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TPS 5000 Pipe
TPS 4000 MV Pipe
TPS 3200 460 V Pipe
Operating instructions
EN
MIG/MAG power source
42,0426,0004,EN 005-17122020
General
Introduction Thank you for the trust you have placed in our company and congratulations on buying
this high-quality Fronius product. This document supplements your machine’s operating
instructions.
EN
Safety
Operating the equipment incorrectly can cause serious injury and damage.
Do not use the functions described until you have thoroughly read and understood the
following documents:
▶
▶
Machine concept The digital machine series is characterised by excellent welding properties and an unri-
valled degree of precision in the welding process. Microprocessor controlled inverter
power sources ensure exactly reproducible welding results. For welding pipelines, the
TimeTwin Digital welding system is used in combination with an automised welding process. Up to four Twin welding torches can be welding the pipeline at the same time.
Areas of utilisation
The components used in the pipe series were specially designed for the laying of
pipelines in extreme climatic conditions. With an operating temperature range of -50 °C
to +40 °C, the machine can be used from Alaska to the Sahara.
WARNING!
these operating instructions
all the operating instructions for the system components, especially the safety rules
System components
System components for use in pipeline construction:
- Power source - TPS 3200 460 V Pipe or TPS 4000 MV Pipe
- Pipe wirefeeder (e.g. VR 1500 Pipe)
- Pipe cooling unit (e.g. FK 9000 R Pipe or FK 6000 Pipe „stand-alone“ for longer
hosepacks)
- Robacta Pipe (Twin) welding torch
- Robot interface (e.g. Rob 4000/5000)
3
TPS 3200 460 V Pipe
General remarks The TPS 3200 460V Pipe is a completely digitised, microprocessor controlled inverter
power source, specially designed for use in extreme climatic conditions. Compared to
the standard power source, the TPS 3200 460V Pipe is able to integrate all the electronic
components required to control the wirefeeder.
NOTE!
Information on function and operation can be found in the enclosed standard
power source operating instructions.
Where a difference occurs between the properties or functions of the Pipe series and the
standard power source, the information in this document takes precedence.
NOTE!
The push-pull unit MUST be calibrated:
prior to each initial start-up
▶
after selecting another push-pull unit
▶
each time the wirefeeder software is updated
▶
Accessories and
options
If the push-pull unit is not calibrated, the standard parameters will be used - which may
result in the welding result not being satisfactory.
- Select the “PPU” function in the second (2nd) menu level (power source operating
instructions)
TPS 3200 V Pipe
High End
LHSB provided optional
Installation set VR 1500 Pipe* optional optional
Welding database
- Twin
- Pipeline edition
Dust filter optional optional
* The VR 1500 Pipe installation set consists of:
- SR 41 motor controller
- NT 60
- Connection socket VR 1500 Pipe
IMPORTANT!
The VR 1500 Pipe installation set is required to control the VR 1500 Pipe
wirefeeder.
- provided
- provided
TPS 3200 460 V Pipe
Basic
- option
- provided
4
TPS 4000 MV Pipe, TPS 5000 Pipe
General remarks The TPS 4000 MV Pipe is a completely digitised, microprocessor controlled inverter
power source, specially designed for use in extreme climatic conditions. Compared to
the standard power source, the TPS 4000 MV Pipe has all the electronic components
required to control the wirefeeder.
NOTE!
Information on function and operation can be found in the enclosed standard
power source operating instructions.
Where a difference occurs between the properties or functions of the Pipe series and the
standard power source, the information in this document takes precedence.
NOTE!
The pushpull-unit MUST be calibrated:
prior to each initial start-up
▶
after selecting another pushpull-unit
▶
each time the wirefeeder software is updated
▶
EN
If the push-pull unit is not calibrated, the standard parameters will be used - which may
result in the welding result not being satisfactory.
- Select the “PPU” function in the second (2nd) menu level (power source operating
instructions)
Accessories - Integrated control and connection socket for wirefeeder control lead
- Pipeline edition welding database
- Dust filter
5
Configuration examples
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1
1
1
2
2
2
2
3 3
4
4
5 5
6
6
7 8
General remarks The system components in the digital machine series can be combined in whichever way
the user chooses. The permissible temperature ranges of the individual system components must be observed.
NOTE!
At temperatures below -5 °C the power sources must be kept in a climatised cabinet at as constant a temperature as possible.
Wirefeeders and torches can be used under more severe conditions.
Double tandem
welding process
For welding pipelines with large diameters and long sections, the TimeTwin Digital welding system is used in conjunction with an automised double tandem welding process.
The double tandem welding process allows four Twin welding torches to weld the
pipeline at the same time.
Configuration example for double tandem welding process
(1) Power source* x 8
(2) Cooling unit FK 9000 R Pipe or, for long hosepacks: FK 6000 Pipe
„Stand-alone“ (6)
(3) Wirefeeder VR 1500 Pipe x 8
(4) Verbindungs-Schlauchpaket Pipe x 8
(5) Pipe interconnecting hosepipe x 4
(7) Climatised cabinet (-5 to +40 °C)
6
(8) Working area (-50 to +40 °C)
As an option, the welding system can be equipped with the RCU 4000 or RCU 5000i
remote control unit.
* TPS 3200 460 V Pipe with installation set VR 1500 Pipe or TPS 4000 MV Pipe
x 4
Single tandem
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1
2
2
3 3
4
5 5
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7 8
welding process
To weld medium diameter pipelines, the TimeTwin Digital welding system is used in conjunction with an automised tandem welding process. The tandem welding process allows
two Twin welding torches to weld the pipeline at the same time.
Configuration example for tandem welding process
(1) Power source* x 4
EN
(2) Cooling unit FK 9000 R Pipe or, for long hosepacks: FK 6000 Pipe
x 2
„Stand-alone“ (6)
(3) Wirefeeder VR 1500 Pipe x 2
(4) Pipe interconnecting hosepipe x 2
(5) Robacta Twin Pipe welding torch x 2
(7) Climatised cabinet (-5 to +40 °C)
(8) Working area (-50 to +40 °C)
As an option, the welding system can be equipped with the RCU 4000 or RCU 5000i
remote control unit.
* TPS 3200 460 V Pipe with installation set VR 1500 Pipe or TPS 4000 MV Pipe
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Single welding
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2
3
5
4
3
5
1
2
66
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process
To weld small diameter pipelines, two TPS 4000 MV Pipe power sources are used. The
single welding process allows two single welding torches to weld the pipeline at the
same time.
Configuration example for single welding process
(1) Power source* x 2
(2) Cooling unit FK 4000 R Pipe or, for long hosepacks: FK 6000 Pipe
x 2
„Stand-alone“ (6)
(3) Wirefeeder VR 1500 Pipe x 2
(4) Pipe interconnecting hosepipe x 2
(5) Robacta Pipe welding torch x 2
(7) Climatised cabinet (-5 to +40 °C)
(8) Working area (-50 to +40 °C)
As an option, the welding system can be equipped with the RCU 4000 or RCU 5000i
remote control unit.
* TPS 3200 460 V Pipe with installation set VR 1500 Pipe or TPS 4000 MV Pipe
8
Average consumption values during welding
EN
Average wire
electrode consumption during
MIG/MAG welding
Average shielding gas consumption during
MIG/MAG welding
Average wire electrode consumption at a wire speed of 5 m/min
1.0 mm wire
electrode dia-
meter
Steel wire electrode 1.8 kg/h 2.7 kg/h 4.7 kg/h
Aluminium wire electrode 0.6 kg/h 0.9 kg/h 1.6 kg/h
CrNi wire electrode 1.9 kg/h 2.8 kg/h 4.8 kg/h
Average wire electrode consumption at a wire speed of 10 m/min
1.0 mm wire
electrode dia-
meter
Steel wire electrode 3.7 kg/h 5.3 kg/h 9.5 kg/h
Aluminium wire electrode 1.3 kg/h 1.8 kg/h 3.2 kg/h
CrNi wire electrode 3.8 kg/h 5.4 kg/h 9.6 kg/h
Wire electrode
diameter
Average consumption
1.0 mm 1.2 mm 1.6 mm 2.0 mm 2 x 1.2 mm (TWIN)
10 l/min 12 l/min 16 l/min 20 l/min 24 l/min
1.2 mm wire
electrode dia-
meter
1.2 mm wire
electrode dia-
meter
1.6 mm wire
electrode dia-
meter
1.6 mm wire
electrode dia-
meter
Average shielding gas consumption during
TIG welding
Gas nozzle size 4 5 6 7 8 10
Average consumption
6 l/min 8 l/min 10 l/min 12 l/min 12 l/min 15 l/min
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Technical data
TPS 3200 460 V
Pipe
Storage temperature - 50 °C to + 55 °C
- 58 °F to + 131 °F
Operating temperature - 40 °C to + 50 °C
- 40 °F to + 122 °F
Mains voltage 3 x 380 - 460 V
Mains voltage tolerance +/- 10 %
Mains frequency 50 / 60 Hz
Mains connection
1)
Restrictions possible
Cos Phi 0,99
Welding current range 3 - 320 A
Welding current at
10 min / 40 °C (104 °F)
10 min / 40 °C (104 °F)
10 min / 40 °C (104 °F)
40 % d.c.
60 % d.c.
100 % d.c.
2)
2)
2)
320 A
260 A
220 A
Open-circuit voltage 65 V
Working voltage 14,2 - 30,0 V
Degree of protection IP 23
Dimensions l x w x h 625 x 2904 x 475 mm
24.6 x 11.4 x 18.7 in.
Weight 35,2 kg
77.6 lb.
Power source efficiency at 400 V 33.5 W
Idle state power consumption at 320 A / 32.8 V 89 %
1)
conntected to public grid at 230/400 V and 50 Hz
2)
d.c. = Duty cycle
10
TPS 4000 MV
Pipe
Storage temperature - 50 °C to + 55 °C
- 58 °F to + 131 °F
Operating temperature - 40 °C to + 50 °C
- 40 °F to + 122 °F
Mains voltage 3 x 200 - 240 V
3 x 380 - 460 V
Mains voltage tolerance +/- 10 %
Mains frequency 50 / 60 Hz
Mains connection
1)
Restrictions possible
Cos Phi 0,99
Welding current range 3 - 400 A
Welding current at
10 min / 40 °C (104 °F)
10 min / 40 °C (104 °F)
10 min / 40 °C (104 °F)
40 % d.c.
60 % d.c.
100 % d.c.
2)
2)
2)
400 A
365 A
300 A
Open-circuit voltage 65 V
Working voltage 14,2 - 34,0 V
EN
Degree of protection IP 23
Dimensions l x w x h 625 x 2904 x 475 mm
24.6 x 11.4 x 18.7 in.
Weight 35,2 kg
77.6 lb.
Power source efficiency at 400 V 44.3 W
Idle state power consumption at 400 A / 36 V 90 %
1)
conntected to public grid at 230/400 V and 50 Hz
2)
d.c. = Duty cycle
11
TPS 5000 Pipe
Storage temperature - 50 °C to + 55 °C
- 58 °F to + 131 °F
Operating temperature - 40 °C to + 50 °C
- 40 °F to + 122 °F
Mains voltage 3 x 200 - 240 V
3 x 380 - 460 V
Mains voltage tolerance +/- 10 %
Mains frequency 50 / 60 Hz
Mains connection
11)
Restrictions possible
Cos Phi 0,99
Welding current range 3 - 500 A
Welding current at
10 min / 40 °C (104 °F)
10 min / 40 °C (104 °F)
40 % d.c.
60 % d.c.
2)
2)
500 A
450 A
Overview with
critical raw
materials, year of
production of the
device
10 min / 40 °C (104 °F) 100 % d.c.
2)
340 A
Open-circuit voltage 65 V
Working voltage 14,2 - 34,0 V
Degree of protection IP 23
Dimensions l x w x h 625 x 2904 x 475 mm
24.6 x 11.4 x 18.7 in.
Weight 35,2 kg
77.6 lb.
Power source efficiency at 400 V 31.8 W
Idle state power consumption at 500 A / 40 V 90 %
1)
conntected to public grid at 230/400 V and 50 Hz
2)
d.c. = Duty cycle
Overview with critical raw materials:
An overview of which critical raw materials are contained in this device can be found at
the following Internet address.
www.fronius.com/en/about-fronius/sustainability.
To calculate the year of production of the device:
- Each device is provided with a serial number
- The serial number consists of 8 digits - for example 28020099
- The first two digits give the number from which the year of production of the device
can be calculated
- This figure minus 11 gives the year of production
• For example: Serial number = 28020065, calculation of the year of production =
28 - 11 = 17, year of production = 2017
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EN
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EN
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FRONIUS INTERNATIONAL GMBH
Froniusstraße 1
A-4643 Pettenbach
AUSTRIA
contact@fronius.com
www.fronius.com
Under www.fronius.com/contact you will find the addresses
of all Fronius Sales & Service Partners and locations
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