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Fronius Transpuls Synergic 2700 4000 & 5000

Fronius Transpuls Owners Manual

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Robert Case
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2K views73 pages

Fronius Transpuls Synergic 2700 4000 & 5000

Fronius Transpuls Owners Manual

Uploaded by

Robert Case
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
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TRANS SYNERGIC 4000 / 5000 TRANS SYNERGIC 4000 / 5000 COMFORT TRANSPULS SYNERGIC 2700 / 4000 / 5000 | Digitales Digital Soudeuse | MIGIMAG-Schweiggerat MIGIMAG welding machine numérique MIG/MAG BEDIENUNGS- OPERATING MODE ANLEITUNG INSTRUCTIONS D’EMPLOI | ERSATZTEIL- SPARE PARTS LISTE DE PIECES LISTE LIST DE RECHANGE 420410,0583 or2002 OPERATING INSTRUCTIONS Ec CONTENTS Dear Fronius Customer, Safety ules General remarks Utisation fr intended purpose only. Obligations of ownerioporator Obligations of personnal Personal protective equipment Hazards from noxious gases and vapours Hazards rom fying sparks Hazards from mains and welding curent. Parlcular danger spo. Informal safety precautions... ‘Safety precautions athe installation location Vagrant wolding curents. Safety precautions in normal operation. Safety inspection. ‘Alteraons to the welding machine Spares and wearing pats Calibration of welding machines (CE-marking ns Copyright. General remarks. Principle ofthe cgtal family of machines Machine concept ‘Areas ofuse Description of control pane. "Remote operating pane Operating modes ‘2tep mode 4.step mode Aluminium welding start-up Spot welding Controls and connections ‘TPS 2700 power source. “75 4000/6000 & TPS 4000/5000 power sources. \VR 4000 / VR 4000 C / VR 4000 Cl wirefeeder. ‘VR 7000 /VR 7000 Cl wirefeedar VR 2000 wirefeeder.... FK 4000 /4000 R cooling unit JoblMaster welding torch TR2000remote-conto unt TR4000 remote-control nit ‘TR4000€ remote-control unit ‘TP 08 remote-control unit RCU 4000 remote-control pane! “LocalNet passive" distributor "LocalNet active" splitter ‘Staring to use the welding machine Utisation for intended purpose only. Machine setup regulations Mains connection Remountig he plug-type connections for coolant forwardand return flow Mounting the cooing uniton the trolley Altaching the cooling unitto the power soures Mounting the gas- shorter are © neutral arcength + longer arc-length Manval electrode we'ding .. for influencing the shert-reuiing am- erage atthe instant of droplet transfor 0... Sof, low-spatter are 100. harder, more stable are Leadthrough for interconnecting cable Lead-through for external welding wire N.B.! Parameters that can be set on the wirefeeder cannot be changed on the power source. Parameter changes can only be made on the wirefeeder, a a Feeder.inching / gas-test button (optional) Press the button down ... to inch the wire electrode into the torch hosepack without any flow of shilding-gas or curent. As iong as the button is held down, the wirefeeder runs at feeder-inching speed. Press the button up ... to set the required gas-low rate on the pressure regulator. As long 2s the button i pressed up, gas ows out Optional “mode selector switch”. inc!‘gas-est/ wire-inch but- Note! Setings made withthe mode selector switch cannot be altered on other contol elements, e. the control pane! of the power source the fron ofthe wirefeader unit the remote contro! unit “Mode selector switch’ for selecting the process + MIGDAAG pulsed-arc welding EEE) ~ MIGIMAG standard welding C= ‘Special process, e.g. manual (FE) Job mode IG welding with contact ignition EES) MMA (manual electrode) welding =a} NBII the wirefeeder is connected up to TS 4000 / 5000 power source, the MIGIMAG pulsed-are welding process is no longer available. 21 "Mode selector switch” for selecting the operating mode = 2step mode SB + 4slep mode EB = Aluminium welding start-up + Spot welding eder-inching / gas-test button Press the button down .. o inch the wire electrode into the torch hosepack without any ow of shielding-gas or eurent. As long as the button is held down, the wirefeeder runs at feeder-inching speed. Press the button up ... to set the required gas-fow rate on the Pressure regulator. As longs the button is pressedup, gas lows out a B VR 4000 Cl operating panel... The operating panel enables you to access al settings that can also be made with thé operating panel of the TR 4000 remote control unit For a detailed description of the controls, please see the section headed "TR 4000 remote control unit 16 VR 2000 WIREFEEDER System requirements for VR 2000 wirefeeder: ~ Software version 2.80.1 (power source) ‘The VR 2000 is designed to be used with wire-spoots of ciameter 20 ‘mm. In conjunction wih the 200 mm diameter wire-spoo,a 2-oller di is used, This results in a compact housing and very ow weight, ‘The VR 2000 was specially developed for use in shipyards and in th offshore industry, and so as well as making it handy’ to use, it signers also ensured that it runs perfectly even when used with ver Tong hosepacks. ‘To facilitate the use of 70 m hosepacks, the VR 2000 has an integrate gastiow regulator with a low-rate indicator. \When using long hosepacks, tis advisable fo install the optional “mode selector switch’, This allows the user to select the processes an ‘operating modes directly from the welding location, as well as to execute the “gas-est” and wiresinch functions. Using the VR 2000 with ong hosepacks often means tha the welder can no longer “keep an eye on’ the powor source from where he is working, If this is often the case, we advise equipping the power source with the ‘optional key-switch’. This provides optimum protection against anybody tampering or accidentaly interfering withthe machine while itis being used. 'N.B.! Applies when using 70m hosepacks that you have prepared yourself or purchased from other manufacturers: ~ Make sure that the cross-sectional area ofthe supply cables forthe witefeeder drive is at least 13 mm. Fae N.B. Parameters that can be set on the VR 2000 wirefeeder cannot be ‘changed on the power source. Any parameter changes that are needed can only be made on the VR 2000 wirefeeder. {8 Torch central connector .. for connecting the welding torch to the machine {Bi Torch contro! connection socket plug for connecting the torch contol F LocalNet connection socket. standardised connection socket for system extensions (e.g. remote control, JobMaster torch, otc) Gl Shielding gas connection socket aD = pak Sse viow of VR 2000 wreteder [® - Socket with bayonet latch welding for MMA (manval electrode) IK Wire-spoo! holder with braking device .. for holding standardised 200 mm welding-wite spoo's weighing upto 5 kg (Ui 2olor drive iN] Plug-type connection for water return flow (ted) (0) Plugstype connection for water forward flow (blue) @ Screw.type connection for water return flow (red) -interconnec- ting cable [G| Screw-type connection for water forward flow (blue) -intercon- necting cable [R| LocalNet connection socket interconnecting cable (8) ®- Socket with bayonet latch... interconnecting cable VR 2000 operating panel .. The operating panel enables you to ‘access all stings that can also be made with the operating panel of the TR 4000 remote control unt, For a detailed description ofthe controls, please see the section headed “TR 4000 remote control uit Gasflow regulator with flow-rate indicator (in SL! min) SL/ min = 1 standard litre per minute 988 under standard conditions (temperature 1 standard litre °C, pressure lite of a bat) N.B.! The indicated shelding-gas flow-rate may deviate slighty from the actual fo-ate if another typeof shielding gas is being used instead of the specified gas mixture (CO, / Ar / Corgon 18) Warning! The gastlow regulator cannot replace the pressure regulator onthe gas cyinder! Never connec the wirefeeder (i, the interconnecting cable) tothe gas cylinder without a pressure regulator For your own safety, and to ensure that the gasflow regulator functions correctly, proceed as follows: = connect the pressure regulator tothe gas oyiinder + open the gasfow regulator to the maximum position A Always hold the welding torch pointing away from your face and body (because ofthe risk of injury from emerging wire) Never point the welding torch at people or at abjects that you do not intond to weld Solect the "é-step mode” Warning! When the gas-fow has been started by pressing the torch trigger, the wirefeed begins as well. Also, the welding voltage is applied tothe welding wire. Press the gas-test button or the torch trigger Carefully open the pressure reguiator on the gas cylinder untl the ‘maximum value (30 Uinin) is shown on the flow-rate indicator Press the gas-test button or the torch trigger Close the gasfiow regulator Optional “mode selector switch” .. inckgas-est/ wice-inch but- ton" Note! Setings made with the mode selector switch &R cannot be altered ‘nother contrl elements, e.g the contro! panel ofthe power source the front ofthe wirefeeder unit the remote control unit i “Mode selector switch” for selecting the process ~ MIGIMAG pulsed-are welding =) MIGIMAG standard welding = + Special process, e., manual EES Job mode TIG welding with contac ignition = MMA (manual electrode) welding C=) N.BIIfthe VR 2000 witefeederis connected up toa TS 4000/5000 power source, the MIGIMAG pulsed-are welding process ls no longer avaliable. G "Mode selector switch” for selecting the operating mode - 2step mode + 4estep mode CB ‘Aluminium welding startup = Spot welding & Foeder-inching / gas-test button Press the button down ... fo inch the wire electrode into the torch bhosepack without any flow of shieding-gas or curent. As long as the button is held down, the wirefeeder runs at feeder-inching speed. Press the button up .. to set the required gas-flow rate on the pressure regulator, As long asthe buttons pressed up, gas flows out General instructions for operating the VR 2000 N.B.1_ We advise equipping the power source with the optional “key- site ‘The VR 2000 wirefeeder is normally used with very iong hosepacks. This ‘means that often the welder can no longer ‘keep an eye on” the power source from where he is working. Here, the optional key-switch provides ‘optimum protection against anybody tampering or accidentally interfering withthe machine while itis being used, N.B.! When using the VR 2000 in conjunction witha 70 m hosepack, be sure to observe the folowing points ~ Hyouare notusing te ful ongth ofthe interconnecting cable lay out the hosepack as shown in Fig. Every time before starting to use the machine, measure the welding Sout resistance (see the section headed ‘Measuring the welding Circuit resistance R’) and the welding circuit inductivty (see “Indica: tng the welding circuit inductivity L") N.B.! Parameters that can be set onthe wirefeeder cannot be changed ‘on the power source. Any parameter changes that are needed can only be made on the wirefeeder, d 7 Motor-shaft lead-through (only on FK 4000 R) W) Plug-type connection / blanking cover for water return flow (red) Plug-type connection / blanking cover for water forward flow {bue) ‘Screw cap filer neck Xl Fuse for coolant pump Coolant inspection window © Coolant draining device JOBMASTER WELDING TORCH SS q y Z cB Corea orangarrt fo Pasepaok FK 4000 / 4000 R COOLING UNIT @ ool wa Fa Font and ar ow PRGGOOTFR 00 R cong uk 18 Fata NB. Ifa service code is shown on the JobMaster torch, it wil be the ‘same asthe service code shown at the same ime.on the operating panel For a descrintion of the service codes shown on the operating panel, please see the section headed ‘Troubleshooting’ “ova welng och © Parameter-display button(s) .. for selecting the parameter to be ispiayed (welding current wire-speed, JOB-N°,arclength correction, "SynchroPuls" option) '& Parameter-setting button(s) .. fr altering the selected parameter @ Welding current parameter 1N.B.1 The “gunrigger* option eniargos the range of functions of the ‘welding-current” parameter (see the section headed “Job mode", sub- section “Changing between operating modes with the JobKlaster torch") ® Wire-spoed parameter Parameter: JOB-N? (job number) @ Parameter: Arc-length correction (@ Parameter: “SynchroPuls” option (not illustrated here) Parameter: "SynchroPuls” option NB. The “SynchroPuls" parameter @ is only available in conjunction withthe “Guntrigger and “SynchroPuls” options. Ifthe "SynchroPuls" parameter @ has been selected, none of the indicators 6) to © will ight up on the display ofthe JoblMaster torch. Depending on which process has been selected, the “SynchroPuls" ‘option can be switched on and off, and in addition it wil also be possible to adjust the frequency, N.B.! Youwil find more detailed information on the “SynchroPuls" option in the section headed ‘MIGIMAG welding’. All the parameters for the “SynchroPuls" option (F, dF, Al.2) can be adjusted inthe Set-up menu (see: "The Set-up menu: Level 1"), quite separately from the value- adjustment facity onthe JobMaster torch, 4. Job mode \When “Job mode” is selected as the process, the “SynchroPuls’ param eter @ offers a facility for switching the ‘SynchroPuls" option on and of. = With the Process” button @, select the ob made" process Pross the parameter-dsplay butto(s) @ on the JobMaster to select the *SynchroPuis” parameter @ (none ofthe indicators to &® will light up). ~ Press the parametersetting buton(s) &@ fo toggle between ON and OFF on the display: ON... "SyncroPuls option is sited on OFF. “SyncnoPus optn is sched of —_ ‘meet — EF] sieassoraat Spec =O A 3 * 3 2 Sot promt: ow : sop Z ° ~~ 5 | [3 Switeh "SynchroPuls” 2 Perma sop me : i 3 i f Fig Joblastor SynaboPae paranetrin eb ode 19 2. Synergic mode: In “Synergic mode", the “SynchroPuls" parameter offers a facility for sitching the “SynchroPuls" option off and on, and for adjusting the associated parameter F "requency), ‘roces"oaton — FFP] Set woman =a | reas ~o. | 2 opecing note — VF] uton { Sect sppoprite — 480 / #80 | MO / MOH A | t - | Geese... | 3 a; > | Switch “SynchroPuls” on ( off : a 0,5 - 5 Hz F 5 Sethe requenc) for“SymehvoPuls* Paranele-seting bute) Te seit “SyrchoPe paramaler in Sarge mde ~ Press the “Operating mode button" ® to select one of the following: “2-step mode’, “4step mode", “Aluminium welding start-up" or Spot- welding” ~ Pressthe ‘Process button’@ to selecteitherthe “MIGIMAG standard” oF MIGIMAG pulsed-arc” welding process Press the parameter-display button(s) @ on the JobMaster to select the “SynchroPuls" parameter @ (none of the indicators ® to @ wil light up). ~ Press the parameter-setting button(s) @® to toggle between OFF and “0.5 -5 Hz" on the display: the “SynchroPuls’ option is switched off 5-5 Hz”... the “SynchroPuls" function is switched on; the parameter F (frequency) can be adjusted by pressing the parameter-stting button(s) ® ‘TR 2000 REMOTE-CONTROL UNIT ‘TR 4000 REMOTE-CONTROL UNIT Fad TR Pio remat-conal ant @ Welding-power setting dial .. for selecting the welding power (manual process:for adjusting the wirefeed speed) @ Arc-length correction and are-force setting dial... has a diferent function assigned to it, depending on what process is being used MIGIMAG welding = shorter arc © neutral arc-length + longer arc-length for correcting the arc length Manual electrode welding .. for influencing the shor-circuiting am erage atthe instant of droplet transfer 0 san Soft, low-spatter are 100 ..harder, more stable are Manual process .. for adjusting the welding votage N.B.! Parameters that can be set on the remote-control unit cannot be ‘changed on the power source. Parameter changes can only be made on the remote-contral unit an FaTe TR orate conta @ Parameter switchover button ... for selecting and displaying the Parameters: welding voltage, welding current, witefeed speed and ‘sheet thickness on the digital display N.B.! When you change a parameter, the value for this parameter is briefly indicated - for control purposes on the digital display of the rc unit @ Welding power / welding current setting dial .. has @ different function assigned to it, depending on what process is being used MIGIMAG welding .. Welding power Manual el. welding .. Welding current TIG welding .. Welding power Manual process .. for adjusting the wirefeed speed @ Arclength correction / Hotstart setting dial .. has a diferent function assigned to it, depending on what process is being used MIGIMAG welding = shorter are 0 neutral are-length + longer arodength {for correcting the arc length Manual electrode welding. influences the welding current during the ignton phase 0 ...n0 influence 10. 100% increase in welding current during the ignition phase Manual process .. for adjusting the welding voltage © Droplet dotachment, are-force correction and arc-force setting dial. has a diferent function assigned to it, depending on the process being used MIGIMAG standard welding .. for influencing the short-circuit force atthe instant of droplet transfer harder and more stable aro 0 neutral aro + soft, low-spattor are MIGIMAG pulsed-are welding arc droplet-detachment energy ~ decreased dropiet-detachment force 0 neutral drople-detachment foroe + increased droplet detachment force stepless correction facility for ‘Manual-clectrode welding .. for influencing the shor-crcuiting am porage at the instant of droplet transfer 0... Sot, low-spatier are 100 .harder, more stable are “Mana” process .. for influencing the shor-citeuiting dynamics at ‘he instant of droplt transfer 0... harder, more stable are 10... soft, low-spatter are 'N.B.! Parameters that can be set onthe remote- contol unit cannot be Changed onthe power source, Parameter changes can only be made on the remote-control unit, The TR 4000 C remote- contro unit gives the user access to al settings ‘hat can be made with the Comfort control panel, except = Processes: TIG welding and manuel electrode welding ~ Selection of type of material (Filer metal / shielding gas), wires diameter ~ Gases, ovor-lemperature indicator, user-defined indicator F3, user- defined Operating Mode 2 When used in conjunction withthe power sources TS 4000 / 000, TS 4000 / 8000 COMFORT, itis also not possible to access the MIG/NIAG. pulsed-are welding process. ‘TR 4000 C REMOTE-CONTROL UNIT For a detailed description of al buttons and indicators, please see the chapter headed “Descrition of control pane!” NB! The power source can be programmed simuitanoously on the Contrel panel ofthe power source and on the TR 4000 C remote contol unit | the TS 4000 / 5000 power sources are programmed from the TR 4000 Cremote-contol unit, itisnotpossiole to select the MIGIMAG pulsed-arc welding process. Fat N.B.If the Koy inthe key-switch @ on the power source (available as {an optional extra for the “Comfort” control panel) isin the horizontal Position, the folowing functions are disabled: + Selecting the welding process with the “Process” button(s) @ ~ Selecting the operating mode with the "Mode" button(s) @) + Selecting the filer metal with the "Material" button(s) @ = Revessing the setup menu withthe "Setup / Store button @® ~ Accessing the job-corection menu (see the section headed “Job made") 2 RCU 4000 REMOTE-CONTROL PANEL | ina ROU 000 rete contolparel The RCU 4000 remote control panel allows you to remote-operate @ Power source which is located e.g. inside @ production cell. It also ‘supports manual operation of the remote power source, for setup purposes. For a detailed description of al buttons and indicators, please see the Section headed “Description of control pane. '¥the TS 4000/5000 power sources are programmed from the RCU 4000 ‘remote-control pane} itis not possible to select the MIGIMAG pulsed-arc wwolding process. ‘TP 08 REMOTE-CONTROL UNIT ‘System requirements: + Software version 2.81.1 ~ With the “Process” button @, select the manual electrode welding process ~ Attach the earth clamp to the workpiece and clamp the electrode holder to the TP 08 remote-control unit ~ Place the TP 08 down onthe workpiece in such a way that there is @ Sold, frm connection between the workpiece and the two contacts fi) N.B.! The welding voltages switched tothe welding sockets after a3 seo time-tag. The TP 08 remote-control unit is then supplied with welding voltage, and indicator lights up, {the TP 08 remote-control unit has been connected up since the poner Source was ist switched on, itis only possibieto set the amperage and are-force dynamic on the TP 08 remote-contrel unit. ‘To make it possible to set the amperage and the arc-force dynamic from ‘he power source once again, as well as from other system add-ons: = Disconnect the TP 08 ~ Switch of the power source, then suite it beck on again 8 Parameter selection button ... For selecting the parameters + Welding current 28 «A, : + Are-orce dynamic ann. a“ ‘button... Increases the value forthe selected parameter “" button... Decreases the value for the selected parameter NB! Irrespective of the service codes given Section, the folowing service codes may be remote-control unit in the "Troubleshooting" displayed on the TP 08 jade Cause Remedy Poor contact with the Create a solid, fmm connec. workpiece tion to the workpiece Overtemperature on Allow the TP 08 0 cool down the TP 08 rc. unit ‘slong as a service code is displayed on the power source or any other system adc-on, the TP 08 remote-control units out of action, “LOCALNET PASSIVE” DISTRIBUTOR ee L Fam | Tho ‘LocalNet passive" distributor makes it possible to connect up and {un several systemad-ons onthe LocalNel connection jack ofthe power Source or of the witefeeder at the same time - e.g. TR 4000 and sJobMaster welding torch simultaneously. Talo dor passe N.BI Tho ‘LocaiNet passive” distributor only functions property if both ends ofthe cistributor are in use / connected. 2 “LOCALNET ACTIVE” SPLITTER The LocalNet active epitter provides total ofthree LocalNetjacks atthe ‘ear ofthe power source. This permits simultaneous operation of numerous system extensions such as ROB 3000, 4000, 5000, remote control units etc N.B.! When using the LocalNet active splitter, always connect up extemal wire drives to the metal LocalNet jack @ only —————___ oo ‘ear view of TSP 4007009 powe auc wih Loa ave or L Fat @ Metal LocaiNet jack... for connecting up extemal wire drives & Plastic LocaiNet jack ons {or connecting up further system extensi- A particular advantago of LocalNet active over the “LocalNet passive" splits found when working with temporarily connected LocalNet users ‘such as the RCU 4000 remote control panel. Unike wth the “LocelNet Passive” spite, its possible here to leave individual connection jacks Unassigned when the extra users are no longer needed, STARTING TO USE THE WELDING MACHINE ‘Warning! Before starting to use forthe fst time, read the section headed "Safety rules" UTILISATION FOR INTENDED PURPOSE ONLY The welding machine is intended tobe used SOLELY for MIGIMAG, rod clactrode and TIG welding ‘ny other use, or any use going beyond the above, is deemed tobe “not forthe intended purpose” and the manufacturer shall not be Fable for any damage resulting therefrom, “Utlsaton for theintended purpose" shall also be deemed to encompass: the observance of all instructions inthe operating manual the carrying out ofall prescribed inspection and maintenance work Ay Wsrin ress ntip nate Paves one MACHINE SET-UP REGULATIONS The welding machine is tested to ‘Degree of protection IP23", mesning: Protection against penetration by solid foreign bodies with diameters larger than #2 mm + Protection against spraywater up to an angle of 60° to the upright, ‘Thewelding machine can be setup and operated outdoorsin accordance with IP23, However, the builtin electrical components must be protected ‘against direct weting, Warning! Place the welding machine on an even, firm floor in such a way that it stands firmly. A welding machine that topples over can easily kil someonel ‘The venting duc is very important safety feature. When choosing the machine location, make sure thats possible forthe cooling ic to enter ‘and exit unhindered through the louvers on the frant and back of the machine. Any electroconductive metallic dust from e.g grinding-work ‘must not be allowed to get sucked into the machine MAINS CONNECTION ‘The welding machine is designed to run on the mains Voltage given on the rating plate. The mains cable and plug are ready-mounted. For details of fuse protection of the mains supply lead, please see the Technical Data Warning! the machine is designed to run on a special voltage, the Technical Data shown on the rating plate apply. The mains ug and mains supply ead, and ther fuse protection, must be dimensioned accordingly. REMOUNTING THE PLUG-TYPE CONNECTIONS FOR COOLANT FORWARD AND RETURN FLOW In order to allow for afferent types of torch central connector, the water connections can be mounted on ether the frontor the back of the cooling nt. !fyou are using an FK 4000 / FK 4000 R cooling unit on a TransPuls ‘Synergic 2700 power source, the plug-type connects for coolant ‘orwardandretum fow must be dismounted from the back and remounted on the front of the unt: ~ Shift the mains switch [] ofthe power souree into the“ + Unplug the power source's mains plug positon 23 Remove the side panel from the cooling unit Undo the plastic nuts onthe plug-type connections Route the water hoses for coolant forward and return flow tothe font ofthe unt Remove blanking covers (U) and [from the front ofthe unit and fit them fo the rear Insert the plug-type connections into the two openings and tighten them withthe plastic nuts N.B.! Mountthe plug-type connection forthe water return low uppermost, ‘and fxitin place wit the red plastic nut (water return flow is denoted by the red insulating tape), + Fit the side panel ofthe cooling unit back on again, "ig Carct ing ard wang oe war connections on heft of ho FR 4000460 esl unt MOUNTING THE COOLING UNIT ON THE TROLLEY = Mount the angle-brackets to the floor of the trolley using three “Extrude-Tite” screws for each bracket (as shown in ilustration below) Place the cooling unit onto the floor of the trolley (Le. onto the angle- brackets) Using the enclosed "Extrude-Tito” screws, bolt the cooling unt to the angle-orackets (2 soreews atthe left-hand bracket and 2 screews at the right-hand bracket) N.B.! To mountthe power source onthe trolley (without the cooling unit), follow the same procedure as described above. eeeaser ‘itu | carvings elder Trey components ATTACHING THE COOLING UNIT TO THE POWER SOURCE ~ Shit the mains switch [into the “O" position ~ Inset the enclosed MS nuts from the inside ino the hexagonal ‘openings 2 ofthe fixing slots ~ Remove the protective cover rom the underside ofthe power source ~ Pull the connecting plug ofthe power soure as far as possible through the opening ~ Attach the connecting plug lo the power source tothe connecting ug ofthe cooing unt ‘ig Procedoa for ataciog thecal und otha power source Place the power source onthe cooling unit and ixitwith the enclosed screws A ‘Warning! When placing the power source on the cooling unit, ‘make sure thatthe connecting plug and cable are not kinked of damaged. MOUNTING THE GAS-CYLINDER HOLDER AND WIREFEEDER FIXTURE ~ Place the gas-cylinder holder onthe floor ofthe trolley ~ Using four “Exirude-Tite" screws, bolt the gas-cylinder holder tothe floor of the tralley. NB! On the TPS 2700 power source, there is no need to mount a Witefeeder fixture, ~ Slot the end ofthe wirefeeder fixture into the power source O ‘Wou e ga a blar © fart O Fig Markt wlocer ar ~ Place the wirefeeder fixture flat ontop ofthe power source ~ Using four “Extrude-Tite” screws, bolt the wirefeeder fixture to the ga8-oylindor holder. ‘Warning! Itis only permitted to hoist / transport the wirefeeder ifit has the optional “insulated wirofeeder suspension arrange- ment’ FIXING THE INTERCONNECTING CABLE TO THE POWER SOURCE AND COOLING UNIT On the TS 4000 / £000 and TPS 4000 / $000 power sources, the interconnecting cable must be used to link the power source to the cooling unit. TPS 2700 users can skip both this section and the one ater it and continue reading in the section headed "Mountinglconnecting the 92s cylinder’ = Shift the mains switch [2] nto the “O" position ~ Insor the strain-rlief device into the opening provided onthe floor of the trolley, and fix itn place N.B.! Where the strain-elafdevico is subjected to heavy loads, it must be screwed to the floor of the toley. For 1.2 m long interconnecting ‘cables, no strain-elief devico is provide. ~ Plug the water forward-low and returfiow hoses of the intercon- necting cable to the plug-on connectors [i] and [i], red-o-red and back-to-back, ~ Plug the “Welding potentat” bayonet plug of the interconnecting ‘cable tothe @- socket [6] and turn it to latch it ~ Plug the ‘LocaiNet" plug of he interconnecting cable tothe LocalNet ‘socket and fastonit tightly withthe swivel nut FIXING THE INTERCONNECTING CABLE TO THE WIREFEEDER On the TS 4000 / 5000 and TPS 4000 / 5000 power sources, the interconnecting cable must be used to link the power source to the \irefeeder. TPS 2700 users can skp this section and continue reading In the section headed Mountingiconnecting the gas cylinder’. ~ Shift the mains switch [into the “O° postion ~ Slot the wirefeeder ino place on the pin ofthe wireeeder fixture + Insert the strain-reliet device ino the opening provided onthe wire- feeder, and fixit in place N.B.! Where the strain-olief device is subjected to heavy loads, it must be screwed tothe wirefeeder. For 1.2 m long interconnecting cables, oo strain-elef device is provided, ~ Plug the gas hose ofthe interconnecting cable tothe “Shelding-gas" socket fi and tighten withthe swivel nut ~ Plug the water forward-low and retum-fiow hoses ofthe intercon- necting cable to the piug-on connectors (P] and (), red-o-red and black-to-black, and tighten with the swivel nut ~ Plug the “LocaiNet” plug ofthe interconnecting cable tothe LocaiNet socket [i] and tighten withthe swivel nut Plug the “Welding potential” bayonet plug of the interconnecting Cable to socket S| and turn it to latch it N.B.! When mounting the cables and hoses of the interconnecting cable, these should be carefully ooled up out ofthe way in order to prevent ‘accidents and wear-and-ter, Fate Intcarecng ce or he Intocorecing cable on he etoder Past MOUNTING/CONNECTING THE GAS CYLINDER Place the gas cyinder onto the floor ofthe trolley = Fixthe gas cylinder in place with safety tape NB. The cylinder will only be optimally fixad in the upper part of the cylinder (not atthe neck) + Remove the protective cap from the gas cylinder + Give the gas-clinder valve a brio tun tothe lft (anticlockwise) to bow off any dirt from around the valve = Check the seal on the pressure regulator ~ Screw the pressure regulator onto the gas cylinder and tighten it Altach the “Shielding gas" connection of the interconnecting cable (on the TS 4000 ! 000, TPS 4000 / 5000) tothe pressure regulator, ‘or (on the TPS 2700 power source) attach shielding gas connection [H tothe pressure regulator by means ofthe ges hose INSTALLING THE WELDING TORCH N.B.I TPS 2700: Its only possible to use water-cooled welding torches with an external water connection ~ Shit the mains switch (into the “O" position ~ Check that the torch is correctly tooled up, Insert it- infeed tube frst into the central torch connector [k] + Tighten the swivel nut by hand to fix the torch in place ~ Plug the contro! plug of the welding torch onto the torch contol connection Oj and latch it ~ Connectup the welding torch hoses for water forward and return flow, ‘8 per the colour markings, to plug-type connectors i] and] on the \witefeeder (TS 4000 / 5000, TPS 4000 5000) or- inthe case ofthe ‘TPS 2700 - to plug-type connectors [Uj and iJon the cooling unit STARTING UP THE COOLING UNIT The Fk 4000 R cooing unitis recommended forte following applications: + TPS 4000 | 5000 and TS 6000 power sources + dobmaster welding torch + PushPull welding torches ~ Robot welding (aiso in conjunction with the optional rate-oflow watchdog) + Hosepacks longer than 5 m + MIGIMAG pulsed-are welding + Higher-power welding operations in general Fy NB. Check the volume and quality of coolant water before starting to Use the unit. The cooling units facory-filed with approx. 21 of coolant (mixing rato 1:1) before dispatch, + Shift the mains switch [6] nto the “ + Remove the screw cap i + Top up with coolant (mixin ratio as per following table) + Screw the cap fi back on aga position NB! Only use clean tap water. The electrical conductivity of al other ‘antireeze agents makes them unsuitable for use here. Warning! As Fronius has no influence on factors such as the ‘quality, purity and fling-level ofthe cootant, no warranty is given for the coolant pump. Outside temperature Water: Spit mixing ratio 001: 1.001 — 875151251 3501: 1.501 3.251:1.781 °C 105°C Warning! The coolant circulation must be checked at regular intervals while the machine is in operation -it must possible to ‘ee that the returnfow tothe reservoir is working corecty A the coolant pump is running buts not making the cootant circulate, the Water forwardfiow circuit must be vented, 2s follows: = Mains switch [] nto the “I” position - coolant pump stars running = Pullback the snap ring onthe plug-type connection for water forward ‘low (YJ and unplug the water forward-ow hose ~ Using a wooden or plastic pin, carefully pushin the conical nipple in the middle ofthe plug-fype connection for water forward fiow [f] and release it again wien wate starts to seep out + Plug the water forward-low hose back in = Check that the water connections are watertight ~ Repeat this procedure as often as necessary until you can see that coolant is flowing back property SETTING THE SHIELDING.GAS RATE + Plugin the mains plug ~ Shift the mains switch () nto the *" position = Pressathe °Gas test’ button @ ~ Turn the ajusting-screw on the underside ofthe pressure regulator ntl the manometer indicates the desired flow-rate MOUNTING THE WIRE SPOOL = Shift the mains switch (into the °0" position ~ Open the wire-spool cover (on the TS 4000/6000, TPS 4000 / 5000) (oF take off the side panel from the TPS 2700 = Mount the wire sp00l onto the spool holder Ik] - the right way round ~ Latch the locking bot into the opening provided on the body of the spool Adjust the braking force with the clamping screw ~ Replace the wire-spool cover or side pane! N.B.! The brake should always be adjusted so that the wire does not continue unreeiing after the end of welding - out without overtightening the clamping screw, as this would cause motor overload, ENGLISH Warning! Make sure thatthe wire-spo0l is siting fimly on the ‘pool holder. Where basket-type spools are being used on the ‘TPS 2700 power source, the Fronius “casket spool adapter” (with ‘no metalic connection tothe wirespool holder] must be used. FEEDING IN THE WIRE ELECTRODE Shift the mains switch (int the °0" poston Remove te ft side panel of the wireteeder or the TPS 2700 power source ~ Pivot the clamping devices @ and @ forwards ~ Pull the pressure levers @ and @ upwards ~ Insert the wire electrode though the infeed tube @ of the 4-roller drive. and around 5 em int the infeed tbe of re welding torch = Push the pressure levers @ and @ downwards: Pivot the camping devices @ and @ into the vertical poston ~ Set the contact pressure by means of the clamping nuts @® and @ NB! Set a contact pressure that is high enough to ensure smooth wire eed, but not so high thatthe wire electrode is deformed, Arrange the hosopack in as straight a line as possible Detach the gas nozzle from the torch Unscrew the contact tube Piug in the mains plug Shift the mains switch (G}into the “position Warning! Ouring the wire-infeed operation, hold the welding torch facing away from your body. = Press the wire-inching bution @ untl the wire electrode protrudes out ‘ofthe end of the torch + Toend the wire-infeed operation, release the wiresinching button 1N.B.I The wire spoo! must not continue to unreel after you release the torch trigger. Re-acjust the brake if necessary. ~ Screwin the contact ube Fit the gas nozzle Replace the lt side panel ofthe wiceteder ortthe TPS2700 power source ~ Shit the main sits into the 0" positon CHANGING THE FEED ROLLERS In order to achieve satisfactory wire travel, the feed rollers must be ‘suitable fr the diameter and alloy ofthe wire to be welded, Please see the spare-parts lists for an overview of the avaliable feed rollers and of ther possible areas of use - depending on te type of ive (2-rolor system /4-ollor system), material and wire diameter. = Shift the mains switch (nto the *O" position = Remove the left side panel ofthe wirefeeder or the TPS 2700 power = Pivot the clamping devices @ and @ forwards + Pullthe pressure levers @ and @ upwards = Pull out axles @ - @ ~ Remove feed rollers @-@ ~ Insert new feed rliers N.B.! Insert the feed rollers in such a way that you can still see and ead the designation for the wire diameter. + Pushaxles @ -@ back in again-the anti-twistlock ofeach axle must latch into place ~ Push the pressure levers @ and @ downwards + Pivot the clamping devices @ and @ into the vertical position = Set the contact pressure by means of the clamping nuts @ and @ = Replace the lf side panel ofthe wirefeeder or ofthe TPS 2700 power source ‘VR 2000: FEEDING IN THE WIRE ELECTRODE Shit the mains switch [into the “O" postion ~ Open the lot side pane! ofthe VR 2000 Pivot ho clamping davco @ forwards Push he pressure lever @ upward Insert the wire electrode though te infeed tube @ofthe 2-oler ave and ‘around 5 cm info the infeed tube ofthe welding torch @ ~ Push the pressure lever @ downward Pivot the clamping device @ into the vertical poston + Sette contact pressure by means ofthe clamping nuts N.B1 Set a contact pressure that is high enough to ensure smoath wire feed, but not so high thatthe wire electrode is deformed, 8 Pipl 2ralordve for V 2000 = Arrange the hosepack in as straight a line as possible + Detach the gas nozzle from the toreh Unserew the contact tube Plug in the mains plug + Shift the mains switch [into the "™ postion BD Messin! wing te wesnfeed operation, hold the wetng torch facing away from your body. Press the wire-inching button @ until the wire electrode protrudes out of the end of the torch ~ To.end the wire-nfeed operation, release the wireinching button @® NB. The wire spoo! must not continue to unreal ater you release the torch trigger. Re-adjust the brake if necessary = Screw inthe contact tube + Fitthe gas nozzle ~ Replace the left side pane! ofthe wirefeeder VR 2000 + Shif the mains switch (| into the “O" position ‘VR 2000: CHANGING THE FEED ROLLERS In order to achieve satistactory wire travel, the feed rollers must be suitable for the diameter and alloy ofthe wire to be welded. Please see the spare-pars lists for an overview ofthe availabe feed rallers and oftheir possible areas of use - depending on the type of drive (roller system | 4-oller system), material and wire diameter. ~ Shift the mains switch [into the *O" position + Open the lft side panel ofthe VR 2000 Pivot the clamping device @ forwards Push the pressure lever @ upward ~ Pullout axle @ + Remove feed roller Undo hexagon socket screw Remove hexagon socket screw ®, washer @ and feed roller © + Inget the new feed rollers 'N.B.! Insert the feed rollers in such @ way that you can stil see and read the designation forthe wire diameter. + Feston the feed roller @ with a washer @ and a hexagon socket screw Fasten the other feed roller wih the axle @. The antitwis lock of the axle must latch into place. + Push the pressure lever @ downward Pivot the clamping device @ into the vertical postion + Sethe contac pressure by means of the clamping nuts @ ~ Replace the lft side pane! ofthe wirefeeder VR 2000 ar MIG/MAG WELDING MA Waring Seo stating up or the fst tine read the sctns headed “Safety rules” and "Starting fo use the power source’ Plug the earth cable into the current socket] and latch tin fly. ~ Connect the other end of the earth cable tothe workpiece ~ Plug the torch ito the central torch connectors) ~ Oniy on water-cooled TPS 2700's: Attach the water hoses of the ‘welding torch to the plugype connections (U] and V7] ~ Only on water-cooled TS 4000 6000's & TPS 4000 / 5000's: Attach the water hoses ofthe welding torch tothe plug-type connections i and (0) = Plug the machine into the mains ~ Shiftthe mains switch (into the "position (athe indicators onthe control pane brief light up) Warning! On water-cooled machines, the walerslow must be checked at regular intervals while the machine isin operation ~ you must be able to see thatthe coolants flowing back property. ~ Use the Process button @ to select the desired weld process (MIG/ MAG pulsed-are or MIGIMAG standard welding) ~ Use tho Material buton @ to select which filler metal and shielding {gas you want to use + Use the Wire Diameter button @) to select the diameter ofthe wire Use the Mode button ® to select the desired operating mode (2-stop mode, 4-step mode, aluminium welding startup, Mode 1 (spot- welding) 1N.B. For details of how to set the parameters forthe aluminium welding start-up mode and for Operating Mode 1 (spot welding), please see the section headed "The Setup Menu’ N.B.! Parameters that can be set on the wirefeeder VR 4000/7000 or on the TR2000 4000 remote-control units cannotbe changed onthe power ‘Source, Parametor changes can only be made onthe wirefeeder VR 4000 177000 or on the TR 2000 / 4000 remote-control units ~ The desired welding power can be set with reference to either the “a= imension parameter @, sheet thickness @, welding current @ or Wwirespeed @ N.B.! The parameters ‘adimension @, sheet thickness @, welding current ® and wirespeed @ are directly interconnected. it is only necessary to alter one of the four parameters, as the three other parameters are immediately adjusted lo match Before selecting the “a'-dimension, you must rst set the welding-speed Parameter @ (recommended welding speed for manual welding: ~35 cm rin), + Open the gas-cyinder valve ~ Sot the gas-ow rate ~ Press the torch trigger and start welding N.B.! The power source is equipped with the “ignition time-out function, This function i explained in tho folowing section headed “igitiontime- out function’ Allparameter command values that have been setby means of either the adjusting dial © or the agusting buttons on the torch will remain stored Unt the next time they are changed, Thisis tue even tthe power source |s suitched off and on again in the meantime, 28 In order to achieve an optimum welding result, itis necessary in son cases to make corrections to the arc-length correction and dropl detachment arc-frce correction parameters.as well asto the beckgrour Derameters gas pre and postiow and /orsoft-sart, For deals of ho {o set the background parameters “gas pre-fow’, ‘gas post-fow” an “feeder creep’, please see the section headed “Set-up menu: Level 1 N.B.! It's not possibe to correct the arc-ength on the Standard cont nel. However, you can set the arc-frce correction as a backgroun Parameter in the Setup Menu, IGNITION TIME-OUT FUNCTION N.B.! Inthe factory setings, the ignition time-out function isnot enabled ‘Where needed, the ignition time-out function can be enabled in “Set-y ‘menu: Level 2" (by setting it to a value of§ to 100 mm “to | 5. 10" See the soction headed “Set-up menu: Level 2", or ‘Parameter 2n, fo information rogerding settings, ranges and measuring-units of theignto time-out parameter (ito) \When the torch trigger is pressed, the gas pro-ow begins immediately followed by wirefeed start-up and ignition. If no current starts to fon before the end ofa wirefeed length thats defined inthe set-up menu, the ‘machine cuts out automatically. The ertor message “Er | Ito" appears o ‘the operating panel The indication “E55"is outputted onthe JobMaster torch and on the eld bus module. ‘To make another attempt to achieve ignition, press the torch trigger again ARC-BREAK WATCHDOG FUNCTION N to OFF, the factory settings, the arc-break watchdog function (Arc) is set Where needed, deactivate the arc-break watchdog function (Arc) n“Set- up menu: Level 2" (by setting ito "Are | OFF’), oF by setting a value of 001 st0.2s (‘Arc | 0.01... 2) See he section headed “Set-up menu: Level”, or ‘Parameter 2d’ for information on setting the ‘arc-break watchdog” parameter (Arc). Itthe are broaks and no current stars to flow again within the time-span ‘definedin the sel-up menu, the machine cuts out automaticaly. The error ‘message ‘no | Arc’ appears on the operating panel To start welding again, press the torch tigger again, MANUAL ‘The ‘Manual’ process is a MIG/MAG standard welding process with no synergic function. in the same way as where the synergic function is active, the user selecis the wolding program (by way ofthe filler meta, ‘shielding gas and wire diameter) and the operating mode, and then sets the parameters. However, changing one parameter does notresultin any ‘automatic adjustments to the other parameters, All of the variable Perameters must thus be individually adjusted, as required by the welding process. N.B.!Foras long asthe “Manual” process is selected, the "SynchroPuls™ option isnot supported In the “Manual” process, the following parameters are available: + Wirefeed speed @ ..0.5 m/min maximum wirefeed speed(e.g.22.0 mimi) + Welding voltage @ ... 10.0 - 40.0 V (TPS 2700: 10.0 - 34,0 V) = Areforee correction @® ... for influencing the short-cireulting dyna- mics atthe instant of droplet transfer 0.0 harder, more stable are 10.0 sot, low-spattr arc + Welding current @ (only displayed as actual value) = Shiftthe Mains switch (Go the postion (all indicators onthe control panel briefly ight up) = Using the process button @, select weld process SP (special processes) ~ Use the Material utton @ to select which filer metal and shielding {ga8 you want to use = Use the Wire Diameter button © to select the diameter ofthe wire N.B.! In the "Manual" process, the "Aluminium welding star-up" mode only corresponds to conventional 4-step operation. + Use the Mode button @ to select the desired operating mode N.B.! Parameters that can be set on the wirefeeder VR 4000/7000 or on the TR 2000 4000 remote-control units cannot be changed on the power soutee. Perameter changes can only be made onthe wiefeeder VR 4000 17000 or on the TR 2000 / 4000 remote-control units, N.B.1If the machine does not reach the pre-set welding voltage, the Power source delivers the highest voltage that is possible et that time, Set the wirespeed (B, welding voltage @, are-force correction @ parameters separately + Open the gas-cyinder valve + Set the gas-fow rate Press the torch trigger and start welding All parameter command values that have boon set by means of either the ‘adjusting dial @ or the adjusting buttons on the torch will remain stored ntl the nexttime they are changed. Tiss true even f the power source is witehed off and on again in the meantime. 29 OPTION: SPATTER-FREE IGNITION NB. External enabling ofthe ‘spatter-ree igition’ option is possible ‘rom software version 2.70.1 (power source) upwards. At present, this ‘option only suppors aluminium wires of diam. 0.8 mm, 1.0 mm, 1.2 mm and 1.6 mm, and Fronius push-pull wirefeed systems. 'N.B.! Optimum functioning ofthe “spattertree ignition” option can only be ensured in conjunction with the Fronius push-pull wirefeed system, ‘System requirements: = Software version 2.60.001 (power source) + Software version 1.40.015 (wirefeeder) ‘The Spatter Free ignition option (SFi) makes it possible to ignite the are with practically no spatter, At the beginning of welding, the wie is slowly {od as far as the surface ofthe workpiece and then slopped as soon as ittouches 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 atthe wirefeed speed specified for this weld process. NB. The stored welding programs are listed on the adhesive label on the power source, The grey-highlighted programs are the ones which ‘support the SFi function To activate the SFi option, proceed as follows: = Select your welding program ‘Select SFi (parameter Fac - feeder creep) in the set-up menu + Exit rom the set-up menu OPTION: SYNCHROPULS N.B.I Exteral enabling of the “SynchroPuls" option is possible from software vrsion2.70.1(pawer source) upwards. This option only supports ‘manual Fronius push-pull and Robacta Drive push-pul (stave) wirefeed systems. System requirements: = Software version 2.60.4 (power source) + Software version 1.40,015 wirefeeder) ‘Tho “SynchroPuis" option is recommended for welds using aluminium alloys where you want to give the weld-seams a rippled appearance, This cffectis achieved by having the welding power alternate between two ‘operating poins. NB.! Please see the section headed “Setup-Menu" for details on the settings, setting range and units of measurement of the avaliable parameters, N.B.I 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 sotting: OFF Fe... Welding-power offset (SynchroPuls . 0.0 - 2.0 min Factory seting: 1.0 mimin LZ... Arclength correction (SynchroPuls).. ++ 30 % ‘ofthe welding vollage, Factory setting: 0 nn]

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