FRONIUS TransSynergic 5000 Leitfaden

/ Battery Charging Systems / Welding Technology / Solar Electronics

42,0426,0001,EN 006-04092012

TransSynergic 4000/5000

TransPuls Synergic 2700

TransPuls Synergic 3200/4000/5000

TIME 5000 Digital

CMT 4000 Advanced

Operating Instructions

Spare parts list

MIG/MAG Power source

Dear reader,

Introduction Thank you for the trust you have placed in our company and congratulations on buying this

high-quality Fronius product. These instructions will help you familiarise yourself with the

product. Reading the instructions carefully will enable you to learn about the many different

features it has to offer. This will allow you to make full use of its advantages.

Please also note the safety rules to ensure greater safety when using the product. Careful

handling of the product will repay you with years of safe and reliable operation. These are

essential prerequisites for excellent results.

Contents

Safety rules ................................................................................................................................................ 9

Explanation of safety symbols .............................................................................................................. 9

General ................................................................................................................................................. 9

Intended purpose .................................................................................................................................. 10

Environmental conditions...................................................................................................................... 10

Obligations of the operator.................................................................................................................... 10

Obligations of personnel ....................................................................................................................... 11

Mains connection .................................................................................................................................. 11

Protecting yourself and others .............................................................................................................. 11

Noise emission values .......................................................................................................................... 12

Danger from toxic gases and vapours .................................................................................................. 12

Danger from flying sparks ..................................................................................................................... 13

Risks from mains current and welding current...................................................................................... 13

Meandering welding currents................................................................................................................ 15

EMC device classifications ................................................................................................................... 15

EMC measures ..................................................................................................................................... 15

EMF measures...................................................................................................................................... 16

Specific hazards.................................................................................................................................... 16

Danger from shielding gas cylinders..................................................................................................... 18

Safety measures at the installation location and during transport ........................................................ 18

Safety measures in normal operation ................................................................................................... 19

Maintenance and repair ........................................................................................................................ 20

Safety inspection................................................................................................................................... 20

Disposal ................................................................................................................................................ 20

Safety symbols...................................................................................................................................... 20

Data protection...................................................................................................................................... 21

Copyright............................................................................................................................................... 21

General information 23

General ...................................................................................................................................................... 25

Device concept ..................................................................................................................................... 25

Functional principle ............................................................................................................................... 25

Application areas .................................................................................................................................. 25

Warning notices on the device.............................................................................................................. 25

Special versions......................................................................................................................................... 27

General ................................................................................................................................................. 27

Alu edition ............................................................................................................................................. 27

CrNi edition ........................................................................................................................................... 27

CMT Variants ........................................................................................................................................ 27

CMT 4000 Advanced ............................................................................................................................ 27

TIME 5000 Digital ................................................................................................................................. 28

Yard edition........................................................................................................................................... 28

Steel edition .......................................................................................................................................... 28

System components .................................................................................................................................. 29

General ................................................................................................................................................. 29

Overview ............................................................................................................................................... 29

Control elements and connections 31

Description of the control panels................................................................................................................ 33

General ................................................................................................................................................. 33

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

Overview ............................................................................................................................................... 33

Standard control panel............................................................................................................................... 34

General ................................................................................................................................................. 34

Standard control panel.......................................................................................................................... 34

Key combinations - special functions.................................................................................................... 36

Displaying the feeder inching speed ..................................................................................................... 36

Displaying the gas pre-flow and gas post-flow time..............................................................................36

Displaying the software version ............................................................................................................ 36

Comfort / CrNi / Steel control panel ........................................................................................................... 38

Difference between Comfort, CrNi and Steel control panels ................................................................ 38

Comfort control panel............................................................................................................................ 38

Key combinations - special functions.................................................................................................... 41

Displaying the feeder inching speed ..................................................................................................... 41

Displaying the gas pre-flow and gas post-flow time..............................................................................42

Displaying the software version ............................................................................................................ 42

US control panel ........................................................................................................................................ 43

US control panel ................................................................................................................................... 43

Key combinations - special functions.................................................................................................... 46

Displaying the feeder inching speed ..................................................................................................... 46

Displaying the gas pre-flow and gas post-flow time..............................................................................46

Displaying the software version ............................................................................................................ 47

TIME 5000 Digital control panel................................................................................................................. 48

TIME 5000 Digital control panel............................................................................................................ 48

Key combinations - special functions.................................................................................................... 51

Displaying the feeder inching speed ..................................................................................................... 51

Displaying the gas pre-flow and gas post-flow time..............................................................................52

Displaying the software version ............................................................................................................ 52

CMT control panel...................................................................................................................................... 53

CMT control panel................................................................................................................................. 53

Key combinations - special functions.................................................................................................... 56

Displaying the feeder inching speed ..................................................................................................... 56

Displaying the gas pre-flow and gas post-flow time..............................................................................56

Displaying the software version ............................................................................................................ 56

Yard control panel...................................................................................................................................... 58

Yard control panel................................................................................................................................. 58

Key combinations - special functions.................................................................................................... 61

Displaying the feeder inching speed ..................................................................................................... 61

Displaying the gas pre-flow and gas post-flow time..............................................................................61

Displaying the software version ............................................................................................................ 62

“Remote” control panel .............................................................................................................................. 63

General ................................................................................................................................................. 63

Remote control panel............................................................................................................................ 63

CMT Remote control panel ........................................................................................................................ 64

General ................................................................................................................................................. 64

CMT Remote and CMT Advanced control panel .................................................................................. 64

Connections, switches and mechanical components ................................................................................ 65

TPS 2700 power source ....................................................................................................................... 65

TPS 2700 CMT power source............................................................................................................... 66

TS 4000 / 5000, TPS 3200 / 4000 / 5000, TIME 5000 Digital power sources ...................................... 67

CMT 4000 Advanced power source...................................................................................................... 68

Installation and commissioning 71

Minimum equipment needed for welding task............................................................................................ 73

General ................................................................................................................................................. 73

MIG/MAG gas-cooled welding .............................................................................................................. 73

MIG/MAG water-cooled welding ........................................................................................................... 73

MIG/MAG automated welding............................................................................................................... 73

CMT manual welding ............................................................................................................................ 73

CMT automated welding ....................................................................................................................... 74

CMT Advanced welding ........................................................................................................................ 74

TIG DC welding..................................................................................................................................... 74

Manual metal arc welding ..................................................................................................................... 74

Before installation and commissioning....................................................................................................... 75

Safety.................................................................................................................................................... 75

Proper use ............................................................................................................................................ 75

Setup regulations .................................................................................................................................. 75

Mains connection .................................................................................................................................. 75

Connecting up the mains cable on US power sources .............................................................................. 76

General ................................................................................................................................................. 76

Stipulated mains cables and strain-relief devices ................................................................................. 76

Safety.................................................................................................................................................... 76

Connecting the mains cable.................................................................................................................. 76

Replacing the strain-relief device.......................................................................................................... 77

Start-up ...................................................................................................................................................... 79

Safety.................................................................................................................................................... 79

Remarks on the cooling unit ................................................................................................................. 79

Information on system components ...................................................................................................... 79

Overview ............................................................................................................................................... 79

Commissioning the TPS 2700 ................................................................................................................... 80

General ................................................................................................................................................. 80

Recommendation for water-cooled applications ................................................................................... 80

Connecting the gas cylinder.................................................................................................................. 80

Establishing a ground (earth) connection ............................................................................................. 81

Connecting the welding torch................................................................................................................ 81

Inserting/replacing feed rollers.............................................................................................................. 81

Inserting the wirespool .......................................................................................................................... 82

Inserting the basket-type spool ............................................................................................................. 82

Feeding in the wire electrode................................................................................................................ 83

Setting the contact pressure ................................................................................................................. 84

Adjusting the brake ............................................................................................................................... 84

Design of the brake............................................................................................................................... 85

Commissioning the TS 4000 / 5000, TPS 3200 / 4000 / 5000, TIME 5000 Digital .................................... 86

General ................................................................................................................................................. 86

Fitting the system components (overview)............................................................................................ 86

Fixing the strain-relief device in place................................................................................................... 87

Connecting the interconnecting hosepack ............................................................................................ 87

Connecting the gas cylinder.................................................................................................................. 88

Establishing a ground (earth) connection ............................................................................................. 89

Connecting the welding torch................................................................................................................ 89

Other tasks............................................................................................................................................ 89

Commissioning the CMT4000 Advanced................................................................................................... 90

Fitting the system components (overview)............................................................................................ 90

Connecting the interconnecting hosepack, CMT welding torch and wire buffer ................................... 90

Other tasks............................................................................................................................................ 90

Preparing the wire-feed unit.................................................................................................................. 91

Welding 93

MIG/MAG modes ....................................................................................................................................... 95

General ................................................................................................................................................. 95

Symbols and their explanations ............................................................................................................ 95

2-step mode .......................................................................................................................................... 96

4-step mode .......................................................................................................................................... 96

Special 4-step mode ............................................................................................................................. 97

Spot welding ......................................................................................................................................... 97

MIG/MAG welding...................................................................................................................................... 98

Safety.................................................................................................................................................... 98

General tasks before MIG/MAG welding .............................................................................................. 98

Overview ............................................................................................................................................... 98

MIG/MAG synergic welding ....................................................................................................................... 99

General ................................................................................................................................................. 99

MIG/MAG synergic welding .................................................................................................................. 99

Corrections during welding ................................................................................................................... 100

Adjusting parameters for correction ...................................................................................................... 100

Remarks on the Standard control panel ............................................................................................... 100

MIG/MAG standard manual welding .......................................................................................................... 101

General ................................................................................................................................................. 101

Available parameters ............................................................................................................................ 101

MIG/MAG standard manual welding ..................................................................................................... 101

Corrections during welding ................................................................................................................... 102

Adjusting parameters for correction ...................................................................................................... 102

CMT welding .............................................................................................................................................. 103

General ................................................................................................................................................. 103

CMT welding ......................................................................................................................................... 103

Corrections during welding ................................................................................................................... 104

Adjusting parameters for correction ...................................................................................................... 106

Special functions and options .................................................................................................................... 107

Arc break watchdog function................................................................................................................. 107

Ignition time-out function....................................................................................................................... 107

Spatter-free ignition option.................................................................................................................... 107

SynchroPulse option ............................................................................................................................. 108

Robot welding ............................................................................................................................................ 110

Prerequisite........................................................................................................................................... 110

General ................................................................................................................................................. 110

Special 2-step mode for robot interface ................................................................................................ 110

Wire-stick control function..................................................................................................................... 111

Changing the welding process during CMT Advanced welding............................................................ 111

TIG welding................................................................................................................................................ 112

Safety.................................................................................................................................................... 112

Prerequisite........................................................................................................................................... 112

Preparation ........................................................................................................................................... 112

TIG welding........................................................................................................................................... 112

Igniting the arc ...................................................................................................................................... 113

Finishing welding .................................................................................................................................. 114

TIG Comfort Stop option ....................................................................................................................... 114

TIG welding with TIG Comfort Stop ...................................................................................................... 116

MMA welding ............................................................................................................................................. 117

Safety.................................................................................................................................................... 117

Prerequisite........................................................................................................................................... 117

Preparation ........................................................................................................................................... 117

Manual metal arc welding ..................................................................................................................... 117

Corrections during welding ................................................................................................................... 118

Adjusting parameters for correction ...................................................................................................... 118

HotStart function ................................................................................................................................... 118

SoftStart function .................................................................................................................................. 119

Anti-stick function.................................................................................................................................. 119

Job mode ................................................................................................................................................... 120

General ................................................................................................................................................. 120

Prerequisites ......................................................................................................................................... 120

Restrictions ........................................................................................................................................... 120

Job mode displays on the left-hand digital display................................................................................ 120

Selecting job mode as the process ....................................................................................................... 120

Creating a job........................................................................................................................................ 120

Retrieving a job ..................................................................................................................................... 121

Copying/overwriting a job...................................................................................................................... 122

Deleting a job ........................................................................................................................................ 123

Setup settings 125

Job correction ............................................................................................................................................ 127

General ................................................................................................................................................. 127

Opening the Job correction menu......................................................................................................... 127

Changing welding parameters .............................................................................................................. 127

Exiting the Job correction menu............................................................................................................ 127

Parameters in the job correction menu ................................................................................................. 128

Permanently settable parameters ......................................................................................................... 128

Parameters that can be corrected at a later time.................................................................................. 130

Shielding gas setup menu.......................................................................................................................... 133

General ................................................................................................................................................. 133

Protective gas shield setup menu for the standard control panel ......................................................... 133

Protective gas shield setup menu for the Comfort, US, TIME 5000 Digital and CMT control panels ... 133

Welding parameters in the Protective gas shield setup menu .............................................................. 133

Setup menu for the standard control panel................................................................................................ 135

General ................................................................................................................................................. 135

Setup menu for the standard control panel........................................................................................... 135

Parameters in the Setup menu for the Standard control panel............................................................. 135

Process setup menu .................................................................................................................................. 138

General ................................................................................................................................................. 138

Process setup menu for the Comfort, US, TIME 5000 Digital and CMT control panels ....................... 138

Parameters for MIG/MAG welding in the Process setup menu ............................................................ 138

Parameters for TIG welding in the Process setup menu ...................................................................... 141

Parameters for MMA welding in the Process setup menu .................................................................... 141

Mode setup menu ...................................................................................................................................... 142

General ................................................................................................................................................. 142

Mode setup menu for the Comfort, US, TIME 5000 Digital and CMT control panels ........................... 142

Welding parameters for "Special 2-step mode" in the Mode setup menu............................................. 142

Welding parameters for "Special 4-step mode" in the Mode setup menu............................................. 143

Parameters for spot welding in the Mode setup menu.......................................................................... 143

Setup menu - Level 2................................................................................................................................. 144

General ................................................................................................................................................. 144

Setup menulevel 2 for the Standard control panel................................................................................144

Setup menu level 2 for the Comfort, US, TIME 5000 Digital and CMT control panels ......................... 145

Parameters for MIG/MAG welding in the Setup menu level 2 .............................................................. 145

Parameters for operating power sources in parallel in the Setup menu level2..................................... 148

Parameters for TimeTwin Digital in the Setup menu level2 .................................................................. 148

Parameters for TIG welding in the Setup menu level2 ......................................................................... 148

Parameters for rod electrode (MMA) welding in the Setup menu level 2.............................................. 150

Notes on the use of the FAC parameter ............................................................................................... 152

Calibrating push-pull unit ........................................................................................................................... 153

General ................................................................................................................................................. 153

Calibrating the push-pull unit - overview ............................................................................................... 153

Calibrating the push-pull unit ................................................................................................................ 153

Service codes for push-pull calibration ...................................................................................................... 157

Safety.................................................................................................................................................... 157

Service codes when the drive units are disengaged ("open-circuit" calibration)................................... 157

Service codes when the drive units are engaged ("engaged" calibration)............................................ 158

Measuring welding circuit resistance r ....................................................................................................... 160

General ................................................................................................................................................. 160

Measuring welding circuit resistance r .................................................................................................. 160

Displaying welding circuit inductivity L ....................................................................................................... 162

General ................................................................................................................................................. 162

Displaying welding circuit inductivity L .................................................................................................. 162

Arranging the interconnecting hosepack correctly ................................................................................162

Troubleshooting and maintenance 163

Troubleshooting ......................................................................................................................................... 165

General ................................................................................................................................................. 165

Safety.................................................................................................................................................... 165

Displayed service codes ....................................................................................................................... 165

Power source - troubleshooting ............................................................................................................ 173

Care, maintenance and disposal ............................................................................................................... 177

General ................................................................................................................................................. 177

Safety.................................................................................................................................................... 177

At every start-up.................................................................................................................................... 177

Every 2 months ..................................................................................................................................... 177

Every 6 months ..................................................................................................................................... 177

Disposal ................................................................................................................................................ 177

Appendix 179

Technical data............................................................................................................................................ 181

Special voltages.................................................................................................................................... 181

TPS 2700 .............................................................................................................................................. 181

TPS 2700 MV........................................................................................................................................ 182

TPS 3200 .............................................................................................................................................. 183

TPS 3200 MV........................................................................................................................................ 184

TPS 3200 460VAC............................................................................................................................... 185

TS/TPS 4000 ........................................................................................................................................ 186

TS/TPS 4000 MV .................................................................................................................................. 187

TS/TPS 5000 ........................................................................................................................................ 187

TS/TPS 5000 MV .................................................................................................................................. 188

Technical data - US devices ................................................................................................................. 189

Technical data - Alu edition, CrNi edition, Yard edition and CMT variants ........................................... 189

TIME 5000 Digital ................................................................................................................................. 189

CMT 4000 Advanced ............................................................................................................................ 190

CMT 4000 Advanced MV...................................................................................................................... 191

Welding program databases ...................................................................................................................... 193

Explanation of symbols ......................................................................................................................... 193

Setting up a welding program database - example............................................................................... 193

Terms and abbreviations used................................................................................................................... 194

General ................................................................................................................................................. 194

Terms and abbreviations A - C ............................................................................................................. 194

Terms and abbreviations D - F ............................................................................................................. 194

Terms and abbreviations G - I .............................................................................................................. 195

Terms and abbreviations J - R.............................................................................................................. 195

Terms and abbreviations S ................................................................................................................... 196

Terms and abbreviations T - 2nd .......................................................................................................... 196

Spare parts list 199

Spare parts list: TransPuls Synergic 2700................................................................................................. 200

Spare parts list: TS/TPS 3200/4000/5000, TIME 5000..............................................................................203

Spare parts list: CMT 4000 Advanced ....................................................................................................... 206

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