: Starting current

unit % of welding current

setting range 0 - 200

factory setting 135

SL

Slope

unit s

setting range 0,1 - 9,9

factory setting 1,0

I-E

I (current) - End: End current

unit % of welding current

setting range 0 - 200

factory setting 50

t-S

time - Starting current: Duration of starting-current

unit s

setting range OFF, 0.1 - 9.9

factory setting OFF

t-E

time - End current: Duration of final current

unit s

setting range OFF, 0.1 - 9.9

factory setting OFF

Important! The parameters above are illustrated in the section headed “MIG/MAG

welding”.

Special 2-step

mode for robot

interface

Page 93: Fronius TPS Operating Instructions

77

Spot weldingSPt

Spot-welding time

unit s

setting range 0,1 - 5,0

factory setting 1,0

Special 4-step

mode (aluminium

welding start-up)

I-S

I (current) - Starting: Starting current

unit % of welding current

setting range 0 - 200

factory setting 135

SL

Slope: 0.1 - 9.9 s

unit s

setting range 0,1 - 9,9

factory setting 1

I-E

I (current) - End: End current

unit % of welding current

setting range 0-200

factory setting 50

Page 94: Fronius TPS Operating Instructions

78

The following functions are located in a second menu level:

Set-up menu: Level 2

General remarks

Changing to the second menu level (2nd)

1. Access Set-up menu: Level 1

2. Select parameter “2nd”

3. Press and hold the Store button (21)

4. Press the “Mode” button (5)

5. Release the Store button (21).

The power source is now in the second level (2nd) of the Set-up menu. The function

“PPU” (push-pull unit) is now displayed.

Selecting the function

6. Use the “Material” button (6) to select the desired function (parameter)

7. Make the settings for this function with the “Mode” button (5)

Exiting from the second menu level (2nd)

8. Press the Store button (21)

Standard control

panel

“Comfort”/“US”

control panel

Changing to the second menu level (2nd)

1. Access Set-up menu: Level 1

2. Select parameter “2nd”

3. Press and hold the Store button (21)

4. Press the “Process” button (4)

5. Release the Store button (21).

The power source is now in the second menu level (2nd) of the Set-up menu. The

function “PPU” (push-pull unit) is now displayed.

Selecting the function

6. Use the “Process” button (4) to select the desired function

7. Set the function with the adjusting dial (1) (see also the sections headed “Push-pull

unit”, “Measuring the welding circuit resistance r” and “Indicating the welding circuit

inductivity L”)

Exiting from the second menu level (2nd)

8. Press the Store button (21)

- PPU (push-pull unit)

- C-C (cooling unit cut-out)

- Stc (wire-stick - only where there is a

robot interface)

- Ito (ignition time-out)

- Arc (arc break watchdog)

- S4t (gun trigger option)

- Gun (“Changing between operating

modes with the JobMaster torch”

option)

- r (measuring the welding circuit

resistance)

- L (indicating the welding circuit induc-

tivity)

- Eln ( Characteristic selection -not on

“Standard” control panel)

- ASt (Anti-Stick - not on “Standard”

control panel)

A complete list of parameters for “Set-up menu: Level 2” may be found in the section

headed “Parameters 2nd”.

Page 95: Fronius TPS Operating Instructions

79

“Comfort” / “US”

control panel

(continued)

8. Press the store button (21)

Example where “MIG/MAG

standard synergic welding” is

the selected process

Fig.50 “Comfort” control panel: “Set-up menu: Level 2” for MIG/MAG standard synergic welding

1. Access Set-up menu: Level 1

2. Select parameter “2nd”

3. Press and hold the Store button (21)

4. Press the “Process” button (4)

5. Release the Store button (21).

7. Set the function with the adjusting dial (1)

6. Use the

“Process”

button (4) to

select thedesired

function

Page 96: Fronius TPS Operating Instructions

80

Parameters 2nd

MIG/MAG stan-

dard synergic/

pulse synergic

welding

The following parameters are not re-set to the factory settings when the FAC parameter

is used (see: “Set-up menu: Level 1”):- PPU

- C-C

- Stc

- Arc

- S4t

- Gun

PPU

Push-Pull Unit (see section „Push-pull unit“)

C-C

Cooling unit Control ... Cooling unit control

unit -

setting range Aut, On, Off

factory setting Aut

- Aut ...... The coolant pump cuts out after a 2-minute welding off-time.

Important! If the optional “FK 4000 thermostat” has been installed in the cooling unit, the

coolant pump cuts out as soon as the return-flow temperature has dropped below 50 °C,

but no sooner than after a 2-minute welding off-time.

- On ...... The coolant pump remains switched on.

- Off ...... The coolant pump remains switched off.

Where an FK 9000 cooling unit is being used, the only possible settings are ON and

OFF.

Important! It is possible to set the parameter C-C for the MIG/MAG welding process

irrespective from the TIG welding process.

Example:

- MIG/MAG welding process ... e.g. use of a water-cooled welding torch: C-C = Aut

- TIG welding process ... e.g. use of a gas-cooled welding torch: C-C = Off

C-t

Cooling Time ... Time from when the rate-of-flow watchdog is triggered until the “no |

H2O” service code is output. For example, if air bubbles occur in the cooling system, the

cooling unit will only cut out at the end of this period.

unit s

setting range 5 - 25

factory setting 10

Important! Every time the power source is switched on, the cooling unit will do a 180-

second test run.

Page 97: Fronius TPS Operating Instructions

81

Stc

Wire Stick control

unit -

setting range OFF, ON

factory setting OFF

The parameters for the wire-stick function (Stc) are available when a robot interface or a

field bus coupler for robot control is connected to the LocalNet.

Important! The wire-stick control (Stc) function is explained in the section headed

“Special 2-step mode for robot interface”.

Ito

Ignition time out: Length of wire that is fed before the safety cut-out is triggered:

unit mm in.

setting range OFF, 5 -100 OFF, 0.20 -3.94

factory setting OFF

Note! The “Ignition time-out” function (ito) is a safety function. Particularly when

the wire is being fed at high wirefeed speeds, the length of wire which is fed

before the safety cut-out is triggered may deviate from the pre-set wire length.

The “Ignition time-out” function (ito) is explained in the section headed “MIG/MAG

welding”.

Arc

Arc break watchdog

unit s

setting range OFF, 0.01 - 2

factory setting 1

Important! The “Arc break watchdog” function (Arc) is explained in the section headed

“MIG/MAG welding”.

FCO

Feeder Control - switching off of wirefeed (wire-end sensor option)

unit -

setting range OFF / ON / noE

factory setting OFF

- OFF .... The power source halts wire feed when the wire-end sensor is triggered.

„Err|056“ appears on the display.

- ON ...... The power sources halts wire feed after completion of the current weld

when the wire-end sensor is triggered. „Err|056“ appears on the display.

- noE ..... The power source does not halt wire feed when the wire-end sensor is

triggered. The wire-end alarm is not displayed and is only transmitted to the robot

control via the field bus.

Important! The setting „noE“ only functions in conjunction with the field bus applications.

Robot interfaces ROB 4000 / 5000 do not support this function.

Dismiss Err | 056:

Insert a new wirespool and feed the welding wire into the hosepack

MIG/MAG stan-

dard synergic/

pulse synergic

welding

(continued)

Page 98: Fronius TPS Operating Instructions

82

MIG/MAG stan-

dard synergic/

pulse synergic

welding

(continued)

SEt

Setting - Country-specific setting (Standard / USA) ... Std / US

unit -

setting range Std, US (Standard / USA)

factory setting Standard version: Std (measurements in cm/mm)

USA version: US (measuring properties: in.)

S4t

Special 4-step - Gun trigger option

unit -

setting range 0, 1 (Off, On)

factory setting 1

Important! The “GunTrigger” (S4t) and “Changing between operating modes with the

JobMaster torch” (Gun) options are explained in more detail in the “Job mode” section of

the JobMaster operating instructions.

Gun

Gun (welding torch) - Changing between operating modes with the JobMaster torch

(optional)

unit -

setting range 0, 1 (Off, On)

factory setting 1

S2t

Special 2-step (only on “US” control panel) - for selecting jobs and groups using the

torch trigger

Press 1 x (< 0.5 s) ... next job within a group is selected

Press 2 x (< 0.5 s) ... next group is selected

r

r (resistance) - welding circuit resistance (in mW)

(see the section headed: “Measuring the welding circuit resistance r”)

L

L (inductivity) - welding circuit inductivity (in microhenrys)

(see the section headed: “Measuring the welding circuit inductivity L”)

P-C

Power Control - for defining the Master and Slave power sources when two power

sources are operated in parallel

unit -

setting range On (Master power source), Off (Slave power source)

factory setting OFF

Important! The P-C parameter is only available when two power sources are connected

via an LHSB (Local High-Speed Bus).

Operating power

sources in paral-

lel

Page 99: Fronius TPS Operating Instructions

83

TimeTwin

Digital pro-

cess

T-C

Twin Control - for defining the leading and trailing power sources in the TimeTwin Digital

process

unit -

setting range On (Leading power source), Off (Trailing power source)

factory setting -

The T-C parameter is only available when two power sources are connected via an

LHSB (Local High-Speed Bus) and the “TimeTwin Digital” option has been enabled.

Important! When a robot interface is connected to the power source, the T-C parameter

can only be adjusted via the robot interface.

TIG weldingC-C

Cooling unit control

unit -

setting range Aut, On, Off

factory setting Aut

- Aut .... The coolant pump cuts out after a 2-minute welding off-time.

Important! If the coolant unit is provided with the optional “temperature limit controller”,

the coolant return-flow temperature is checked all the time. If the return-flow temperature

is less than 50 °C, the cooling unit is switched off automatically.

- On .... The coolant pump remains switched on

- Off .... The coolant pump remains switched off.

If you are using an FK 9000 cooling unit, the only possible settings are ON and OFF.

Important! You can set the C-C parameter for the TIG welding process separately from

the C-C parameter for the MIG/MAG welding process.

Example:

- TIG welding process ... e.g. use of a gas-cooled welding torch: C-C = Off

- MIG/MAG welding process ... e.g. use of a water-cooled welding torch: C-C = Aut

CSS

Comfort Stop Sensitivity - sensitivity of the response characteristic of TIG Comfort Stop

unit -

setting range 0.5 - 5.0, OFF

factory setting OFF

Important! We recommend a value of 2.0. However, if welding frequently stops unex-

pectedly, increase the value of the CSS parameter.

Page 100: Fronius TPS Operating Instructions

84

TIG welding

(continued)

r

r (resistance) - welding circuit resistance (in mΩ)

(see the section headed: “Measuring the welding circuit resistance r”)

L

L (inductivity) - welding circuit inductivity (in microhenrys)

(see the section headed: “Measuring the welding circuit inductivity L”)

Rod electrode

(MMA) weldingEln

Electrode line ... Characteristic selection function

unit 1

setting range con, 0.1 - 20, P

factory setting con

Depending on the value that has been set for the CSS parameter, the following is re-

quired for triggering the TIG Comfort Stop function:

0.5 - 2.0 small increase in the size of the arc

2.0 - 3.5 medium increase in the size of the arc

3.5 - 5.0 large increase in the size of the arc

0 400200100 300 I (A)

U (V)

Fig.51 Characteristics that can be selected using the Eln function

con - 20 A / V(1) Load line for rod electrode

(2) Load line for rod electrode where arc length is

increased

(3) Load line for rod electrode where arc length is

reduced

(4) Characteristic where “con” parameter is

selected (constant welding current)

(5) Characteristic where “0.1 - 20” parameter is

selected (falling characteristic with adjustableslope)

(6) Characteristic where “P” parameter is selected

(constant welding power)

(7) Example of pre-set arc force dynamic wherecharacteristic (4) is selected

(8) Example of pre-set arc force dynamic where

characteristic (5) or (6) is selected

“con” (constant welding current) parameter

- If the “con” parameter is set, the welding current will be kept constant, irrespective

of the welding voltage. This results in a vertical characteristic (4).

- The “con” parameter is especially suitable for rutile electrodes and basic electrodes,

as well as for gouging.

- For gouging, set the arc-force dynamic to “100”.

Parameter “0.1 - 20” (falling characteristic with adjustable slope)

- Parameter “0.1 - 20” is used to set a falling characteristic (5). The setting range

extends from 0.1 A / V (very steep) to 20 A / V (very flat).

- Setting a flat characteristic (5) is only advisable for cellulose electrodes.

(4)

(5)

(6)

(7) (8)

(1)(2)(3)

Page 101: Fronius TPS Operating Instructions

85

Rod electrode

(MMA) welding

(continued)

Important! When setting a flat characteristic (5), set the arc-force dynamic to a higher

value.

“P” parameter (constant welding power)

- If the “P” parameter is set, the welding power is kept constant, irrespective of the

welding voltage and welding current. This results in a hyperbolic characteristic (6)

(Fig.54).

- The “P” parameter is particularly suitable for cellulose electrodes.

Important! If there are problems with a rod electrode tending to “stick”, set the arc-force

dynamic to a higher value.

(1) Load line for rod electrode

(2) Load line for rod electrode where arc length is

increased

(3) Load line for rod electrode where arc length is

reduced

(4) Characteristic where “con” parameter isselected (constant welding current)

(5) Characteristic where “0.1 - 20” parameter is

selected (falling characteristic with adjustableslope)

(6) Characteristic where “P” parameter is selected

(constant welding power)

(8) Example of pre-set arc force dynamic where

characteristic (5) or (6) is selected

(9) Possible change in the current where

characteristic (5) or (6) is selected, as a

function of the welding voltage (arc length)

(a) Operating point where arc-length is long

(b) Operating point where welding current IH is set

(c) Operating point where arc-length is short

10

20

30

40

50

60

U (V)

100 300 400200 I (A)

IH + arc-force

dynamicIH - 50 %

Fig.52 Settings example: IH = 250 A, arc-force dynamic = 50

The characteristics (4), (5) and (6) shown here apply when using a rod electrode whose

characteristic corresponds - at a given arc length - to the load line (1).

Depending on the welding current (i) set, the point of intersection (operating point) of

characteristics (4), (5) and (6) is displaced along the load line (1). The operating point

provides information on the actual welding voltage and the actual welding current.

Where the welding current (IH) is permanently set, the operating point may migrate along

the characteristics (4), (5) and (6), depending on the welding voltage at that moment in

time. The welding voltage U is dependent upon the length of the arc.

(9)

(2)

(1)

(3)

(8)

(c)

(c)

(b)

(a)

(a)

(6)

(5)

(4)

Page 102: Fronius TPS Operating Instructions

86

If the arc length changes, e.g. in accordance with the load line (2), the resulting opera-

ting point will be the point where the corresponding characteristic (4), (5) or (6) intersects

with the load line (2).

Applies to characteristics (5) and (6): Depending upon the welding voltage (arc length),

the welding current (I) will also become either smaller or larger, even though the value

set for IH remains the same

r

r (resistance) - Welding circuit resistance (in mΩ)

(see the section headed: “Measuring the welding circuit resistance r”)

L

L (inductivity) - Welding circuit inductivity (in microhenrys)

(see the section headed: “Measuring the welding circuit inductivity L”)

ASt

Anti-Stick

unit -

setting range On, OFF

factory setting OFF

Uco

U (Voltage) cut-off - Limiting the welding voltage:

unit V

setting range OFF or 5 -95

factory setting OFF

Important! The arc-length is basically dependent upon the welding voltage. In order to

end the welding operation, it is usually necessary to make a pronounced lifting motion of

the rod electrode away from the workpiece. With the “Uco” parameter, the welding

voltage can be limited to a value that makes it possible to end the welding operation

simply by slightly lifting the rod electrode.

Note! If, during welding, you often find that the welding operation is ended

unintentionally, set the “Uco” parameter to a higher value.

Rod electrode

(MMA) welding

(continued)

Page 103: Fronius TPS Operating Instructions

87

Push-pull unit

General remarks

Calibrating the

push-pull unit

For an overview of the error messages that may occur during alignment of the push-pull

unit, please refer to “Service codes for push-pull alignment”.

The push-pull unit must be aligned prior to each initial start-up and each time the wire-

feeder software is updated. If no alignment of the push-pull unit is carried out, the stan-

dard parameters will be used - which may result in the welding result not being satisfac-

tory.

1. Select the “PPU” function in the

second menu level (2nd).

2. Use the adjusting dial (1) (or “Mode”

button (5) on the “Standard” control

panel) to select the relevant push-pull

unit from the following list:

0 ... Fronius unreeling device “VR 1530-22” 22 m/min or 865 ipm *)

1 ... Fronius unreeling device “VR 1530-30” 30 m/min or 1180 ipm (display reads: 1.18) *)

2 ... Fronius robot push-pull “KD Drive” 10m/min *)

3 ... Fronius robot push-pull “Robacta Drive” (Master control) *)

4 ... Fronius robot push-pull “Robacta Drive” (Slave-control)

5 ... Fronius manual push-pull “PullMig” with power potentiometer

6 ... Fronius manual push-pull “PullMig” without power potentiometer

7 ... Binzel manual push-pull 42V” with power potentiometer **)

8 ... Binzel manual push-pull 42V” without power potentiometer **)

9 ... Binzel robot push-pull 42V **)

10 . Binzel robot push-pull 24V **)

11 . Dinse robot push-pull 42V **)

12 . Hulftegger manual push-pull 24 V **)

13 . Fronius “VR 143-2“ intermediate drive

14 . Fronius unreeling device “MS” 22 m/min or 865 ipm *)

16 . “Cobra Gold” manual push-pull 24 V **)

20 . Fronius unreeling device “VR 1530-12” 12 m/min or 470 ipm *)

23 . Binzel robot push-pull 32V **)

24 . Dinse robot push-pull new 42V **)

50 . Fronius manual push-pull “PT Drive” (d=0.8 mm or 0.030 in.; material: aluminium) ***)

51 . Fronius manual push-pull “PT Drive” (d=1.0 mm or 0.040 in.; material: aluminium) ***)

52 . Fronius manual push-pull “PT Drive” (d=1.2 mm or 0.045 in.; material: aluminium) ***)

53 . Fronius manual push-pull “PT Drive” (d=1.6 mm or 1/16 in; material: aluminium) ***)

54 . Binzel robot push-pull “Master Feeder BG II” *) **) ***)

55 . Fronius “VR 1530 PD” unreeling device (d = 1.0mm or 0.040 in; material: steel) ***)

56 . Fronius “VR 1530 PD” unreeling device (d = 1.2mm or 0.045 in; material: steel) ***)

57 . Fronius “VR 1530 PD” unreeling device (d = 1.6mm or 1/16 in; material: steel) ***)

59 . Fronius manual push-pull “PT Drive” (d=1.0 mm or 0.040 in.; materials: steel, CrNi,

CuSi3) ***)

60 . Fronius manual push-pull “PT Drive” (d=1.2mm or 0.045 in; materials: steel, CrNi) ***)

61 . Fronius manual push-pull “PT Drive” (d=0.8mm or 0.030 in; materials: steel, CrNi) ***)

62 . Binzel robot push-pull 32V with IWG *) **) ***)

*)...... It is not necessary to calibrate the unit under load (St2)

**).....Motor and gear tolerances may cause functional anomalies. Calibration may have to be carried out by

Fronius.***)

...Software must be specially enabled

Page 104: Fronius TPS Operating Instructions

88

7. Engage the drive units of both wirefeeder motors (e.g. welding torch and wirefeeder)

once again - the wirefeeder motors must be under load (push-pull alignment -

engaged)

Calibrating the

push-pull unit

(continued)

9. The alignment operation on the push-

pull unit is finished when the previous-

ly set values - e.g. “PPU” and “5” -

reappear on the display.

10. Press the Store button twice to exit

from the Set-up menu.

8. Press the torch trigger or the “Feeder

inching” button

The wirefeeder motors are aligned

while under load. During the align-

ment operation, the right-hand display

will read “run”.

If it is not necessary to perform the

alignment on a push-pull unit while

this unit is under load (St2), the

previously set values - e.g. “PPU” and

“5” - will appear on the display as

soon as you press the torch trigger or

the “Feeder inching” button.

3. Press the torch trigger or the “Feeder

inching” button

4. Disengage the drive units of both

wirefeeder motors (e.g. welding torch

and wirefeeder) - the wirefeeder

motors must not be under load (push-

pull alignment - open circuit)

5. Press the torch trigger or the “Feeder

inching” button

The wirefeeder motors are aligned

while not under load. During the

alignment operation, the right-hand

display will read “run”.

6. As soon as the alignment operation -

in the unloaded state - is complete,

the display will read “St2”.

Caution! Danger from welding wire emerging at speed and from rotating cogs

and drive parts. Hold the torch so that it points away from your face and body.

Keep hands away from rotating cogs and the wire drive.

Caution! Danger from rotating cogs and drive parts. Keep hands away from

rotating cogs and the wire drive.

Page 105: Fronius TPS Operating Instructions

89

Calibrating the

push-pull unit

(continued)

- Select “Parameter 2nd”

- Access Set-up menu: Level 1

10. Press the store button (21)

Fig.53 “Comfort” control panel: Aligning the push-pull unit

- Press and hold the Store button (21)

- Press the “Process” button (4)

- Release the Store button (21).

1. Select the “PPU” function

2. With the adjusting dial (1),

select the relevant push-pull

unit3. Press the torch trigger or the

“Feeder inching” button (23) ...

... “St1” is shown on the display4. Disengage the

drive units

5. Press the torch trigger or the“Feeder inching” button (23) ...

... “St1 | run” is shown on the display

6. “St2” is shown on the display7. Engage the drive units

8. Press the torch trigger or the“Feeder inching” button (23) ...

... “St2 | run” is shown on the display

9. The alignmentoperation on the push-pull unit is finished

Page 106: Fronius TPS Operating Instructions

90

Service codes for push-pull calibration

Safety

Err | Eto

Cause: Incorrect measurement during push-pull alignment.

Remedy: Repeat push-pull alignment

St1 | E 1

Cause: At minimum wirefeed speed, the wirefeeder motor does not deliver any

actual rotational speed value.

Remedy: Repeat the push-pull alignment. If the error message re-appears: Contact

After-Sales Service

St1 | E 2

Cause: At maximum wirefeed speed, the wirefeeder motor does not deliver any

actual rotational speed value.

Remedy: Repeat the push-pull alignment. If the error message re-appears: Contact

After-Sales Service.

St1 | E 3

Cause: At minimum wirefeed speed, the wirefeeder motor does not deliver any

actual rotational speed value.

Remedy: Repeat the push-pull alignment. If the error message re-appears: Contact

After-Sales Service.

St1 | E 4

Cause: At minimum wirefeed speed, the motor of the push-pull unit does not deliver

any actual rotational speed value.

Remedy: Repeat the push-pull alignment. If the error message re-appears: Contact

After-Sales Service.

St1 | E 5

Cause: At maximum wirefeed speed, the wirefeeder motor does not deliver any

actual rotational speed value.

Remedy: Repeat the push-pull alignment. If the error message re-appears: Contact

After-Sales Service.

St1 | E 6

Cause: At maximum wirefeed speed, the motor of the push-pull unit does not

deliver any actual rotational speed value.

Remedy: Repeat the push-pull alignment. If the error message re-appears: Contact

After-Sales Service.

Warning! An electric shock can be fatal. Before opening up the machine

- Switch the mains switch to the “O” position

- Unplug machine from the mains

- Put up an easy-to-understand warning sign to stop anybody inadvertently

switching it back on again

- Using a suitable measuring instrument, check to make sure that electrical-

ly charged components (e.g. capacitors) have been discharged

Error codes

shown when the

drive units are

engaged (“enga-

ged” calibration)

Page 107: Fronius TPS Operating Instructions

91

St1 | E 16

Cause: Push-pull alignment has been interrupted: Quick-stop was activated by

pressing the torch trigger.

Remedy: Repeat push-pull alignment

St2 | E 7

Cause: “Push-pull alignment - open-circuit” has not been carried out

Remedy: Carry out “push-pull alignment - open-circuit”

St2 | E 8

Cause: At minimum wirefeed speed, the wirefeeder motor does not deliver any

actual rotational speed value.

Remedy: Repeat the push-pull alignment. If the error message re-appears: Contact

After-Sales Service.

St2 | E 9

Cause: At minimum wirefeed speed, the motor of the push-pull unit does not deliver

any actual rotational speed value.

Remedy: Repeat the push-pull alignment. If the error message re-appears: Contact

After-Sales Service.

St2 | E 10

Cause: At minimum wirefeed speed, the motor current of the wirefeeder motor is

outside the permitted range. Possible causes of this include the wirefeeder

motors not being engaged, and other wirefeed problems.

Remedy: Engage the drive units of both wirefeeder motors, arrange the hosepack in

as straight a line as possible; check the inner liner for kinks or soiling;

check the contact pressure on the 2-roller or 4-roller drive of the push-pull

unit.

Repeat the push-pull alignment. If the error message re-appears: Contact

After-Sales Service.

St2 | E 11

Cause: At minimum wirefeed speed, the motor current of the push-pull unit is

outside the permitted range. Possible causes of this include the wirefeeder

motors not being engaged, and other wirefeed problems.

Remedy: Engage the drive units of both wirefeeder motors, arrange the hosepack in

as straight a line as possible; check the inner liner for kinks or soiling;

check the contact pressure on the 2-roller or 4-roller drive of the push-pull

unit.

Repeat the push-pull alignment. If the error message re-appears: Contact

After-Sales Service.

St2 | E 12

Cause: At maximum wirefeed speed, the wirefeeder motor does not deliver any

actual rotational speed value.

Remedy: Repeat the push-pull alignment. If the error message re-appears: Contact

After-Sales Service.

St2 | E 13

Cause: At maximum wirefeed speed, the motor of the push-pull unit does not

deliver any actual rotational speed value.

Remedy: Repeat the push-pull alignment. If the error message re-appears: Contact

After-Sales Service (faulty actual-value pick-up)

Error codes

shown when the

drive units are

engaged (“enga-

ged” calibration)

Page 108: Fronius TPS Operating Instructions

92

Error codes

shown when the

drive units are

engaged (“enga-

ged” alignment)

(continued)

St2 | E 14

Cause: At maximum wirefeed speed, the motor current of the wirefeeder motor is

outside the permitted range. Possible causes of this include the wirefeeder

motors not being engaged, and other wirefeed problems.

Remedy: Engage the drive units of both wirefeeder motors, arrange the hosepack in

as straight a line as possible; check the inner liner for kinks or soiling;

check the contact pressure on the 2-roller or 4-roller drive of the push-pull

unit.

Repeat the push-pull alignment. If the error message re-appears: Contact

After-Sales Service

St2 | E 15

Cause: At maximum wirefeed speed, the motor current of the push-pull unit is

outside the permitted range. Possible causes of this include the wirefeeder

motors not being engaged, and other wirefeed problems.

Remedy: Engage the drive units of both wirefeeder motors, arrange the hosepack in

as straight a line as possible; check the inner liner for kinks or soiling;

check the contact pressure on the 2-roller or 4-roller drive of the push-pull

unit.

Repeat the push-pull alignment. If the error message re-appears: Contact

After-Sales Service.

St2 | E 16

Cause: Push-pull alignment has been interrupted: Quick-stop was activated by

pressing the torch trigger.

Remedy: Repeat push-pull alignment

Page 109: Fronius TPS Operating Instructions

93

Measuring the welding circuit resistance “r”

General remarks Measuring the welding circuit resistance “r” makes it possible to have a constant welding

result at all times, even with hosepacks of different lengths. The welding voltage at the

arc is then always precisely regulated, regardless of the length and cross-sectional area

of the hosepack. It is no longer necessary to adjust with the “Arc length correction”

parameter (15).

After it has been measured, the welding circuit resistance is indicated on the right-hand

display.

r ... Welding circuit resistance (in mΩ)

If the welding circuit resistance “r” has been measured correctly, the welding voltage will

correspond exactly to the welding voltage at the arc. If you manually measure the volta-

ge on the output jacks of the power source, this voltage will be higher than the welding

voltage at the arc - that is, higher by the same amount as the voltage-drop taking place

in the hosepack.

Note! The welding circuit resistance “r” will depend upon which hosepack is

being used. This means that the measurement to find out the welding circuit

resistance “r” will have to be:

- repeated if there is any change in the length or cross-sectional area of the

hosepack

- repeated if there is any change in the length or cross-sectional area of the

hosepack

Measuring the

welding circuit

resistance “r”

5. Take off the gas nozzle from the welding torch

6. Tighten the contact tube

7. Place the contact tube down firmly on the surface of the workpiece

Note! Make sure that the contact between the contact tube and the workpiece is

on a clean part of the workpiece. While the measurement is being performed,

the wirefeeder and the cooling unit are deactivated.

8. Briefly press the torch trigger or the “Feeder inching” button.

The welding circuit resistance is now calculated; during the measurement, the right-

hand display reads “run”.

1. Make a ground (earth) connection to the workpiece

Note! In order to obtain good welding results, it is essential to measure the

welding circuit resistance correctly. Make sure that the contact between the

grounding (earthing) clamp and the workpiece is on a clean part of the workpiece.

2. Plug in the mains plug

3. Switch the mains switch (G) to the “I” position

4. Select function “r” in the second menu level (2nd)

Page 110: Fronius TPS Operating Instructions

94

9. The measurement is finished when the welding circuit resistance is shown on the

right-hand display (e.g. 11.4 milliohms)

10. Fit the gas nozzle back onto the welding torch

Measuring the

welding circuit

resistance “r”

(continued)

Page 111: Fronius TPS Operating Instructions

95

Indicating the welding circuit inductivity L

The way that the hosepack is arranged has a very significant effect on the welding

properties. Particularly with MIG/MAG pulse synergic welding, a high welding circuit

inductivity may occur, depending on the length of the hosepack and the way it is arran-

ged. The result is that the current rise during the droplet transfer is limited.

The welding circuit inductivity L is calculated during welding and shown on the right-hand

display.

- Select function “L” in the second menu level (2nd)

L ... Welding circuit inductivity (in microhenrys)

Important! Wherever possible, compensation for the welding circuit inductivity is perfor-

med automatically. Where very high welding circuit inductivity occurs, it is also possible

to attempt to influence the welding results with the droplet detachment correction para-

meter (16). If this does not lead to the desired result, you must re-arrange the hosepack.

Fig.54 Correct arrangement of the hosepack

Indicating the

welding circuit

inductivity L

Correct arrange-

ment of the

hosepack

Page 112: Fronius TPS Operating Instructions

96

The digital power sources are equipped with an intelligent safety system. This means

that apart from the fuse for the coolant-pump, it has been possible to dispense with

melting-type fuses entirely. After a possible malfunction or error has been remedied, the

power source can be put back into normal operation again without any melting-type

fuses having to be changed.

Troubleshooting

If any error message that is not described here appears on the displays, then the fault is

one that can only be put right by a service technician. Make a note of the error message

shown in the display, and of the serial number and configuration of the power source,

and get in touch with our after-sales service, giving them a detailed description of the

error.

-St | oP-

Where the power source is being operated with a robot interface or a field bus

Cause: Robot not ready

Remedy: Initialise “Robot ready” signal, initialise “Source error reset” signal (N.B.

“Source error reset” only available in conjunction with ROB 5000 and field-

bus coupler for robot control)

dsP | A21

Can only occur when power sources are being operated in parallel or in “Twin” mode

Cause: The power source is configured for either parallel operation (set-up parame-

ter P-C is set to “ON”) or for TimeTwin Digital (set-up parameter T-C is set

to “ON”). However, the LHSB link has been disconnected, or has become

faulty, while the power source was switched on.

Remedy: Dismiss the service code: Switch the power source off and back on again.

If necessary, restore or repair the LHSB link.

dSP | Axx, dSP | Cxx, dSP | Exx, dSP | Sy, dSP | nSy

Cause: Fault in central control and regulation unit

Remedy: Contact After-Sales Service

General remarks

Displayed service

codes

Warning! An electric shock can be fatal. Before opening up the machine

- Switch the mains switch to the “O” position

- Unplug machine from the mains

- Put up an easy-to-understand warning sign to stop anybody inadvertently

switching it back on again

- Using a suitable measuring instrument, check to make sure that electrical-

ly charged components (e.g. capacitors) have been discharged

Caution! Inadequate PE conductor connections can cause serious injury and

damage. The housing screws provide a suitable PE conductor connection for

grounding (earthing) the housing and must NOT be replaced by any other

screws that do not provide a reliable PE conductor connection.

Page 113: Fronius TPS Operating Instructions

97

Displayed service

codes

(continued)

EFd | xx.x, EFd | 8.1

Cause: Fault in the wirefeed system (overcurrent in wirefeeder drive)

Remedy: Arrange the hosepack in as straight a line as possible; check that there

are no kinks or dirt in the inner liner; check the contact pressure on the 2-

roller (or 4-roller) drive

Cause: Wirefeeder motor is stuck or defective

Remedy: Check / change the wirefeeder motor

EFd | 8.2

Cause: Fault in the wirefeed system (overcurrent in drive of push-pull unit)

Remedy: Arrange the hosepack in as straight a line as possible; check the inner

liner for kinks or soiling; check the contact pressure on the 2-roller or 4-

roller drive of the push-pull unit

EFd | 9.1

Cause: External supply voltage: Supply voltage has dropped below the tolerance

range

Remedy: Check the external supply voltage

Cause: Wirefeeder motor is stuck or defective

Remedy: Check / change the wirefeeder motor

EFd | 9.2

Cause: External supply voltage: Supply voltage has risen above the tolerance range

Remedy: Check the external supply voltage

EFd | 12.1

Cause: No actual rotational speed value from the wirefeeder motor

Remedy: Check the actual-value pick-up and the cable connections to and from it,

and replace if necessary

EFd | 12.2

Cause: No actual rotational speed value from the motor of the push-pull unit

Remedy: Check the actual-value pick-up and the cable connections to and from it,

and replace if necessary

EFd | 15.1 Wire buffer not reached

Cause: counter lever on main wirefeeder open

Remedy: close counter lever on main wirefeeder

Acknowledge service code by pressing “feeder inching” button

Cause: main wirefeeder slipping

Remedy: check wearing parts on wire feeder

use suitable feed rollers

decrease wire braking force

increase contact pressure on main wirefeeder

acknowledge service code by pressing “Feeder inching” button

Cause: end of wire reached

Remedy: check whether sufficient wire available

acknowledge service code using “Feeder inching” button

Page 114: Fronius TPS Operating Instructions

98

EFd | 15.2 Wire buffer exceeded

Cause: counter lever on push-pull unit open

Remedy: close counter lever on push-pull unit

acknowledge service code by pressing “feeder inching” button

Cause: push-pull unit slipping

Remedy: check wearing parts for wire inching

use suitable feed rollers

increase contact pressure on the push-pull unit

acknowledge service code by pressing the “Feeder inching” button”

Cause: arc not igniting

Remedy: select wire diameter and material type in accordance with material used

check earth connection

acknowledge service code by pressing “Feeder inching” button

Cause: end of wire reached

Remedy: check whether sufficient wire available

acknowledge service code using “Feeder inching” button

EFd | 15.3 No wire buffer available

Cause: connection to wire buffer missing

Remedy: check connection to wire buffer

EFd | 30.1

Cause: LHSB connection to power source missing

Remedy: check LHSB connection to power source

EFd | 30.3

Cause: LHSB connection to CMT drive unit missing

Remedy: check LHSB connection to CMT drive unit

EFd | 31.1

Cause: CMT drive unit - rotor calibration failed

Remedy: switch power source off and on again; if the service code “EFd | 31.1”

remains, switch off power source, disengage CMT drive unit and switch

power source back on again; if still unsuccessful, contact After-Sales

Service

EFd | 31.2

Cause: CMT drive unit - rotor calibration running

Remedy: wait for rotor calibration to finish

EiF XX.Y

The values XX and Y should be taken from the Operating Instructions for Robot Inter-

face

Cause: Interface error

Remedy: See Operating Instructions for Robot Interface

Err | 049

Cause: Phase failure

Remedy: Check the mains fuse protection, the mains supply lead and the mains

plug

Err | 050

Cause: Intermediate circuit-balance error

Remedy: Contact After-Sales Service

Displayed service

codes

(continued)

Page 115: Fronius TPS Operating Instructions

99

Displayed service

codes

(continued)

Err | 051

Cause: Mains undervoltage: The mains voltage has dropped below the tolerance

range

Remedy: Check the mains voltage

Err | 052

Cause: Mains overvoltage: The mains voltage has risen above the tolerance range

Remedy: Check the mains voltage

Err | 054

Cause: “Sticking” of the wire in the solidifying weld pool

Remedy: Cut off the sticking wire-tip; there is no need to dismiss this error message

Err | 056

Cause: The “Wire-end check” option has detected the end of the welding wire

Remedy: Insert a new wire spool and feed the wire into the hosepack; dismiss Err |

056 by pressing the Store button (21)

Cause: Additional fan filter of the VR 1500 - 11 / 12 / 30 is contaminated -air supply

for the additional fan is no longer sufficient for cooling the power electronics

-the power electronics temperature switch has responded

Remedy: Clean filter or replace; dismiss Err | 056 by pressing the Store button (21)

Cause: Excessive ambient temperature on the VR 1500 - 11 / 12 / 30

Remedy: Reduce ambient temperature, if necessary position and operate welding

machine at a cooler location; dismiss Err | 056 by pressing the Store

button (21)

Cause: Excessive motor current on the VR 1500 - 11 / 12 / 30, e.g. due to wire feed

problems or an adequately dimensioned feed

Remedy: Check wire feed conditions, rectify errors; dismiss Err | 056 by pressing

the Store button (21)

Cause: Wire feeder cover VR 1530 open or interlock release handles not snapped

into place

Remedy: Close wire feeder cover VR 1530 properly, dismiss Err | 056 by pressing

the Store button (21)

Err | 062

„E62“ is displayed simultaneously on remote controller TP 08

Cause: Overheating of remote controller TP 08

Remedy: Allow remote controller TP 08 to cool down

Err | 069

Cause: Illegal mode change during welding

Remedy: Re-start welding procedure

Err 70.X

Cause: Fault in digital gas sensor

Err 70.1 ... Gas sensor not found

Err 70.2 ... No gas

Err 70.3 ... Calibration error

Err 70.4 ... Solenoid valve faulty

Err 70.5 ... Solenoid valve not found

Remedy: Check gas supply

Page 116: Fronius TPS Operating Instructions

100

Displayed service

codes

(continued)

Err 71.X

Set limits have been exceeded or have not been reached.

Cause: Err 71.1 ... Current limit exceeded

Err 71.2 ... Current limit not reached

Err 71.3 ... Voltage limit exceeded

Err 71.4 ... Voltage limit not reached

Remedy: Check quality of weld seam

Err | bPS

Cause: Fault in power module

Remedy: Contact After-Sales Service

Err | Cfg

Can only occur when power sources are being operated in parallel or in “Twin” mode

Cause: Power source is configured for parallel operation (set-up parameter P-C is

set to “ON”) or TimeTwin Digital (set-up parameter T-C is set to “ON”).

However, after being switched on, the power source was unable to estab-

lish an LHSB link (LHSB link was previously detached or became faulty).

Remedy: Dismiss the service code: Switch the power source off and back on again.

If necessary, restore or repair the LHSB link.

Err | IP

Cause: Primary overcurrent

Remedy: Contact After-Sales Service

Err | PE

Cause: The earth fault-current watchdog has triggered the safety cut-out of the

power source.

Remedy: Switch off the power source, wait for 10 seconds and then switch it on

again. If you have tried this several times and the error keeps on occurring

- contact After-Sales Service.

Err tJo

Cause: Jobmaster temperature sensor faulty

Remedy: Contact After-Sales Service

hot | H2O

Cause: Thermostat on cooling unit has been tripped

Remedy: Wait until the end of the cooling phase, i.e. until “Hot | H2O” is no longer

displayed. ROB 5000 or field-bus coupler for robot control: Before resu-

ming welding, initialise the “Source error reset” signal.

no | Arc

Cause: Arc-break

Remedy: Shorten the wire stickout; press the torch trigger repeatedly; clean the

surface of the workpiece

no | GAS

Cause: The “Gas watchdog” option has detected that there is no gas pressure

Remedy: Connect a new gas cylinder and open the gas cylinder valve/pressure

regulator;

Dismiss no | GAS by pressing the Store button

Page 117: Fronius TPS Operating Instructions

101

Displayed service

codes

(continued)

no | IGn

Cause: “Ignition time-out” function is active: No current started flowing before the

length of wire specified in the set-up menu had been fed. The safety cut-out

of the power source has been triggered.

Remedy: Shorten the wire stickout; press the torch trigger repeatedly; clean the

surface of the workpiece; if necessary, increase the setting in “Set-up

menu: Level 2” for the length of wire that is fed before the safety cut-out is

triggered.

no | H2O

Cause: Cooling-unit flow watchdog has been triggered

Remedy: Check the cooling unit; if necessary, top up the coolant and/or vent the

water forward-flow hose as described in “Putting the cooling unit into

service”. Then dismiss the error by pressing the “Store” button.

no | Prg

Cause: No pre-programmed program has been selected

Remedy: Select a pre-programmed program

r | E30

Cause: r-Alignment: There is no contact with the workpiece.

Remedy: Connect the grounding (earthing) cable; ensure a tight connection

r | E31

Cause: r-Alignment: Procedure has been interrupted by repeated pressing of the

torch trigger.

Remedy: Ensure a tight connection between the contact tube and the workpiece -

press the torch trigger once only.

r | E32

Cause: r-Alignment: Grounding (earthing) cable, current cable or hosepack defecti-

ve (value is below 0.5 mOhm or exceeds 30 mOhm)

Remedy: Check grounding (earthing) cable, current cable and/or hosepack, and

change if necessary

r | E33, r | E34

Cause: r-Alignment: Poor contact between the contact tube and the workpiece.

Remedy: Clean the point of contact, tighten the contact tube, check the grounding

(earthing) connection

tJO | xxx

At the same time, “E66” is displayed on the JobMaster

Remark: xxx stands for a temperature value

Cause: Overtemperature in Jobmaster welding torch

Remedy: Allow the torch to cool, then dismiss the error by pressing the “Store”

button

tP1 | xxx, tP2 | xxx, tP3 | xxx, tP4 | xxx, tP5 | xxx, tP6 | xxx

Remark: xxx stands for a temperature value

Cause: Over-temperature in the primary circuit of the power source

Remedy: Allow the power source to cool down

tS1 | xxx, tS2 | xxx, tS3 | xxx

Remark: xxx stands for a temperature value

Cause: Over-temperature in the secondary circuit of the power source

Remedy: Allow the power source to cool down

Page 118: Fronius TPS Operating Instructions

102

Power source -

troubleshootingtSt | xxx

Remark: xxx stands for a temperature value

Cause: Over-temperature in the control circuit

Remedy: Allow the power source to cool down

Power source does not function

Mains switch is ON, but indicators are not lit up

Cause: There is a break in the mains lead; the mains plug is not plugged in

Remedy: Check the mains supply lead, make sure that the mains plug is plugged in

Cause Mains outlet socket or plug is faulty

Remedy: Exchange faulty components

Power source does not function

Mains switch is ON, but indicators are not lit up

Cause: Mains fuse is faulty

Remedy: Change the mains fuse

No welding current

Mains switch is ON, overtemperature indicator is lit up

Cause: Overloading; the duty cycle has been exceeded

Remedy: Do not exceed the duty cycle

Cause: Thermostatic cut-out system has been tripped

Remedy: Wait until the power source automatically comes back on after the end of

the cooling phase

Cause: The fan in the power source is defective

Remedy: Change the fan

No welding current

Mains switch is ON and indicators are lit up

Cause: Grounding (earthing) connection is wrong

Remedy: Check the grounding (earthing) connection and clamp for correct polarity

Cause: There is a break in the current cable in the welding torch

Remedy: Exchange the torch

The machine does not function when the torch trigger is pressed

Mains switch is ON and indicators are lit up

Cause: The control plug is not plugged in

Remedy: Plug in the control plug

Cause: The welding torch or torch control lead is defective

Remedy: Exchange the torch

The machine does not function when the torch trigger is pressed

Mains switch is ON and indicators are lit up

Cause: the interconnecting hosepack is defective or not connected properly (not in

the case of TPS 2700)

Remedy: check interconnecting hosepack

Page 119: Fronius TPS Operating Instructions

103

Power source -

troubleshooting

(continued)

No shielding gas

All other functions are OK

Cause: The gas cylinder is empty

Remedy: Change the gas cylinder

Cause: The gas pressure regulator is faulty

Remedy: Change the gas pressure regulator

Cause: The gas hose is not mounted, or is damaged

Remedy: Mount / change the gas hose

Cause: The welding torch is defective

Remedy: Change the welding torch

Cause: The gas solenoid valve is defective

Remedy: Change the gas solenoid valve

Poor welding properties

Cause: Incorrect welding parameters

Remedy: Check the settings

Cause: Poor grounding (earthing) connection

Remedy: Ensure good contact to workpiece

Cause: Not enough shielding gas, or none at all

Remedy: Check the pressure regulator, gas hose, gas solenoid valve, torch gas

connection etc.

Cause: Welding torch is leaking

Remedy: Change the welding torch

Cause: Wrong contact tube, or contact tube is worn out

Remedy: Change the contact tube

Cause: Wrong wire alloy and/or wrong wire diameter

Remedy: Check the wire spool that has been inserted

Cause: Wrong wire alloy and/or wrong wire diameter

Remedy: Check the weldability of the base metal

Cause: The shielding gas is not suitable for this wire alloy

Remedy: Use the correct shielding gas

Irregular wirefeed speed

The welding wire forms a loop between the feed rollers and the wire inlet nozzle of the

welding torch

Cause: The braking force has been set too high

Remedy: Loosen the brake

Cause: The borehole of the contact tube is too narrow

Remedy: Use a suitable contact tube

Cause: The wirefeed inner liner in the welding torch is defective

Remedy: Check the wire inner liner for kinks, dirt etc.

Page 120: Fronius TPS Operating Instructions

104

Irregular wirefeed speed

The welding wire forms a loop between the feed rollers and the wire inlet nozzle of the

welding torch

Cause: The wirefeed rollers are unsuitable for the wire being used

Remedy: Use suitable wirefeed rollers

Cause: The wirefeed rollers have the wrong contact pressure

Remedy: Optimize the contact pressure

The welding torch becomes very hot

Cause: The design dimensions of the torch are not sufficient for this task

Remedy: Respect the duty cycle and loading limits

Cause: Only on water-cooled machines: Water through-flow is insufficient

Remedy: Check the coolant level, through-flow rate, cleanliness of coolant etc.

Power source -

troubleshooting

(continued)

Page 121: Fronius TPS Operating Instructions

105

Care, maintenance and disposal

Under normal operating conditions the power source requires only a minimum of care

and maintenance. However, it is vital to observe some important points to ensure the

welding machine remains in a usable condition for many years.

- Check mains plug, mains cable, welding torch, interconnecting hosepack and

grounding (earthing) connection for damage

- Check whether the allround distance of 0.5 m (1 ft 8 in.) is kept to ensure that the

cooling air can easily flow and escape.

Note! Furthermore, air inlets and outlets must in no case be covered, not even

covered partly.

- Optional: clean air filter

- Dismantle machine side panels and clean machine inside with dry reduced com-

pressed air

Note! Risk of damage to electronic components. Clean electronic components

from a certain distance only.

- If a lot of dust has accumulated, clean the cooling-air ducts.

Carry out disposal in accordance with the valid national and local regulations.

Warning! An electric shock can be fatal. Before opening up the machine

- Switch the mains switch to the “O” position

- Unplug machine from the mains

- Put up an easy-to-understand warning sign to stop anybody inadvertently

switching it back on again

- Using a suitable measuring instrument, check to make sure that electrical-

ly charged components (e.g. capacitors) have been discharged

General remarks

Every start-up

Every 2 months

Every 6 months

Disposal

Page 122: Fronius TPS Operating Instructions

106

Technical data

Special voltages

TPS 2700

For machines designed for special voltages, the technical data on the rating plate ap-

plies.

For all machines with a permitted mains voltage of up to 460 V: the mains plug supplied

as standard allows operation at voltages of up to 400 V. For mains voltages up to 460 V,

fit an approved mains plug or install the mains supply directly.

Mains voltage 3 x 400 V

Mains voltage tolerance ± 15 %

Power frequency 50 / 60 Hz

Mains fuse protection 16 A slow-blow

Primary continuous current (100 % d.c.) 6.6 A

Primary continuous power 4.5 - 8.7 kVA

Cos phi 0,99

Degree of efficiency 87 %

Welding current range:

MIG/MAG 3 - 270 A

Rod electrode (MMA) 10 - 270 A

TIG 3 - 270 A

Welding current at 10 min/40°C (104°F) 40 % d.c. 270 A

60 % d.c. 210 A

100 % d.c. 170 A

Welding voltage range according to standard characteristic

MIG/MAG 14.2 - 27.5 V

Rod electrode (MMA) 20.4 - 30.8 V

TIG 10.1 - 20.8 V

Max. welding voltage -

Open-circuit voltage 50 V

Protection IP 23

Type of cooling AF

Insulation class B

Marks of conformity CE, CSA

Safety S

Measurements l x b x h 625 x 290 x 475 mm

24.6 x 11.4 x 18.7 in.

Weight 27 kg

59.5 lb.

Page 123: Fronius TPS Operating Instructions

107

TPS 2700 MV Mains voltage 3 x 200-240 V

3 x 380-460 V

Mains voltage tolerance ± 10 %

Power frequency 50/60 Hz

Mains fuse protection 25/16 A slow-blow

Primary continuous current (100 % d.c.) 6.4 -14.2 A

Primary continuous power 4.6 - 10.7 kVA

Cos phi 0,99

Degree of efficiency 88 - 91 %

Welding current range

MIG/MAG 3 - 270 A

Rod electrode (MMA) 10 - 270 A

TIG 3 - 270 A

Welding current at 10 min/40°C (104°F) 35 % d.c. 270 A

60 % d.c. 210 A

100 % d.c. 170 A

Welding voltage range according to standard characteristic

MIG/MAG 14.2 - 27.5 V

Rod electrode (MMA) 20.4 - 30.8 V

TIG 10.1 - 20.8 V

Max. welding voltage -

Open-circuit voltage 50 V

Protection IP 23

Type of cooling AF

Insulation class B

Marks of conformity CE, CSA

Safety S

Measurements l x b x h 625 x 290 x 475 mm

24.6 x 11.4 x 18.7 in.

Weight 27 kg

59.5 lb.

Page 124: Fronius TPS Operating Instructions

108

TPS 3200 Mains voltage 3 x 400 V

Mains voltage tolerance ± 15 %

Power frequency 50/60 Hz

Mains fuse protection 35 A slow-blow

Primary continuous current (100 % d.c.) 12.6 -16.7 A

Primary continuous power 8.7 - 11.5 kVA

Cos phi 0,99

Degree of efficiency 91 %

Welding current range:

MIG/MAG 3 -320 A

Rod electrode (MMA) 10 -320 A

TIG 3 -320 A

Welding current at 10 min/40°C (104°F) 40 % d.c. 320 A

60 % d.c. 260 A

100 % d.c. 220 A

Welding voltage range according to standard characteristic

MIG/MAG 14.2 - 30.0 V

Rod electrode (MMA) 20.4 - 32.8 V

TIG 10.1 - 22.8 V

Max. welding voltage (320 A) 52,1

Open-circuit voltage 65 V

Degree of protection IP 23

Type of cooling AF

Insulation class F

Marks of conformity CE

Safety S

Dimensions l x b x h 625 x 290 x 475 mm

24.6 x 11.4 x 18.7 in.

Weight 35.6 kg

35.61 lb.

Page 125: Fronius TPS Operating Instructions

109

TPS 3200 MV Mains voltage 3 x 200-240 V

3 x 380-460 V

Mains voltage tolerance ± 10 %

Power frequency 50 / 60 Hz

Mains fuse protection 35 A slow-blow

Primary continuous current (100 % d.c.) 10.6 -31.2 A

Primary continuous power 8.7 - 11.5 kVA

Cos phi 0,99

Degree of efficiency 90 - 91 %

Welding current range:

MIG/MAG 3 -320 A

Rod electrode (MMA) 10 -320 A

TIG 3 -320 A

Welding current at 10 min/40°C (104°F) 40 % d.c. 320 A

60 % d.c. 260 A

100 % d.c. 220 A

Welding voltage range according to standard characteristic

MIG/MAG 14.2 - 30.0 V

Rod electrode (MMA) 20.4 - 32.8 V

TIG 10.1 - 22.8 V

Max. welding voltage (320 A) 49.1 -63.1 V

Open-circuit voltage 64 -67 V

Degree of protection IP 23

Type of cooling AF

Insulation class F

Marks of conformity CE

Safety S

Measurements l x b x h 625 x 290 x 475 mm

24.6 x 11.4 x 18.7 in.

Weight 35.6 kg

78.5 lb.

Page 126: Fronius TPS Operating Instructions

110

TS/TPS 4000 Mains voltage 3 x 400 V

Mains voltage tolerance ± 15 %

Power frequency 50 / 60 Hz

Mains fuse protection 35 A slow-blow

Primary continuous current (100 % d.c.) -

Primary continuous power 12.2 kVA

Cos phi 0,99

Degree of efficiency 88 %

Welding current range:

MIG/MAG 3 -400 A

Rod electrode (MMA) 10 -400 A

TIG 3 -400 A

Welding current at 10 min/40°C (104°F) 50 % d.c. 400 A

60 % d.c. 365 A

100 % d.c. 320 A

Welding voltage range according to standard characteristic

MIG/MAG 14.2 - 34.0 V

Rod electrode (MMA) 20.4 - 36.0 V

TIG 10.1 - 26.0 V

Max. welding voltage -

Open-circuit voltage 70 V

Protection IP 23

Type of cooling AF

Insulation class F

Marks of conformity CE, CSA

Safety S

Measurements l x b x h 625 x 290 x 475 mm

24.6 x 11.4 x 18.7 in.

Weight 35.2 kg

77.6 lb.

Page 127: Fronius TPS Operating Instructions

111

TS/TPS 4000 MV Mains voltage 3 x 200-240 V

3 x 380-460 V

Mains voltage tolerance ± 10 %

Power frequency 50 / 60 Hz

Mains fuse protection 63/35 A slow-blow

Primary continuous current (100 % d.c.) 15.3 - 34.4 A

Primary continuous power 10.6 - 12.4 kVA

Cos phi 0,99

Degree of efficiency 88 - 91 %

Welding current range:

MIG/MAG 3 - 400 A

Rod electrode (MMA) 10 - 400 A

TIG 3 - 400 A

Welding current at 10 min/40°C (104°F) 50 % d.c. 400 A

60 % d.c. 365 A

100 % d.c. 280 - 320 A

Welding voltage range according to standard characteristic

MIG/MAG 14.2 - 34.0 V

Rod electrode (MMA) 20.4 - 36.0 V

TIG 10.1 - 26.0 V

Max. welding voltage -

Open-circuit voltage 68 - 78 V

Protection IP 23

Type of cooling AF

Insulation class F

Marks of conformity CE, CSA

Safety S

Measurements l x b x h 625 x 290 x 475 mm

24.6 x 11.4 x 18.7 in.

Weight 35.2 kg

77.6 lb.

Page 128: Fronius TPS Operating Instructions

112

TS/TPS 5000 Mains voltage 3 x 400 V

Mains voltage tolerance ± 15 %

Power frequency 50 / 60 Hz

Mains fuse protection 35 A slow-blow

Primary continuous current (100 % d.c.) 18 - 29.5 A

Primary continuous power 13.1 kVA

Cos phi 0,99

Degree of efficiency 90 %

Welding current range:

MIG/MAG 3 - 500 A

Rod electrode (MMA) 10 - 500 A

TIG 3 -500 A

Welding current at 10 min/40°C (104°F) 40 % d.c. 500 A

60 % d.c. 450 A

100 % d.c. 360 A

Welding voltage range according to standard characteristic

MIG/MAG 14.2 - 39.0 V

Rod electrode (MMA) 20.4 - 40.0 V

TIG 10.1 - 30.0 V

Max. welding voltage -

Open-circuit voltage 70 V

Protection IP 23

Type of cooling AF

Insulation class F

Marks of conformity CE, CSA

Safety S

Measurements l x b x h 625 x 290 x 475 mm

24.6 x 11.4 x 18.7 in.

Weight 35.6 kg

78.5 lb.

Page 129: Fronius TPS Operating Instructions

113

See TPS 2700 MV / 3200 MV / 4000 MV / 5000 MV

The technical data of the Alu-Edition, CrNi-Edition and CMT special versions are identi-

cal to those of the standard power sources.

Mains voltage 3 x 200-240 V

3 x 380-460 V

Mains voltage tolerance ± 10 %

Power frequency 50 / 60 Hz

Mains fuse protection 63/35 A slow-blow

Primary continuous current (100 % d.c.) 10.1 - 36.1 A

Primary continuous power 12.4 - 13.9 kVA

Cos phi 0,99

Degree of efficiency 88 - 91 %

Welding current range:

MIG/MAG 3 - 500 A

Rod electrode (MMA) 10 - 500 A

TIG 3 - 500 A

Welding current at 10 min/40°C (104°F) 40 % d.c. 500 A

60 % d.c. 450 A

100 % d.c. 320 - 340 A

Welding voltage range according to standard characteristic

MIG/MAG 14.2 - 39.0 V

Rod electrode (MMA) 20.4 - 40.0 V

TIG 10.1 - 30.0 V

Max. welding voltage -

Open-circuit voltage 68 - 78 V

Protection IP 23

Type of cooling AF

Insulation class F

Marks of conformity CE, CSA

Safety S

Measurements l x b x h 625 x 290 x 475 mm

24.6 x 11.4 x 18.7 in.

Weight 35.6 kg

78.5 lb.

TS/TPS 5000 MV

Technical data -

US power source

Technical data

Alu-Edition, CrNi-

Edition and CMT

variants

Page 130: Fronius TPS Operating Instructions

114

Mains voltage 3 x 380-460 V

Mains voltage tolerance ± 10 %

Power frequency 50 / 60 Hz

Mains fuse protection 35 A slow-blow

Primary continuous current (450 A, 60 % d.c.) 32.5 A

Primary continuous power 21.4 kVA

Cos Phi (500 A) 0,99

Degree of efficiency 91 %

Welding current range

TIME 3 - 500 A

MIG/MAG 3 - 500 A

Rod electrode (MMA) 10 - 500 A

TIG 3 - 500 A

Welding current at 10 min/40°C (104°F) 40 % d.c. 500 A

60 % d.c. 450 A

100 % d.c. 360 A

Welding voltage range according to standard characteristic

TIME 28.0 - 48.0 V

MIG/MAG 14.2 - 39.0 V

Rod electrode (MMA) 20.4 - 40.0 V

TIG 10.1 - 30.0 V

Max. welding voltage -

Open-circuit voltage 70 V

Protection IP 23

Type of cooling AF

Insulation class F

Marks of conformity CE

Safety S

Measurements l x b x h 625 x 290 x 475 mm

24.6 x 11.4 x 18.7 in.

Weight 37.4 kg

82.45 lb.

TIME 5000 Digital

Page 131: Fronius TPS Operating Instructions

115

Welding program databases

The key symbols for the welding program databases are explained below. The databa-

ses contain the welding programs depending on the following settings on the control

panel:

- Operating mode:

P = pulse synergic welding

S = standard synergic welding

Example:

Explanation of

symbols

Fig.55 Example of a welding database

Welding programs that require the SFi (spatter free ignition) option have a grey back-

ground.

(B)(C)

(A)

(D)

Every welding database has

- The date of the last change (C)

- A number (D)

- Example:

- Material (A)

- Wire diameter (B)

Page 132: Fronius TPS Operating Instructions

116

Terms and abbreviations used

AL.c .... Arc length.correction ... Correction boundaries (high and low) for the arc length

(JobCorrection function)

AL.1 .... Arc length correction.1 ... General arc-length correction (JobCorrection function)

AL.2 .... Arc length correction.2 ... Arc length correction for the higher operating point of

the pulsed welding power (SynchroPuls)

Arc ...... Arc ... Arc-break monitoring

ASt ...... Anti-stick ... For reducing the effect of a “sticking” rod electrode (MMA welding)

bbc ..... burn-back time correction

C-C ..... Cooling unit cut-out. In position “Aut“, it is switched off automatically as a func-

tion of the coolant temperature. In position “On“ / “Off“, the cooling unit remains

always switched-on/switched-off. Separate adjustment for the MIG/MAG and

TIG processes is supported.

CSS .... Comfort stop sensitivity ... sensitivity of the response characteristic of the TIG

Comfort Stop function. The TIG Comfort Stop function supports the TIG welding

process without torch trigger. A down-slope is triggered by briefly lifting or

lowering the welding torch (ramp decrease of the welding current).

C-t ...... Cooling time ... Time from when the rate-of-flow watchdog is triggered until the

“no | H2O” service code is output

dFd ..... delta Feeder ... Welding-power offset (SynchroPuls - defined by the wirefeed

speed)

dYn ..... Dynamic ... Arc-force dynamic correction (standard arc) or pulse correction

(pulsed arc) (JobCorrection option, i.e. background setting of the arc-force

dynamic or pulse correction for the “Standard” control panel)

Eln ...... Electrode-line ... Characteristic selection (rod electrode [MMA] welding)

F ......... Frequency ... (SynchroPuls)

FAC .... Factory ... Reset the welding machine

FCO.... Feeder Control ... Wirefeeder cut-out (“Wire-end sensor” option)

Fdc ..... Feeder creep ... Soft start

Fdi ...... Feeder inching ... inching speed

GPo .... Gas post-flow time

General remarks

Terms and abbre-

viations

The terms and abbreviations listed here are used in connection with functions that are

either included in the standard scope of supply or that are available as optional extras.

Page 133: Fronius TPS Operating Instructions

117

Terms and

abbreviations

(continued)

GPr ..... Gas pre-flow time

Gun .... Gun (welding torch) ... “Changing between operating modes with the JobMaster

torch” (optional) ... 0 / 1

HCU ... Hot-start current ... (for rod electrode [MMA] welding)

Hti ....... Hot current time ... (for rod electrode [MMA] welding)

I-E ....... I (current) - End ... End current

I-S ....... I (current) - Starting ... Starting current

Ito ....... Ignition Time-Out

Job ..... Job for which the parameters are to be adjusted (JobCorrection function)

JSL ..... Job Slope ... defines the time between the Job that is currently selected and the

next following Job

L ......... L (inductivity) ... Indicating the welding-circuit inductivity

P ......... Power correction ... (defined by the wirefeed speed, JobCorrection function)

P-C ..... Power Control ... for defining the Master and Slave power sources when two

power sources are operated in parallel

PcH .... Power-correction High ... Correction boundary (high) for the welding power

(JobCorrection function)

PcL ..... Power-correction Low ... Correction boundary (low) for the welding power

(JobCorrection function)

PPU .... Push-pull unit ... For selecting and aligning the connected push-pull unit

r .......... r (resistance) ... Measuring the welding-circuit resistance

SEt ..... Setting ... Country-specific setting (Standard / USA)

SL ....... Slope

Spt ...... Spot-welding time

Stc ...... Wire stick control ... For detecting a “stuck” wire tip

S2t ...... Special 2-Step (only on “US” control panel) ... for selecting Jobs and Groups by

pressing the torch trigger

S4t ...... Special 4-step ... GunTrigger option, switching from one job to the next from the

JobMaster welding torch; is also the symbol for the “Special 4-step” mode on the

Jobmaster torch

t-C ...... Twin Control ... for defining the leading and trailing power sources in the Ti-

meTwin Digital process

t-E ....... time - End current ... Duration of final current

t-S ....... time - Starting current ... Duration of starting-current

tri ........ Trigger ... Subsequent correction of the operating mode

Page 134: Fronius TPS Operating Instructions

118

Terms and

abbreviations

(continued)

Uco ..... U (voltage) cut-off ... Limiting the welding voltage in the case of rod-electrode

welding. Makes it possible to stop the welding process by slightly raising the rod

electrode.

2nd ..... Second level of set-up menu

Page 135: Fronius TPS Operating Instructions

Liste de pièces de rechange

ErsatzteillisteD

Lista parti di ricambio

Lista de repuestos

Lista de peças sobresselentes

GB

F

I

E

P

NL

N

CZ

RUS

Spare Parts List

Onderdelenlijst

Reservdelsliste

Seznam náhradních dílů

Ñïèñîê çàïàñíûõ ÷àñòåé

ud_fr_st_tb_00150 012002

Page 136: Fronius TPS Operating Instructions

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi

TransPuls Synergic 2700

1/3

el_fr_st_mi_00154 012004

TransPulsSyn. 2700 4R/Z 4,075,095TransPulsSyn. 2700 4R/E 4,075,095,001TransPulsSyn. 2700 4R/D 4,075,095,002 MV TransPulsSyn. 2700 MV/4R/Z 4,075,095,630TransPulsSyn. 2700 MV/4R/E 4,075,095,631 ALU - Edition TransPulsSyn. 2700 4R/Z/ALU 4,075,095,633TransPulsSyn. 2700 4R/E/ALU 4,075,095,634 MV / ALU - Edition TransPulsSyn. 2700 MV/4R/Z/ALU 4,075,095,635TransPulsSyn. 2700 MV/4R/E/ALU 4,075,095,636 CrNi TransPulsSynerg.2700 4R/Z CrNi 4,075,095,856TransPulsSynerg.2700 4R/E CrNi 4,075,095,857 MV / CrNi TransPulsSynerg.2700 MV/4R/Z CrNi 4,075,095,858TransPulsSynerg.2700 MV/4R/E CrNi 4,075,095,859 DUO / TIG TransPulsSyn. 2700 4R/Z TIG 4,075,095,850TransPulsSyn. 2700 4R/Z DUO 4,075,095,851TransPulsSyn. 2700 4R/Z DUO/TIG 4,075,095,852TransPulsSyn. 2700 4R/E TIG 4,075,095,853TransPulsSyn. 2700 4R/E DUO 4,075,095,854TransPulsSyn. 2700 4R/E DUO/TIG 4,075,095,855 US TransPulsSyn. 2700 MV/4R/Z US 4,075,095,800TransPulsSyn. 2700 MV/4R/E US 4,075,095,801 AUS TransPulsSyn. 2700 4R/E AUS 4,075,095,638

Page 137: Fronius TPS Operating Instructions

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi

TransPuls Synergic 2700

2/3

el_fr_st_mi_00154 012004

42,0405,0219

12,0405,0206

12,0405,0208

44,0001,1196 - E44,0001,1207 - D

43,0001,0600

43,0001,1092

33,0010,0227

43,0010,0164

43,0030,0045

43,0001,1139

42,0001,3045,Z

41,0003,0215

44,0550,0060

33,0024,003244,0001,1195 - Z

40,0009,0043

AM2,0200,9330

45,0200,103045,0200,1077 - ALU

45,0200,091845,0200,1078 - ALU

42,0200,8860

42,0406,0292

42,0405,0220

42,0407,0449

32,0405,0164

44,0001,1309

45,0200,1187 - CrNi

45,0200,1186 - CrNi

Page 138: Fronius TPS Operating Instructions

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TransPuls Synergic 2700

3/3

el_fr_st_mi_00154 012004

4,070,662,Z - NF3160

NF3160

43,0004,2382 - DUO

42,0406,0073 - DUO

43,0004,2384 - DUO

43,0001,3268 - AUS

SNT4

ASU27

42,0001,3541 - US

32,0409,2639

32,0409,2640

43,0001,3260 - US43,0001,3234

42,0409,3012 - AUS42,0409,2932 - DUO/TIG

42,0409,2930 - TIG42,0409,2931 - DUO

42,0409,2760 - ALU42,0409,2649

43,0004,0507 - MV43,0004,0789

43,0001,1095 4,070,677,Z - SR41

4,070,626,Z - NT24A

4,070,691,Z - ASU27-MV

4,070,776 - SNT4-DUO

43,0013,0015

43,0002,0371

42,0407,0532 - US42,0300,1511

43,0004,2323 - US

41,0002,0059

42,0409,2973 - DUO

43,0003,0031 - DUO

43,0003,0031

4,100,423

42,0407,0063

42,0407,0284

40,0001,0352 - *

40,0001,0012 - *

42,0409,2914 - TIG

42,0405,0056

42,0405,0154

42,0404,0024

43,0003,048532,0405,0229

43,0003,0485

32,0409,2976

4,070,627,Z - NT60

42,0406,0315

42,0406,0093

NT24A32,0405,0183

42,0406,0297

40,0009,0043

SR41

4,070,860,Z - UST2A

UST2

NT604,100,217 - PM41

42,0407,0284 - E

PM41

43,0001,3270 - CrNi

4,070,739,Z - BPT27

BPT27

* gewünschte Länge angeben * Specify the length required * Indiquer la longueur désirée * Indicar la longitud deseada * Indicare la lunghezza desiderat * indicar o comprimento desejado* uved'te požadovanou délku

Page 139: Fronius TPS Operating Instructions

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi

TS / TPS / 3200 / 4000 / 5000, TIME 5000 Digital

1/3

el_fr_st_mi_00153 032006

TransPuls Synergic 3200 4,075,124TransSynergic 4000 C 4,075,097TransSynergic 5000 C 4,075,098TransSynergic 4000 4,075,099TransSynergic 5000 4,075,101TransPuls Synergic 4000 4,075,100TransPuls Synergic 5000 4,075,102

MVTransPuls Synergic 3200 MV 4,075,124,630TransSynergic 4000 C MV 4,075,097,630TransSynergic 5000 C MV 4,075,098,630TransSynergic 4000 MV 4,075,099,630TransSynergic 5000 MV 4,075,101,630TransPuls Synergic 4000 MV 4,075,100,630TransPuls Synergic 5000 MV 4,075,102,630

RCTransPuls Synergic 3200 R 4,075,124,RTransSynergic 4000 R 4,075,097,RTransSynergic 5000 R 4,075,098,RTransPuls Synergic 4000 R 4,075,100,RTransPuls Synergic 5000 R 4,075,102,R

MV/RCTransPuls Synergic 3200 MV R 4,075,124,630,RTransSynergic 4000 MV R 4,075,097,630,RTransSynergic 5000 MV R 4,075,098,630,RTransPulsSynergic 4000 MV R 4,075,100,630,RTransPulsSynergic 5000 MV R 4,075,102,630,R

AUSTransPuls Synergic 3200 4,075,124,638TransPuls Synergic 4000 4,075,100,638TransPuls Synergic 5000 4,075,102,638

CMTTransPuls Synergic 3200 CMT 4,075,137TransPuls Synergic 4000 CMT 4,075,138TransPuls Synergic 5000 CMT 4,075,139TransPuls Synergic 3200 CMT MV 4,075,137,630TransPuls Synergic 4000 CMT MV 4,075,138,630TransPuls Synergic 5000 CMT MV 4,075,139,630TransPuls Synerg.3200 CMT MV US 4,075,137,800TransPuls Synerg.4000 CMT MV US 4,075,138,800TransPuls Synerg.5000 CMT MV US 4,075,139,800TransPuls Synerg.3200 CMT 460 V 4,075,137,801TransPuls Synerg.4000 CMT 460 V 4,075,138,801TransPuls Synerg.5000 CMT 460 V 4,075,139,801

CMT/RCTransPuls Synergic 3200 CMT R 4,075,137,RTransPuls Synergic 4000 CMT R 4,075,138,RTransPuls Synergic 5000 CMT R 4,075,139,RTransPuls Synergic 3200 CMT MV R 4,075,137,630,RTransPuls Synergic 4000 CMT MV R 4,075,138,630,RTransPuls Synergic 5000 CMT MV R 4,075,139,630,RTransPulsSynerg.3200 CMT MV US R 4,075,137,800,RTransPulsSynerg.4000 CMT MV US R 4,075,138,800,RTransPulsSynerg.5000 CMT MV US R 4,075,139,800,R

USTransPuls Synergic 3200 MV 4,075,124,800TransSynergic 4000 C MV 4,075,097,800TransSynergic 5000 C MV 4,075,098,800TransPuls Synergic 4000 MV 4,075,100,800TransPuls Synergic 5000 MV 4,075,102,800TransPuls Syn. 4000 MV Pipe 4,075,100,810

US/RCTransPuls Synergic 3200 MV R 4,075,124,800,RTransSynergic 4000 MV R 4,075,097,800,RTransSynergic 5000 MV R 4,075,098,800,RTransPulsSynergic 4000 MV R 4,075,100,800,RTransPulsSynergic 5000 MV R 4,075,102,800,R

460VTransPuls Synergic 3200 460V 4,075,124,801TransPuls Syn. 3200 460V Pipe 4,075,124,809TransPuls Syn. 3200 460V Pipe HE 4,075,124,810TransPuls Syn. 3200 460V Pipe BA 4,075,124,811TransSynergic 4000 C 460V 4,075,097,801TransSynergic 4000 C 460V 4,075,097,930TransSynergic 4000 460V 4,075,099,930TransSynergic 5000 C 460V 4,075,098,801TransSynergic 5000 C 460V 4,075,098,930TransSynergic 5000 460V 4,075,101,930TransPuls Synergic 4000 460V 4,075,100,801TransPuls Synergic 4000 460V 4,075,100,930TransPuls Synergic 5000 460V 4,075,102,801TransPuls Synergic 5000 460V 4,075,102,930

460V/RCTransSynergic 4000 460V R 4,075,097,930,RTransSynergic 5000 460V R 4,075,098,930,RTransPulsSynergic4000 460V R 4,075,100,930,RTransPulsSynergic5000 460V R 4,075,102,930,R

CrNiTransPuls Synergic 3200 CrNi 4,075,124,631TransPuls Synergic 3200 MV CrNi 4,075,124,632TransPuls Synergic 4000 CrNi 4,075,100,631TransPuls Synergic 4000 MV CrNi 4,075,100,632TransPuls Synergic 5000 CrNi 4,075,102,631TransPuls Synergic 5000 CrNi 460V 4,075,102,632

TIME 5000 Digital 4,075,140,930

Page 140: Fronius TPS Operating Instructions

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi

TS / TPS / 3200 / 4000 / 5000, TIME 5000 Digital

2/3

el_fr_st_mi_00153 032006

45,0200,91845,0200,1186 - CrNi45,0200,1201 - CMT

45,0200,91845,0200,1186 - CrNi45,0200,1201 - CMT

43,0001,1186

33,0005,4120 - MV

42,0200,8860

AM2,0200,8819

32,0405,0164

40,0009,0043

41,0002,0060

41,0003,0203

43,0001,0600

43,0001,0600

43,0001,1104

41,0003,0203

40,0009,0043

33,0005,4112

43,0001,1139

43,0001,1103

43,0001,1187

43,0001,1092 - TPS3200

41,0009,0187

12,0405,0208

12,0405,0208

33,0005,4120 - 460V/US

BPS

4,100,413

43,0006,0152

4,070,681,Z - BPS32 TS/TPS 32004,070,738,Z - BPS42 TS/TPS 3200/40004,070,771,Z - BPS43 TS/TPS 3200/40004,070,658,Z - BPS50 TS/TPS 5000/TIME4,070,772,Z - BPS53 TS/TPS 5000/TIME

33,0010,0335

33,0010,0345 - TIME 5000

Page 141: Fronius TPS Operating Instructions

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi

TS / TPS / 3200 / 4000 / 5000, TIME 5000 Digital

3/3

el_fr_st_mi_00153 032006

NT24

NT60

43,0002,0358

43,0004,2955 - US AWG 10

42,0406,0315

42,0406,0093

42,0400,0132

32,0409,2740 - MV/US

BE2,0201,1355 - US

ASU4043,0003,0485

32,0405,0229

32,0405,0183

42,0300,1511

43,0004,0586 - 460V

43,0003,0031

4,070,685,Z - ASU40

4,070,860,Z - UST2B4,070,960,Z - UST2C

4,070,626,Z - NT244,070,928 - NT24T Pipe

4,070,627,Z - NT60

43,0004,0664 - MV

42,0407,0437 - MV

43,0006,0168

32,0409,2657

43,0003,0031

42,0406,0299

32,0409,2656

32,0409,2658

42,0300,152341,0005,0288

43,0004,0987

BE2,0201,1593 - US

43,0004,2324 - US AWG 6

42,0407,0534 - US AWG 1042,0407,0533 - US AWG 6

4,070,677,Z - SR41

SR41

4,100,423

42,0407,0284

40,0001,0352 - *

43,0013,0015

* gewünschte Länge angeben * Specify the length required * Indiquer la longueur désirée * Indicar la longitud deseada * Indicare la lunghezza desiderat * indicar o comprimento desejado* uved'te požadovanou délku

43,0001,1213 - MV/US 80A

43,0001,1199 - 40A

UST2

43,0004,2727 - TIME 5000

42,0300,1815 - TIME 5000

BE2,0201,1934 - MV

43,0001,3234 - COMF43,0001,3235 - TS43,0001,3253 - RC43,0001,3260 - US43,0001,3268 - AUS43,0001,3270 - CrNi43,0001,3276 - CMT Rem.43,0001,3277 - TIME 500043,0001,3306 - CMT COMF

42,0409,5083 - TPS 320042,0409,3055 - TPS 3200 AUS42,0409,2650 - TS 400042,0409,2651 - TPS 400042,0409,2652 - TS 500042,0409,2653 - TPS 500042,0409,3013 - TPS 4000 AUS42,0409,3014 - TPS 5000 AUS42,0409,3027 - TPS 4000 Pipe42,0409,3097 - TPS 3200 Pipe42,0409,3082 - TIME 5000

Page 142: Fronius TPS Operating Instructions

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FRONIUS France SARL60306 SENLIS CEDEX,13 avenue Félix Louat - B.P.195Tél: +33 (0)3 44 63 80 00Fax:+33 (0)3 44 63 80 01E-Mail: [email protected]

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USA

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UA

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Fronius Worldwide - www.fronius.com/addresses

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Under http://www.fronius.com/addresses you will find all addresses of our sales branches and partner firms!

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CZA

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