Fronius TransSynergic 4000, TransSynergic 5000 Operating instructions

Download

Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).

/ Perfect Charging / Perfect Welding / Solar Energy

TransSynergic 4000/5000 TransPuls Synergic 2700 TransPuls Synergic

3200/4000/5000 TIME 5000 Digital CMT 4000 Advanced

Operating instructions

MIG/MAG power source

42,0426,0001,EN 023-17092020

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Contents

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Safety rules 9

Explanation of safety notices 9 General 9 Proper use 9 Environmental conditions 10 Obligations of the operator 10 Obligations of personnel 10 Mains connection 10 Protecting yourself and others 11 Noise emission values 11 Danger from toxic gases and vapours 12 Danger from flying sparks 12 Risks from mains current and welding current 13 Meandering welding currents 14 EMC Device Classifications 14 EMC measures 14 EMF measures 15 Specific hazards 15 Requirement for the shielding gas 16 Danger from shielding gas cylinders 16 Danger from escaping shielding gas 17 Safety measures at the installation location and during transport 17 Safety measures in normal operation 17 Commissioning, maintenance and repair 18 Safety inspection 18 Disposal 19 Safety symbols 19 Data protection 19 Copyright 19

General information 21

General 23

Device concept 23 Functional principle 23 Application areas 23 Warning notices on the device 24 Description of Warning Notices on the Device 25

Special versions 27

General 27 Alu edition 27 CrNi edition 27 CMT Variants 27 CMT 4000 Advanced 28 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

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Displaying the feeder inching speed 36 Displaying the gas pre-flow and gas post-flow time 36 Displaying the software version 37

Comfort / CrNi / Steel control panel 38

Difference between Comfort, CrNi and Steel control panels 38 Comfort control panel 38 Key combinations - special functions 42 Displaying the feeder inching speed 42 Displaying the gas pre-flow and gas post-flow time 43 Displaying the software version 43

US control panel 44

US control panel 44 Key combinations - special functions 47 Displaying the feeder inching speed 47 Displaying the gas pre-flow and gas post-flow time 48 Displaying the software version 48

TIME 5000 Digital control panel 49

TIME 5000 Digital control panel 49 Key combinations - special functions 52 Displaying the feeder inching speed 53 Displaying the gas pre-flow and gas post-flow time 53 Displaying the software version 53

CMT control panel 54

CMT control panel 54 Key combinations - special functions 57 Displaying the feeder inching speed 57 Displaying the gas pre-flow and gas post-flow time 57 Displaying the software version 58

Yard control panel 59

Yard control panel 59 Key combinations - special functions 62 Displaying the feeder inching speed 62 Displaying the gas pre-flow and gas post-flow time 63 Displaying the software version 63

“Remote” control panel 64

General 64 Remote control panel 64

CMT Remote control panel 65

General 65 CMT Remote and CMT Advanced control panel 65

Connections, switches and mechanical components 66

TPS 2700 power source 66 TPS 2700 CMT power source 67 TS 4000 / 5000, TPS 3200 / 4000 / 5000, TIME 5000 Digital power sources 68 CMT 4000 Advanced power source 69

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

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Mains connection 75

Connecting up the mains cable on US power sources 77

General 77 Stipulated mains cables and strain-relief devices 77 Safety 77 Connecting the mains cable 77 Replacing the strain-relief device 79

Start-up 80

Safety 80 Remarks on the cooling unit 80 Information on system components 80 Overview 81

Commissioning the TPS 2700 82

General 82 Recommendation for water-cooled applications 82 Connecting the gas cylinder 82 Establishing a ground (earth) connection 83 Connecting the welding torch 83 Inserting/replacing feed rollers 84 Inserting the wirespool 84 Inserting the basket-type spool 85 Feeding in the wire electrode 86 Setting the contact pressure 87 Adjusting the brake 87 Design of the brake 88

Commissioning the TS 4000 / 5000, TPS 3200 / 4000 / 5000, TIME 5000 Digital 89

General 89 Fitting the system components (overview) 89 Fixing the strain-relief device in place 90 Connecting the interconnecting hosepack 90 Connecting the gas cylinder 91 Establishing a ground (earth) connection 92 Connecting the welding torch 92 Other tasks 92

Commissioning the CMT4000 Advanced 93

Fitting the system components (overview) 93 Connecting the interconnecting hosepack, CMT welding torch and wire buffer 93 Other tasks 94 Preparing the wire-feed unit 94

Welding 95

MIG/MAG modes 97

General 97 Symbols and their explanations 97 2-step mode 98 4-step mode 98 Special 4-step mode 99 Spot welding 99

MIG/MAG welding 100

Safety 100 General tasks before MIG/MAG welding 100 Overview 100

MIG/MAG synergic welding 101

General 101 MIG/MAG synergic welding 101 Corrections during welding 102 Adjusting parameters for correction 103 Remarks on the Standard control panel 103

MIG/MAG standard manual welding 104

General 104

Available parameters 104

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

MIG/MAG standard manual welding 104 Corrections during welding 105 Adjusting parameters for correction 106

CMT welding 107

General 107 CMT welding 107 Corrections during welding 108 Adjusting parameters for correction 110

Special functions and options 111

Arc break watchdog function 111 Ignition time-out function 111 Spatter-free ignition option 111 SynchroPulse option 112

Robot welding 114

Prerequisite 114 General 114 Special 2-step mode for robot interface 114 Wire-stick control function 115 Changing the welding process during CMT Advanced welding 115

TIG welding 116

Safety 116 Prerequisite 116 Preparation 116 TIG welding 117 Igniting the arc 117 Finishing welding 118 TIG Comfort Stop option 118 TIG welding with TIG Comfort Stop 119

MMA welding 121

Safety 121 Prerequisite 121 Preparation 121 Manual metal arc welding 122 Corrections during welding 122 Adjusting parameters for correction 123 HotStart function 123 SoftStart function 123 Anti-stick function 124

Job mode 125

General 125 Prerequisites 125 Restrictions 125 Job mode displays on the left-hand digital display 125 Selecting job mode as the process 125 Creating a job 126 Retrieving a job 127 Copying/overwriting a job 128 Deleting a job 129

Setup settings 131

Job correction 133

General 133 Opening the Job correction menu 133 Changing welding parameters 133 Exiting the Job correction menu 133 Parameters in the job correction menu 134 Permanently settable parameters 134 Parameters that can be corrected at a later time 137

Shielding gas setup menu 139

General 139

Protective gas shield setup menu for the standard control panel 139

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Protective gas shield setup menu for the Comfort, US, TIME 5000 Digital and CMT control panels 139 Welding parameters in the Protective gas shield setup menu 139

Setup menu for the standard control panel 141

General 141 Setup menu for the standard control panel 141 Parameters in the Setup menu for the Standard control panel 141

Process setup menu 144

General 144 Process setup menu for the Comfort, US, TIME 5000 Digital and CMT control panels 144 Parameters for MIG/MAG welding in the Process setup menu 144 Parameters for TIG welding in the Process setup menu 147 Parameters for MMA welding in the Process setup menu 147

Mode setup menu 149

General 149 Mode setup menu for the Comfort, US, TIME 5000 Digital and CMT control panels 149 Welding parameters for "Special 2-step mode" in the Mode setup menu 149 Welding parameters for "Special 4-step mode" in the Mode setup menu 150 Parameters for spot welding in the Mode setup menu 151

Setup menu - Level 2 152

General 152 Setup menulevel 2 for the Standard control panel 152 Setup menu level 2 for the Comfort, US, TIME 5000 Digital and CMT control panels 153 Parameters for MIG/MAG welding in the Setup menu level 2 153 Parameters for operating power sources in parallel in the Setup menu level 2 156 Parameters for TimeTwin Digital in the Setup menu level 2 157 Parameters for TIG welding in the Setup menu level 2 157 Parameters for rod electrode (MMA) welding in the Setup menu level 2 158 Notes on the use of the FAC parameter 161

Calibrating push-pull unit 162

General 162 Calibrating the push-pull unit - overview 162 Calibrating the push-pull unit 163

Service codes for push-pull calibration 167

Safety 167 Service codes when the drive units are disengaged ("open-circuit" calibration) 167 Service codes when the drive units are engaged ("engaged" calibration) 168

Measuring welding circuit resistance r 170

General 170 Measuring welding circuit resistance r 170

Displaying welding circuit inductivity L 172

General 172 Displaying welding circuit inductivity L 172 Arranging the interconnecting hosepack correctly 172

Troubleshooting and maintenance 173

Troubleshooting 175

General 175 Safety 175 Displayed service codes 175 Power source - troubleshooting 183

Care, maintenance and disposal 187

General 187 Safety 187 At every start-up 187 Every 2 months 187 Every 6 months 187 Disposal 187

Appendix 189

Technical data 191

Special voltages 191

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

TPS 2700 191 TPS 2700 MV 192 TPS 3200 193 TPS 3200 MV 194 TPS 3200 460 V AC 195 TS/TPS 4000 196 TS/TPS 4000 MV 197 TS/TPS 5000 198 TS/TPS 5000 MV 199 Technical data - US devices 200 Technical data - Alu edition, CrNi edition, Yard edition and CMT variants 200 TIME 5000 Digital 200 CMT 4000 Advanced 201 CMT 4000 Advanced MV 202

Welding program databases 204

Explanation of symbols 204 Setting up a welding program database - example 204

Terms and abbreviations used 205

General 205 Terms and abbreviations A - C 205 Terms and abbreviations D - F 205 Terms and abbreviations G - I 206 Terms and abbreviations J - R 207 Terms and abbreviations S 207 Terms and abbreviations T - 2nd 208

Safety rules

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Explanation of safety notices

DANGER!

Indicates immediate danger.

If not avoided, death or serious injury will result.

▶

WARNING!

Indicates a potentially hazardous situation.

If not avoided, death or serious injury may result.

▶

CAUTION!

Indicates a situation where damage or injury could occur.

If not avoided, minor injury and/or damage to property may result.

▶

NOTE!

Indicates a risk of flawed results and possible damage to the equipment.

General The device is manufactured using state-of-the-art technology and according to recog-

nised safety standards. If used incorrectly or misused, however, it can cause:

- injury or death to the operator or a third party,

- damage to the device and other material assets belonging to the operating company,

- inefficient operation of the device.

All persons involved in commissioning, operating, maintaining and servicing the device must:

- be suitably qualified,

- have sufficient knowledge of welding and

- read and follow these operating instructions carefully.

The operating instructions must always be at hand wherever the device is being used. In addition to the operating instructions, attention must also be paid to any generally applicable and local regulations regarding accident prevention and environmental protection.

All safety and danger notices on the device

- must be in a legible state,

- must not be damaged,

- must not be removed,

- must not be covered, pasted or painted over.

For the location of the safety and danger notices on the device, refer to the section headed "General" in the operating instructions for the device. Before switching on the device, rectify any faults that could compromise safety.

This is for your personal safety!

Proper use The device is to be used exclusively for its intended purpose.

The device is intended solely for the welding processes specified on the rating plate.

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage.

Proper use includes:

- carefully reading and following all the instructions given in the operating instructions

- studying and obeying all safety and danger notices carefully

- performing all stipulated inspection and maintenance work.

Never use the device for the following purposes:

- Thawing out pipes

- Charging batteries

- Starting engines

The device is designed for use in industry and the workshop. The manufacturer accepts no responsibility for any damage caused through use in a domestic setting.

The manufacturer likewise accepts no liability for inadequate or incorrect results.

Environmental conditions

Obligations of the operator

Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage.

Ambient temperature range:

- during operation: -10 °C to + 40 °C (14 °F to 104 °F)

- during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)

Relative humidity:

- up to 50% at 40 °C (104 °F)

- up to 90% at 20 °C (68 °F)

The surrounding air must be free from dust, acids, corrosive gases or substances, etc. Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)

The operator must only allow persons to work with the device who:

- are familiar with the fundamental instructions regarding safety at work and accident prevention and have been instructed in how to use the device

- have read and understood these operating instructions, especially the section "safety rules", and have confirmed as much with their signatures

- are trained to produce the required results.

Checks must be carried out at regular intervals to ensure that operators are working in a safety-conscious manner.

Obligations of personnel

Before using the device, all persons instructed to do so undertake:

- to observe the basic instructions regarding safety at work and accident prevention

- to read these operating instructions, especially the "Safety rules" section and sign to confirm that they have understood them and will follow them.

Before leaving the workplace, ensure that people or property cannot come to any harm in your absence.

Mains connection Devices with a higher rating may affect the energy quality of the mains due to their cur-

rent consumption.

This may affect a number device types in terms of:

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

- Connection restrictions

Criteria with regard to the maximum permissible mains impedance

Criteria with regard to the minimum short-circuit power requirement

at the interface with the public grid

see "Technical data"

In this case, the plant operator or the person using the device should check whether the device may be connected, where appropriate by discussing the matter with the power supply company.

IMPORTANT! Ensure that the mains connection is earthed properly

Protecting yourself and others

Anyone working with the device exposes themselves to numerous risks, e.g.

- flying sparks and hot pieces of metal

- Arc radiation, which can damage eyes and skin

- Hazardous electromagnetic fields, which can endanger the lives of those using cardiac pacemakers

- Risk of electrocution from mains current and welding current

- Greater noise pollution

- Harmful welding fumes and gases

Suitable protective clothing must be worn when working with the device. The protective clothing must have the following properties:

- Flame-resistant

- Insulating and dry

- Covers the whole body, is undamaged and in good condition

- Safety helmet

- Trousers with no turn-ups

Protective clothing refers to a variety of different items. Operators should:

- Protect eyes and face from UV rays, heat and sparks using a protective visor and regulation filter

- Wear regulation protective goggles with side protection behind the protective visor

- Wear stout footwear that provides insulation even in wet conditions

- Protect the hands with suitable gloves (electrically insulated and providing protection against heat)

- Wear ear protection to reduce the harmful effects of noise and to prevent injury

Keep all persons, especially children, out of the working area while any devices are in operation or welding is in progress. If, however, there are people in the vicinity:

- Make them aware of all the dangers (risk of dazzling by the arc, injury from flying sparks, harmful welding fumes, noise, possible risks from mains current and welding current, etc.)

- Provide suitable protective equipment

- Alternatively, erect suitable safety screens/curtains.

Noise emission values

The device generates a maximum sound power level of <80 dB(A) (ref. 1pW) when idling and in the cooling phase following operation at the maximum permissible operating point under maximum rated load conditions according to EN 60974-1.

It is not possible to provide a workplace-related emission value during welding (or cutting) as this is influenced by both the process and the environment. All manner of different welding parameters come into play, including the welding process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the power range, the type of weld metal, the resonance characteristics of the workpiece, the workplace environment, etc.

Danger from

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

toxic gases and vapours

The fumes produced during welding contain harmful gases and vapours.

Welding fumes contain substances that cause cancer, as stated in Monograph 118 of the International Agency for Research on Cancer.

Use at-source extraction and a room extraction system. If necessary, use a welding torch with an integrated extraction device.

Keep your face away from welding fumes and gases.

Fumes and hazardous gases

- must not be breathed in

- must be extracted from the working area using appropriate methods.

Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least 20 m³ per hour at all times.

Otherwise, a welding helmet with an air supply must be worn.

If there is any doubt about whether the extraction capacity is sufficient, the measured toxic emission values should be compared with the permissible limit values.

The following components are responsible, amongst other things, for the degree of toxicity of welding fumes:

- Metals used for the workpiece

- Electrodes

- Coatings

- Cleaners, degreasers, etc.

- Welding process used

Danger from flying sparks

The relevant material safety data sheets and manufacturer's specifications for the listed components should therefore be studied carefully.

Recommendations for trade fair scenarios, risk management measures and for identifying working conditions can be found on the European Welding Association website under Health & Safety (https://european-welding.org).

Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation area.

Close the shielding gas cylinder valve or main gas supply if no welding is taking place.

Flying sparks may cause fires or explosions.

Never weld close to flammable materials.

Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the arc, or alternatively covered with an approved cover.

A suitable, tested fire extinguisher must be available and ready for use.

Sparks and pieces of hot metal may also get into adjacent areas through small gaps or openings. Take appropriate precautions to prevent any danger of injury or fire.

Welding must not be performed in areas that are subject to fire or explosion or near sealed tanks, vessels or pipes unless these have been prepared in accordance with the relevant national and international standards.

Do not carry out welding on containers that are being or have been used to store gases, propellants, mineral oils or similar products. Residues pose an explosive hazard.

Risks from mains

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

current and welding current

An electric shock is potentially life threatening and can be fatal.

Do not touch live parts either inside or outside the device.

During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed rollers and all pieces of metal that are in contact with the welding wire are live.

Always set the wirefeeder up on a sufficiently insulated surface or use a suitable, insulated wirefeeder holder.

Make sure that you and others are protected with an adequately insulated, dry base or cover for the earth or ground potential. This base or cover must extend over the entire area between the body and the earth or ground potential.

All cables and leads must be secured, undamaged, insulated and adequately dimensioned. Replace loose connections and scorched, damaged, or inadequately dimensioned cables and leads immediately. Use the handle to ensure the power connections are tight before every use. In the case of power cables with a bayonet connector, rotate the power cable around the longitudinal axis by at least 180° and pretension.

Do not wrap cables or leads around the body or parts of the body.

The electrode (rod electrode, tungsten electrode, welding wire, etc.) must

- never be immersed in liquid for cooling

- Never touch the electrode when the power source is switched on.

Double the open circuit voltage of a power source can occur between the welding electrodes of two power sources. Touching the potentials of both electrodes at the same time may be fatal under certain circumstances.

Arrange for the mains cable to be checked regularly by a qualified electrician to ensure the ground conductor is functioning properly.

Protection class I devices require a mains supply with ground conductor and a connector system with ground conductor contact for proper operation.

Operation of the device on a mains supply without ground conductor and on a socket without ground conductor contact is only permitted if all national regulations for protective separation are observed. Otherwise, this is considered gross negligence. The manufacturer shall not be held liable for any damage arising from such usage.

If necessary, provide adequate earthing for the workpiece.

Switch off unused devices.

Wear a safety harness if working at height.

Before working on the device, switch it off and pull out the mains plug.

Attach a clearly legible and easy-to-understand warning sign to the device to prevent anyone from plugging the mains plug back in and switching it on again.

After opening the device:

- Discharge all live components

- Ensure that all components in the device are de-energised.

If work on live parts is required, appoint a second person to switch off the main switch at the right moment.

Meandering weld-

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

ing currents

If the following instructions are ignored, meandering welding currents can develop with the following consequences:

- Fire hazard

- Overheating of parts connected to the workpiece

- Irreparable damage to ground conductors

- Damage to device and other electrical equipment

Ensure that the workpiece is held securely by the workpiece clamp.

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

Position the device with sufficient insulation against electrically conductive environments, e.g. Insulation against conductive floor or insulation to conductive racks.

If distribution boards, twin-head mounts, etc., are being used, note the following: The electrode of the welding torch / electrode holder that is not used is also live. Make sure that the welding torch / electrode holder that is not used is kept sufficiently insulated.

In the case of automated MIG/MAG applications, ensure that only an insulated wire electrode is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeeder.

EMC Device Classifications

Devices in emission class A:

- Are only designed for use in industrial settings

- Can cause line-bound and radiated interference in other areas

Devices in emission class B:

- Satisfy the emissions criteria for residential and industrial areas. This is also true for residential areas in which the energy is supplied from the public low-voltage mains.

EMC device classification as per the rating plate or technical data.

EMC measures In certain cases, even though a device complies with the standard limit values for emis-

sions, it may affect the application area for which it was designed (e.g. when there is sensitive equipment at the same location, or if the site where the device is installed is close to either radio or television receivers). If this is the case, then the operator is obliged to take appropriate action to rectify the situation.

Check and evaluate the immunity to interference of nearby devices according to national and international regulations. Examples of equipment that may be susceptible to interference from the device include:

- Safety devices

- Power, signal and data transfer lines

- IT and telecommunications devices

- Measuring and calibrating devices

Supporting measures for avoidance of EMC problems:

1. Mains supply

- If electromagnetic interference arises despite correct mains connection, addi-

tional measures are necessary (e.g. use a suitable line filter).

2. Welding power leads

- must be kept as short as possible

- must run close together (to avoid EMF problems)

- must be kept well apart from other leads

3. Equipotential bonding

4. Earthing of the workpiece

- If necessary, establish an earth connection using suitable capacitors.

5. Shielding, if necessary

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

- Shield off other nearby devices

- Shield off entire welding installation

EMF measures Electromagnetic fields may pose as yet unknown risks to health:

- effects on the health of others in the vicinity, e.g. wearers of pacemakers and hearing aids

- wearers of pacemakers must seek advice from their doctor before approaching the device or any welding that is in progress

- for safety reasons, keep distances between the welding cables and the welder's head/torso as large as possible

- do not carry welding cables and hosepacks over the shoulders or wind them around any part of the body

Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example:

- Fans

- Cogs

- Rollers

- Shafts

- Wirespools and welding wires

Do not reach into the rotating cogs of the wire drive or into rotating drive components.

Covers and side panels may only be opened/removed while maintenance or repair work is being carried out.

During operation

- Ensure that all covers are closed and all side panels are fitted properly.

- Keep all covers and side panels closed.

The welding wire emerging from the welding torch poses a high risk of injury (piercing of the hand, injuries to the face and eyes, etc.).

Therefore always keep the welding torch away from the body (devices with wire-feed unit) and wear suitable protective goggles.

Never touch the workpiece during or after welding - risk of burns.

Slag can jump off cooling workpieces. The specified protective equipment must therefore also be worn when reworking workpieces, and steps must be taken to ensure that other people are also adequately protected.

Welding torches and other parts with a high operating temperature must be allowed to cool down before handling.

Special provisions apply in areas at risk of fire or explosion - observe relevant national and international regulations.

Power sources for work in areas with increased electric risk (e.g. near boilers) must carry the "Safety" sign. However, the power source must not be located in such areas.

Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting coolant flow or return lines.

Observe the information on the coolant safety data sheet when handling coolant. The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer's website.

Use only suitable load-carrying equipment supplied by the manufacturer when transporting devices by crane.

- Hook chains and/or ropes onto all suspension points provided on the load-carrying

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

equipment.

- Chains and ropes must be at the smallest angle possible to the vertical.

- Remove gas cylinder and wire-feed unit (MIG/MAG and TIG devices).

If the wire-feed unit is attached to a crane holder during welding, always use a suitable, insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).

If the device has a carrying strap or handle, this is intended solely for carrying by hand. The carrying strap is not to be used if transporting with a crane, counterbalanced lift truck or other mechanical hoist.

All lifting accessories (straps, handles, chains, etc.) used in connection with the device or its components must be tested regularly (e.g. for mechanical damage, corrosion or changes caused by other environmental factors). The testing interval and scope of testing must comply with applicable national standards and directives as a minimum.

Odourless and colourless shielding gas may escape unnoticed if an adapter is used for the shielding gas connection. Prior to assembly, seal the device-side thread of the adapter for the shielding gas connection using suitable Teflon tape.

Requirement for the shielding gas

Danger from shielding gas cylinders

Especially with ring lines, contaminated shielding gas can cause damage to equipment and reduce welding quality. Meet the following requirements regarding shielding gas quality:

- Solid particle size < 40 µm

- Pressure condensation point < -20 °C

- Max. oil content < 25 mg/m³

Use filters if necessary.

Shielding gas cylinders contain gas under pressure and can explode if damaged. As the shielding gas cylinders are part of the welding equipment, they must be handled with the greatest of care.

Protect shielding gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked flames, sparks and arcs.

Mount the shielding gas cylinders vertically and secure according to instructions to prevent them falling over.

Keep the shielding gas cylinders well away from any welding or other electrical circuits.

Never hang a welding torch on a shielding gas cylinder.

Never touch a shielding gas cylinder with an electrode.

Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.

Only use shielding gas cylinders suitable for the application in hand, along with the correct and appropriate accessories (regulator, hoses and fittings). Only use shielding gas cylinders and accessories that are in good condition.

Turn your face to one side when opening the valve of a shielding gas cylinder.

Close the shielding gas cylinder valve if no welding is taking place.

If the shielding gas cylinder is not connected, leave the valve cap in place on the cylinder.

The manufacturer's instructions must be observed as well as applicable national and

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

international regulations for shielding gas cylinders and accessories.

Danger from escaping shielding gas

Safety measures at the installation location and during transport

Risk of suffocation from the uncontrolled escape of shielding gas

Shielding gas is colourless and odourless and, in the event of a leak, can displace the oxygen in the ambient air.

- Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/hour.

- Observe safety and maintenance instructions on the shielding gas cylinder or the main gas supply.

- Close the shielding gas cylinder valve or main gas supply if no welding is taking place.

- Check the shielding gas cylinder or main gas supply for uncontrolled gas leakage before every start-up.

A device toppling over could easily kill someone. Place the device on a solid, level surface such that it remains stable

- The maximum permissible tilt angle is 10°.

Special regulations apply in rooms at risk of fire or explosion

- Observe relevant national and international regulations.

Use internal directives and checks to ensure that the workplace environment is always clean and clearly laid out.

Only set up and operate the device in accordance with the degree of protection shown on the rating plate.

Safety measures in normal operation

When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft. 7.69 in.) to ensure that cooling air can flow in and out freely.

When transporting the device, observe the relevant national and local guidelines and accident prevention regulations. This applies especially to guidelines regarding the risks arising during transport.

Do not lift or transport operational devices. Switch off devices before transport or lifting.

Before transporting the device, allow coolant to drain completely and detach the following components:

- Wirefeeder

- Wirespool

- Shielding gas cylinder

After transporting the device, the device must be visually inspected for damage before commissioning. Any damage must be repaired by trained service technicians before commissioning the device.

Only operate the device when all safety devices are fully functional. If the safety devices are not fully functional, there is a risk of

- injury or death to the operator or a third party

- damage to the device and other material assets belonging to the operator

- inefficient operation of the device

Any safety devices that are not functioning properly must be repaired before switching on the device.

Never bypass or disable safety devices.

Before switching on the device, ensure that no one is likely to be endangered.

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Check the device at least once a week for obvious damage and proper functioning of safety devices.

Always fasten the shielding gas cylinder securely and remove it beforehand if the device is to be transported by crane.

Only the manufacturer's original coolant is suitable for use with our devices due to its properties (electrical conductibility, anti-freeze agent, material compatibility, flammability, etc.).

Only use suitable original coolant from the manufacturer.

Do not mix the manufacturer's original coolant with other coolants.

Only connect the manufacturer's system components to the cooling circuit.

The manufacturer accepts no liability for damage resulting from use of other system components or a different coolant. In addition, all warranty claims will be forfeited.

Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under certain conditions. Transport the coolant only in its original, sealed containers and keep well away from any sources of ignition.

Used coolant must be disposed of properly in accordance with the relevant national and international regulations. The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer's website.

Check the coolant level before starting to weld, while the system is still cool.

Commissioning, maintenance and repair

It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made of them, or that they satisfy safety requirements.

- Use only original spare and wearing parts (also applies to standard parts).

- Do not carry out any modifications, alterations, etc. to the device without the manufacturer's consent.

- Components that are not in perfect condition must be replaced immediately.

- When ordering, please give the exact designation and part number as shown in the spare parts list, as well as the serial number of your device.

The housing screws provide the ground conductor connection for earthing the housing parts. Only use original housing screws in the correct number and tightened to the specified torque.

Safety inspection The manufacturer recommends that a safety inspection of the device is performed at

least once every 12 months.

The manufacturer recommends that the power source be calibrated during the same 12month period.

A safety inspection should be carried out by a qualified electrician

- after any changes are made

- after any additional parts are installed, or after any conversions

- after repair, care and maintenance has been carried out

- at least every twelve months.

For safety inspections, follow the appropriate national and international standards and directives.

Further details on safety inspection and calibration can be obtained from your service

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

centre. They will provide you on request with any documents you may require.

Disposal Do not dispose of this device with normal domestic waste! To comply with the European

Directive on Waste Electrical and Electronic Equipment and its implementation as national law, electrical equipment that has reached the end of its life must be collected separately and returned to an approved recycling facility. Any device that you no longer require must either be returned to your dealer or given to one of the approved collection and recycling facilities in your area. Ignoring this European Directive may have potentially adverse affects on the environment and your health!

Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage and elec-

tromagnetic compatibility directives (e.g. relevant product standards of the EN 60 974 series).

Fronius International GmbH hereby declares that the device is compliant with Directive 2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following address: http://www.fronius.com

Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA.

Data protection The user is responsible for the safekeeping of any changes made to the factory settings.

The manufacturer accepts no liability for any deleted personal settings.

The text and illustrations are all technically correct at the time of printing. We reserve the right to make changes. The contents of the operating instructions shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for improvement, or can point out any mistakes that you have found in the instructions, we will be most grateful for your comments.

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

General information

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

General

VR 70

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Device concept

The TransSynergic (TS) 4000 and TS 5000 and TransPulsSynergic (TPS) 2700, TPS 3200, TPS 4000 and TPS 5000 power sources are fully digitised microprocessor-controlled inverter power sources.

The modular design and potential for system add-ons ensure a high degree of flexibility. The devices can be adapted to any specific situation.

The TransPuls Synergic 2700 features an integral 4-roller drive. There is no longer an interconnecting hosepack between the power source and wire-feed unit. Its compact design makes the TPS 2700 particu-

TS 4000 / 5000, TPS 3200 / 4000 / 5000 and TPS

2700 welding plants

larly suitable for mobile applications.

All models except the TS 4000/5000 are multiprocess devices:

- MIG/MAG welding

- TIG welding with touchdown ignition (excluding CMT power sources)

- Manual metal arc welding

Functional principle

Application areas

The central control and regulation unit of the power sources is coupled with a digital signal processor. The central control and regulation unit and the signal processor control the entire welding process. During the welding process, the actual data is measured continuously and the device responds immediately to any changes. Control algorithms ensure that the desired target state is maintained.

This results in:

- a precise welding process

- exact reproducibility of all results

- excellent weld properties.

The devices are used in workshops and industry for manual and automated applications with classical steel, galvanised sheets, chrome/nickel and aluminium.

The integral 4-roller drive, high performance and light weight of the TPS 2700 power source make it the ideal choice for portable applications on building sites or in repair workshops.

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

- Automobile and component supply industry

- Machinery and rail vehicle construction

- Equipment construction

- Shipyards, etc.

- Chemical plant construction

Warning notices

Nur vorhanden bei Stromquelle „TPS 2700“ und auf Drahtvorschüben

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

on the device

US power sources come with extra warning notices affixed to the unit. The warning notices must NOT be removed or painted over.

Description of

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Warning Notices on the Device

On certain device versions, warning notices are attached to the device.

The arrangement of the symbols may vary.

. Warning! Watch Out!

There are possible hazards as shown by the symbols.

A Drive rolls can injure fingers.

B Welding wire and drive parts are at welding voltage during operation

Keep hands and metal objects away.

1. Electric shock can kill.

1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear

wet or damaged gloves.

1.2 Protect yourself from electric shock by insulating yourself from work and ground.

1.3 Disconnect input plug or power before working on machine

2. Breathing welding fumes can be hazardous to your health.

2.1 Keep your head out of the fumes.

2.2 Use forced ventilation or local exhaust to remove the fumes.

2.3 Use ventilating fan to remove fumes.

3 Welding sparks can cause explosion or fire.

xx,xxxx,xxxx *

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

3.1 Keep flammables away from welding. Don’t weld near flammables.

3.2 Welding sparks can cause fires.Have a fire extinguisher nearby and have a

watchperson ready to use it.

3.3 Do not weld on drums or any closed containers.

4. Arc rays can burn eyes and injure skin.

4.1 Wear hat and safety glasses. Use ear protection and button shirt collar. Use

welding helmet with correct shade of filter. Wear complete body protection.

5. Become trained and read the instructions before working on the machine or

welding.

6. Do not remove or paint over (cover) the label.

* identifying number to order label from manufacturer

Special versions

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

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

cially matched to the different materials in question. The special versions of the digital power sources are perfectly matched to these requirements. As a result the most important welding programs can be called up directly from the operating panel. Furthermore, the power sources are characterised by standard functions that assist the user when welding these materials.

NOTE!

The technical data of the special versions is identical to that of the standard power sources.

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

minium. Special aluminium welding programs assist in the professional processing of aluminium. The Alu edition power sources are equipped as standard with the following options:

- Special aluminium welding programs

- SynchroPulse option

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

CrNi. Special CrNi welding programs assist in the professional processing of high-grade steels. The CrNi edition power sources are equipped as standard with the following options:

- Special CrNi welding programs

- SynchroPulse option

- TIG Comfort Stop option

- TIG welding torch connection

- Gas solenoid valve

NOTE!

It is not possible to install the “Uni Box” system add-on on the CrNi edition (e.g. for the field bus connection of a robot control).

However, the CrNi edition supports a robot connection via ROB 4000 / 5000 robot interfaces.

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

process. CMT (Cold Metal Transfer) is a special MIG short-arc process. Its special features include low heat input and a controlled, low-current material transfer. CMT is suitable for:

- Virtually spatter-free MIG brazing

- Welding on light-gauge sheet with minimal distortion

- Joining steel and aluminium (weld brazing)

CMT 4000

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Advanced

In addition to the conventional MIG/MAG welding processes, MMA welding and the CMT process, the CMT 4000 Advanced power source supports the improved CMT Advanced process. The functional principle of the CMT Advanced process is based on a combination arc with negatively polarised CMT cycles and positively polarised CMT cycles or positively polarised pulse cycles. Special features are targeted heat input, a higher deposition rate, better gap bridging properties, precise droplet detachment and an extremely stable arc. CMT Advanced is suitable for:

- joining thin sheets with outstanding gap bridging properties

- High-strength steels with low heat input

- Spots: precisely defined drop volumes and defined heat input

- Root passes with no pool support

- Brazing high-strength and ultra high-strength steels

TIME 5000 Digital Concept

As a universal power source, the TIME 5000 Digital is particularly suited for manual applications. In addition to conventional welding processes, the TIME 5000 Digital also supports the TIME high-performance welding process.

Functional principle

Compared with conventional MIG/MAG processes, the following features bring about faster welding speeds, with an increase in deposition rate of up to 30%:

- Power module with high voltage reserves

- High performance welding programs

- Specially selected shielding gases

- High-performance wire-feed unit with water-cooled disc armature motor for wire feed speeds of up to 30 m/min

- TIME welding torch with dual circuit cooling system

Application

Anywhere where long weld seams, large seam cross-sections and controlled heat input are required, e.g.:

- Mechanical engineering

- Steel engineering

- Crane construction

- Shipbuilding

- Boiler manufacture

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

Material types

The high-performance welding process is especially suitable for

- unalloyed steels

- low-alloy steels EN 10027

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

- steels resistant to low temperatures

Yard edition Yard edition power sources are designed especially for use in shipyards and offshore

applications. The welding programs are designed primarily for steel and CrNi applications with solid and flux cored wires.

Steel edition Steel edition power sources are designed specifically for use in the steel sector. The spe-

cial characteristics can be set on the control panel - both for standard and pulsed arcs.

System components

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(11)

(10)

(9)

(8)

F R

O NI

U S

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

General Digital power sources can be run with various system components and options. This

makes it possible to optimise procedures and to simplify machine handling and operation, as necessitated by the particular field of application in which the power source is to be used.

Overview

Overview of system components

Legend:

(1) “Human” hosepack boom (2) Remote controls (3) Welding torches (4) Wire-feed units (5) Wire-feed unit mount (6) Interconnecting hosepacks (7) Robot accessories (8) Power sources (9) Cooling units (10) Trolleys and gas cylinder holders (11) Grounding (earthing) cable and electrode cable

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Control elements and connections

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Description of the control panels

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

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

parameters can easily be selected using buttons and can just as easily be

- altered using buttons or the adjusting dial

- displayed on the digital display during welding

The synergic function ensures that all other welding parameters are adjusted when an individual parameter has been changed.

NOTE!

As a result of software updates, you may find that your device has certain functions that are not described in these operating instructions, or vice versa.

Certain illustrations may also differ slightly from the actual control elements on your device, but these controls function in exactly the same way.

Safety

Danger from incorrect operation.

Possible serious injury and damage to property.

▶ ▶

Overview "Description of the control panels" is composed of the following sections:

- Standard control panel

- Comfort control panel

- "US" control panel

- TIME 5000 Digital control panel

- CMT control panel

- Yard control panel

- Remote control panel

- CMT remote control panel

- CrNi control panel

- Steel control panel

WARNING!

Do not use the functions described here until you have read and completely understood these Operating Instructions. Do not use the functions described here until you have fully read and understood all of the Operating Instructions for the system components, in particular the safety rules!

Standard control panel

(3) (5)

(15)(14)

(6) (9) (10)(8)(7)(4)

(13)

(12) (11)

(2)(1)

(16)

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

General

Standard control panel

NOTE!

On the Standard control panel, only the MIG/MAG standard synergic welding process is available.

The following processes and functions are not available and cannot be retrofitted:

MIG/MAG pulse synergic welding

▶

Job mode

▶

TIG welding

▶

Manual metal arc welding

▶

Spot welding

▶

Any changes to the “Welding current” and “Arc-length correction” parameters have to be made on the wire-feed unit.

No. Function

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

(1) Feeder inching button

for feeding the wire electrode into the torch‑hosepack without any flow of gas or current

For information on the various wire feed sequences that are possible when the welder presses and holds the "Feeder inching" button, see the Fdi parameter in the Setup menu.

(2) Parameter selection button

for selecting the following parameters:

Sheet thickness

Sheet thickness in mm or in.

Welding current

Welding current in A Before the start of welding, the machine automatically displays a standard value based on the programmed parameters. During welding, the actual value is displayed.

Wire feed speed

Wire feed speed in m/min or ipm.

Welding voltage

Welding voltage in V Before the start of welding, the machine automatically displays a standard value based on the programmed parameters. During welding, the actual value is displayed.

If one parameter is selected, then the synergic function means that all other parameters are automatically set as well.

(3) Left digital display

(4) Sheet thickness LED

lights up when the sheet thickness parameter is selected

(5) Welding current LED

lights up when the welding current parameter is selected

(6) Wire feed speed LED

lights up when the wire feed speed parameter is selected

(7) Overtemperature indicator

lights up if the power source overheats (e.g. because the duty cycle has been exceeded). For more information on this, see the "Troubleshooting" section.

(8) HOLD indicator

every time a welding operation finishes, the actual values for welding current and welding voltage are stored, and the HOLD indicator lights up.

(9) Right digital display

(10) Welding voltage LED

lights up when the welding voltage parameter is selected

(11) Mode button

for selecting the mode

2-step mode

4-step mode

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

When a mode is selected, the LED behind the relevant symbol lights up.

No. Function

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

(12) Material button

for selecting the filler metal and shielding gas to be used. Parameters SP1 and SP2 are reserved for additional materials.

When a material is selected, the LED behind the relevant filler metal lights up.

(13) Wire diameter button

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

When a wire diameter is selected, the LED behind the relevant wire diameter lights up.

(14) Intermediate arc indicator

a spatter-prone intermediate arc occurs between the short arc and the spray arc. The intermediate arc indicator lights up to alert you to this critical area

(15) Store button

for opening the Setup menu

(16) Gas test button

for setting the required gas flow rate on the pressure regulator. Gas will flow out for 30 s after pressing the gas test button. Press the button again to stop the gas test flow before the end of this period.

Key combinations - special functions

Displaying the feeder inching speed

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

The following special functions can be called by pressing buttons simultaneously or repeatedly.

The set feeder inching speed is shown (e.g.: Fdi | 10 m/min or Fdi | 393.70 ipm).

Alter the feeder inching speed using the Material buttons (12)

Press the Store button to exit.

The set gas pre-flow time is displayed (e.g. GPr | 0.1 s).

Alter the gas pre-flow time using the Material buttons (12)

Then press the Process button (11) to display the gas post-flow time setting (e.g. GPo | 0.5 s)

Alter the gas post-flow time using the Material buttons (12)

Press the Store button to exit.

Displaying the

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

software version

In addition to the software version, these special functions can also be used to display the version number of the welding database, the wire-feed unit number, the software version of the wire-feed unit and the arc burning time.

The software version is displayed

Press the Material button (12) to display the version number of the welding database (e.g.: 0 | 029 = M0029).

Press the Material button (12) again to display the number of the wire-feed unit (A or B in the case of twin-head mounts) and the software version of the wire-feed unit (e.g.: A 1.5 | 0.23).

Press the Material button (12) a third time to display the actual arc burning time since starting for the first time (e.g. "654 | 32.1" = 65,432.1 h = 65,432 h, 6 min)

NOTE! The arc burning time indicator is not suitable as a basis for

calculating hiring fees, guarantee, etc.

Press the Store button to exit.

Comfort / CrNi / Steel control panel

(14)(4)

(1)

(28) (26)

(25)

(5)

(18)

(15)

(12)

(11)

(10)

(3)

(6)

(9)(7)

(16)(8)

(27)

(24)

(23)

(22)

(13)

(2)

(19)

(17)

(20)

(21)

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Difference between Comfort, CrNi and Steel control panels

Comfort control panel

The Comfort, CrNi and Steel control panels are identical except for the type of material used in their construction. The following section deals specifically with the Comfort control panel, but all the functions described apply equally to the CrNi and Steel control panels.

No. Function

(1) Feeder inching button

for feeding the wire electrode into the welding torch‑hosepack without any flow of gas or current

For information on the various wire feed sequences that are possible when the welder presses and holds the "Feeder inching" button, see the Fdi parameter in the Setup menu.

No. Function

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

(2) Keylock switch (optional)

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

- Selecting the welding process using the Process button(s) (22)

- Selecting the mode using the Mode button(s) (23)

- Selecting the filler metal using the Material button(s) (24)

- Opening the Setup menu using the Store button (27)

- Opening the job correction menu (see “Job mode”)

NOTE! The functions available on the control panel of system com-

ponents are restricted in the same way as those on the control panel of the power source.

(3) Parameter selection button

for selecting the following parameters:

a-dimension

Dependent on the set welding speed

Sheet thickness

Sheet thickness in mm or in.

Welding current

Welding current in A Before the start of welding, the machine automatically displays a standard value based on the programmed parameters. During welding, the actual value is displayed.

Wire feed speed

Wire feed speed in m/min or ipm.

F1 indicator

indicates that the current-input PushPull drive is switched on

Wire-feed rate drive current-input indicator

indicates that the wire-feed rate drive current-input is switched on

If the indicators are lit up on the parameter selection button (3) and on the adjusting dial (21), then the indicated/selected parameter can be altered using the adjusting dial (21).

The synergic function means that if one of these parameters is selected during MIG/MAG pulse synergic welding or MIG/MAG standard synergic welding, then all other parameters including the welding voltage parameter are automatically set as well.

(4) F1 indicator LED

lights up when the F1 indicator parameter is selected

(5) Wire-feed rate drive current-input indicator LED

lights up when the wire-feed rate drive current-input indicator parameter is selected

(6) a-dimension LED

lights up when the a-dimension parameter is selected

(7) Left digital display

(8) Sheet thickness LED

lights up when the sheet thickness parameter is selected

(9) Welding current LED

lights up when the welding current parameter is selected

No. Function

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

(10) Wire feed speed LED

lights up when the wire feed speed parameter is selected

(11) Overtemperature indicator

lights up if the power source overheats (e.g. because the duty cycle has been exceeded). For more information on this, see the "Troubleshooting" section.

(12) HOLD indicator

every time a welding operation finishes, the actual values for welding current and welding voltage are stored, and the HOLD indicator lights up.

(13) Arc length correction LED

lights up when the arc length correction parameter is selected

(14) Droplet detachment correction/arc force dynamic correction/arc force

dynamic LED

lights up when the droplet detachment correction/arc force dynamic correction/arc force dynamic parameter is selected

(15) Welding voltage LED

lights up when the welding voltage parameter is selected

(16) Welding speed LED

lights up when the welding speed parameter is selected

(17) Right digital display

(18) Job no. LED

lights up when the job number parameter is selected

(19) F3 indicator LED

lights up when the F3 indicator parameter is selected

No. Function

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

(20) Parameter selection button

for selecting the following parameters:

Arc length correction

for correcting the arc length

Droplet detachment correction/arc force dynamic correction/arc force dynamic

has a different function assigned to it, depending on the process being used. A description of the various functions can be found in the Welding chapter under the corresponding process.

Welding voltage

Welding voltage in V Before the start of welding, the machine automatically displays a standard value based on the programmed parameters. During welding, the actual value is displayed.

Welding speed

Welding speed in cm/min or ipm (necessary for the a-dimension parameter)

Job N

In the job mode process for retrieving parameter records stored under job numbers

F3 indicator

indicates the real energy inputs in KJ. The real energy input must be activated in level 2 of the Setup menu – parameter EnE. If the indicator is not activated, the coolant flow is displayed when the coolant device FK 4000 Rob is available.

If the indicators are lit up on the parameter selection button (20) and on the adjusting dial (21), then the indicated/selected parameter can be altered using the adjusting dial (21).

(21) Adjusting dial

for altering parameters. If the indicator on the adjusting dial is lit up, then the selected parameter is one that can be altered.

(22) Process button(s)

for selecting the welding process

MIG/MAG pulse synergic welding

MIG/MAG standard synergic welding

MIG/MAG standard manual welding

Job mode

TIG welding with touchdown ignition

Manual metal arc welding

When a process is selected, the LED on the relevant symbol lights up.

No. Function

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

(23) Mode button

for selecting the mode

2-step mode

4-step mode

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

Spot welding mode

Operating mode

When a mode is selected, the LED behind the relevant symbol lights up.

(24) Material button

for selecting the filler metal and shielding gas to be used. Parameters SP1 and SP2 are reserved for additional materials.

When a material is selected, the LED behind the relevant filler metal lights up.

(25) Wire diameter button

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

When a wire diameter is selected, the LED behind the relevant wire diameter lights up.

Key combinations - special functions

Displaying the feeder inching speed

(26) Intermediate arc indicator

a spatter-prone intermediate arc occurs between the short arc and the spray arc. The intermediate arc indicator lights up to alert you to this critical area

(27) Store button

for opening the Setup menu

(28) Gas test button

for setting the required gas flow rate on the gas pressure regulator. After pressing this button, gas flows for 30 seconds. Press the button again to stop the gas test flow before the end of this period.

The following special functions can be called by pressing buttons simultaneously or repeatedly.

The set feeder inching speed is shown (e.g.: Fdi | 10 m/min or Fdi | 393.70 ipm).

Use the adjusting dial to change the feeder inching speed

Press the Store button to exit.

Displaying the

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

gas pre-flow and gas post-flow time

The set gas pre-flow time is displayed (e.g. GPr | 0.1 s)

Use the adjusting dial to change the gas pre-flow time

Displaying the software version

Then press the Process button (22) to display the gas post-flow time setting (e.g. GPo | 0.5 s)

Use the adjusting dial to change the gas post-flow time

Press the Store button to exit.

The software version is displayed

Press the Material button (24) to display the version number of the welding database (e.g.: 0 | 029 = M0029).

Press the Material button (24) again to display the number of the wire-feed unit (A or B in the case of twin-head mounts) and the software version of the wire-feed unit (e.g.: A 1.5 | 0.23).

Press the Material button (24) a third time to display the actual arc burning time since starting for the first time (e.g. "654 | 32.1" = 65,432.1 h = 65,432 h, 6 min)

NOTE! The arc burning time indicator is not suitable as a basis for

calculating hiring fees, guarantee, etc.

Press the Store button to exit.

US control panel

(14)(4)

(1)

(26)

(25)

(5)

(18)

(15)

(12)

(11)

(10)

(3)

(6)

(9)(7)

(16)(8)

(24)

(23)

(22)

(13)

(2)

(19)

(17)

(20)

(21)

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

US control panel

No. Function

(1) Inch Forward (feeder inching) button

(2) Keylock switch (optional)

NOTE! The functions available on the control panel of system com-

for feeding the wire electrode into the torch‑hosepack with no accompanying flow of gas or current

For information on the various wire feed sequences that are possible when the welder presses and holds the "Feeder inching" button, see the Fdi parameter in the Setup menu.

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

- Selecting the welding process using the Process button(s) (20)

- Selecting the mode using the Mode button(s) (21)

- Selecting the filler metal using the Material button(s) (22)

- Opening the Setup menu using the Store button (25)

- Opening the job correction menu (see “Job mode”)

ponents are restricted in the same way as those of the control panel on the power source.

No. Function

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

(3) Parameter selection button

for selecting the following parameters:

Sheet thickness

Sheet thickness in mm or in.

Welding current

Welding current in A Before the start of welding, the machine automatically displays a standard value based on the programmed parameters. During welding, the actual value is displayed.

Wire feed speed

Wire feed speed in m/min or ipm.

F1 indicator

indicates that the PushPull drive is switched on

Wire-feed unit drive current-input indicator

indicates that the wire-feed unit drive is switched on

If the indicators are lit up on the parameter selection button (3) and on the adjusting dial (19), then the indicated / selected parameter can be altered using the adjusting dial (19).

(4) F1 indicator LED

lights up when the F1 indicator parameter is selected

(5) Wire-feed unit drive current-input indicator LED

lights up when the wire-feed unit drive current-input indicator parameter is selected

(6) Left digital display

(7) Sheet thickness LED

lights up when the sheet thickness parameter is selected

(8) Welding current LED

lights up when the welding current parameter is selected

(9) Wire feed speed LED

lights up when the wire feed speed parameter is selected

(10) Overtemperature indicator

lights up if the power source overheats (e.g. because the duty cycle has been exceeded). For more information on this, see the "Troubleshooting" section.

(11) HOLD indicator

every time a welding operation finishes, the actual values for welding current and welding voltage are stored, and the HOLD indicator lights up.

(12) Arc length correction LED

lights up when the arc length correction parameter is selected

(13) Droplet detachment correction/arc force dynamic correction/arc force

dynamic LED

lights up when the Droplet detachment correction/arc force dynamic correction/arc force dynamic parameter is selected

No. Function

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

(14) Welding voltage LED

lights up when the welding voltage parameter is selected

(15) Right digital display

(16) Job no. LED

lights up when the job number parameter is selected

(17) F3 indicator LED

lights up when the F3 indicator parameter is selected

(18) Parameter selection button

for selecting the following parameters:

Arc length correction

for correcting the arc length

Droplet detachment correction/arc force dynamic correction/arc force dynamic

has a different function assigned to it, depending on the process being used. A description of the various functions can be found in the Welding chapter under the corresponding process.

Welding voltage

Welding voltage in V Before the start of welding, the machine automatically displays a standard value based on the programmed parameters. During welding, the actual value is displayed.

Job N

In the job mode process for retrieving parameter records stored under job numbers

F3 indicator

If the indicators are lit up on the parameter selection button (18) and on the adjusting dial (19), then the indicated / selected parameter can be altered using the adjusting dial (19).

(19) Adjusting dial

for altering welding parameters. If the indicator on the adjusting dial is lit up, then the selected parameter is one that can be altered.

(20) Process button(s)

for selecting the welding process

MIG/MAG pulse synergic welding

MIG/MAG standard synergic welding

MIG/MAG standard manual welding

Job mode

TIG welding with touchdown ignition

Manual metal arc welding

When a process is selected, the LED on the relevant symbol lights up.

No. Function

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

(21) Mode button

for selecting the mode

2-step mode

4-step mode

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

Spot welding mode

Operating mode

When a mode is selected, the LED behind the relevant symbol lights up.

(22) Material button

for selecting the filler metal and shielding gas to be used. Parameters SP1 and SP2 are reserved for additional materials.

When a material is selected, the LED behind the relevant filler metal lights up.

(23) Diameter / Index (wire diameter) button

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

When a wire diameter is selected, the LED behind the relevant wire diameter lights up.

(24) Intermediate arc indicator

a spatter-prone intermediate arc occurs between the short arc and the spray arc. The intermediate arc indicator lights up to alert you to this critical area

Key combinations - special functions

Displaying the feeder inching speed

(25) Store button

for opening the Setup menu

(26) Purge (Gas test) button

The following special functions can be called by pressing buttons simultaneously or repeatedly.

The set feeder inching speed is shown (e.g.: Fdi | 10 m/min or Fdi | 393.70 ipm).

Use the adjusting dial to change the feeder inching speed

Press the Store button to exit.

Displaying the

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

gas pre-flow and gas post-flow time

The set gas pre-flow time is displayed (e.g. GPr | 0.1 s)

Use the adjusting dial to change the gas pre-flow time

time setting (e.g. GPo | 0.5 s)

Then press the Process button (20) to display the gas post-flow

Use the adjusting dial to change the gas post-flow time

Press the Store button to exit.

Displaying the software version

The software version is displayed

Press the Material button (22) to display the version number of the welding database (e.g.: 0 | 029 = M0029).

Press the Material button (22) again to display the number of the wire-feed unit (A or B in the case of twin-head mounts) and the software version of the wire-feed unit (e.g.: A 1.5 | 0.23).

Press the Material button (22) a third time to display the actual arc burning time since starting for the first time (e.g. "654 | 32.1" = 65,432.1 h = 65,432 h, 6 min)

NOTE! The arc burning time indicator is not suitable as a basis for

calculating hiring fees, guarantee, etc.

Press the Store button to exit.

TIME 5000 Digital control panel

(14)(4)

(1)

(28) (26)

(25)

(5)

(18)

(15)

(12)

(11)

(10)

(3)

(6)

(9)(7)

(16)(8)

(27)

(24)

(23)

(22)

(13)

(2)

(19)

(17)

(20)

(21)

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

TIME 5000 Digital control panel

No. Function

(1) Inch Forward (feeder inching) button

(2) Keylock switch (optional)

NOTE! The functions available on the control panel of system com-

for feeding the wire electrode into the torch‑hosepack with no accompanying flow of gas or current

For information on the various wire feed sequences that are possible when the welder presses and holds the "Feeder inching" button, see the Fdi parameter in the Setup menu.

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

- Selecting the welding process using the Process button(s) (20)

- Selecting the mode using the Mode button(s) (21)

- Selecting the filler metal using the Material button(s) (22)

- Opening the Setup menu using the Store button (25)

- Opening the job correction menu (see “Job mode”)

ponents are restricted in the same way as those of the control panel on the power source.

No. Function

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

(3) Parameter selection button

for selecting the following parameters:

a-dimension

depending on the set welding speed

Sheet thickness

Sheet thickness in mm or in.

Welding current

Welding current in A Before the start of welding, the machine automatically displays a standard value based on the programmed parameters. During welding, the actual value is displayed.

Wire feed speed

Wire feed speed in m/min or ipm.

F1 indicator

indicates that the PushPull drive is switched on

Wire-feed unit drive current-input indicator

indicates that the wire-feed unit drive is switched on

If the indicators are lit up on the parameter selection button (3) and on the adjusting dial (19), then the indicated / selected parameter can be altered using the adjusting dial (19).

(4) F1 indicator LED

lights up when the F1 indicator parameter is selected

(5) Wire-feed unit drive current-input indicator LED

lights up when the wire-feed unit drive current-input indicator parameter is selected

(6) a-dimension LED

lights up when the a-dimension parameter is selected

(7) Left digital display

(8) Sheet thickness LED

lights up when the sheet thickness parameter is selected

(9) Welding current LED

lights up when the welding current parameter is selected

(10) Wire feed speed LED

lights up when the wire feed speed parameter is selected

(11) Overtemperature indicator

lights up if the power source overheats (e.g. because the duty cycle has been exceeded). For more information on this, see the "Troubleshooting" section.

(12) HOLD indicator

every time a welding operation finishes, the actual values for welding current and welding voltage are stored, and the HOLD indicator lights up.

(13) Arc length correction LED

lights up when the arc length correction parameter is selected

No. Function

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

(14) Droplet detachment correction/arc force dynamic correction/arc force

dynamic LED

lights up when the Droplet detachment correction/arc force dynamic correction/arc force dynamic parameter is selected

(15) Welding voltage LED

lights up when the welding voltage parameter is selected

(16) Welding speed LED

lights up when the welding speed parameter is selected

(17) Right digital display

(18) Job no. LED

lights up when the job number parameter is selected

(19) F3 indicator LED

lights up when the F3 indicator parameter is selected

(20) Parameter selection button

for selecting the following parameters:

Arc length correction

for correcting the arc length

Droplet detachment correction/arc force dynamic correction/arc force dynamic

has a different function assigned to it, depending on the process being used. A description of the various functions can be found in the Welding chapter under the corresponding process.

Welding voltage

Welding voltage in V Before the start of welding, the machine automatically displays a standard value based on the programmed parameters. During welding, the actual value is displayed.

Welding speed

Welding speed in cm/min or ipm (necessary for the a-dimension parameter)

Job N

In the job mode process for retrieving parameter records stored under job numbers

F3 indicator

If the indicators are lit up on the parameter selection button (20) and on the adjusting dial (21), then the indicated / selected parameter can be altered using the adjusting dial (21).

(21) Adjusting dial

for altering welding parameters. If the indicator on the adjusting dial is lit up, then the selected parameter is one that can be altered.

No. Function

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

(22) Process button(s)

for selecting the welding process

MIG/MAG pulse synergic welding

MIG/MAG standard synergic welding

MIG/MAG standard manual welding

Job mode

TIG welding with touchdown ignition

Manual metal arc welding

When a process is selected, the LED on the relevant symbol lights up.

(23) Mode button

for selecting the mode

2-step mode

4-step mode

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

Spot welding mode

Operating mode

When a mode is selected, the LED behind the relevant symbol lights up.

(24) Material button

for selecting the filler metal and shielding gas to be used. Parameters SP1 and SP2 are reserved for additional materials.

When a material is selected, the LED behind the relevant filler metal lights up.

(25) Diameter / Index (wire diameter) button

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

When a wire diameter is selected, the LED behind the relevant wire diameter lights up.

(26) Intermediate arc indicator

a spatter-prone intermediate arc occurs between the short arc and the spray arc. The intermediate arc indicator lights up to alert you to this critical area

(27) Store button

for opening the Setup menu

(28) Purge (Gas test) button

Key combinations - special

The following special functions can be called by pressing buttons simultaneously or repeatedly.

functions

Displaying the

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

feeder inching speed

The set feeder inching speed is shown (e.g.: Fdi | 10 m/min or Fdi | 393.70 ipm).

Use the adjusting dial to change the feeder inching speed

Press the Store button to exit.

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

Displaying the software version

The set gas pre-flow time is displayed (e.g. GPr | 0.1 s)

Use the adjusting dial to change the gas pre-flow time

time setting (e.g. GPo | 0.5 s)

Then press the Process button (20) to display the gas post-flow

Use the adjusting dial to change the gas post-flow time

Press the Store button to exit.

The software version is displayed

Press the Material button (24) to display the version number of the welding database (e.g.: 0 | 029 = M0029).

Press the Material button (24) again to display the number of the wire-feed unit (A or B in the case of twin-head mounts) and the software version of the wire-feed unit (e.g.: A 1.5 | 0.23).

Press the Material button (24) a third time to display the actual arc burning time since starting for the first time (e.g. "654 | 32.1" = 65,432.1 h = 65,432 h, 6 min)

NOTE! The arc burning time indicator is not suitable as a basis for

calculating hiring fees, guarantee, etc.

Press the Store button to exit.

CMT control panel

(14)(4)

(1)

(25)

(5)

(18)

(15)

(12)

(11)

(10)

(3)

(6)

(9)(7)

(16)(8)

(24)

(23)

(22)

(13)

(2)

(19)

(17)

(20)

(21)

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

CMT control panel

No. Function

(1) Inch Forward (feeder inching) button

(2) Parameter selection button

for feeding the wire electrode into the torch‑hosepack with no accompanying flow of gas or current

For information on the various wire feed sequences that are possible when the welder presses and holds the "Feeder inching" button, see the Fdi parameter in the Setup menu.

for selecting the following parameters:

Sheet thickness

Sheet thickness in mm or in.

Welding current

Welding current in A Before the start of welding, the machine automatically displays a standard value based on the programmed parameters. During welding, the actual value is displayed.

Wire feed speed

Wire feed speed in m/min or ipm.

No. Function

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

F1 indicator

indicates that the PushPull drive is switched on

Wire-feed unit drive current-input indicator

indicates that the wire-feed unit drive is switched on

If the indicators are lit up on the parameter selection button (3) and on the

adjusting dial (19), then the indicated / selected parameter can be altered using the adjusting dial (19).

(3) F1 indicator LED

lights up when the F1 indicator parameter is selected

(4) Wire-feed unit drive current-input indicator LED

lights up when the wire-feed unit drive current-input indicator parameter is selected

(5) Left digital display

(6) Sheet thickness LED

lights up when the sheet thickness parameter is selected

(7) Welding current LED

lights up when the welding current parameter is selected

(8) Wire feed speed LED

lights up when the wire feed speed parameter is selected

(9) Overtemperature indicator

lights up if the power source overheats (e.g. because the duty cycle has been exceeded). For more information on this, see the "Troubleshooting" section.

(10) HOLD indicator

every time a welding operation finishes, the actual values for welding current and welding voltage are stored, and the HOLD indicator lights up.

(11) Arc length correction LED

lights up when the arc length correction parameter is selected

(12) Droplet detachment correction/arc force dynamic correction/arc force

dynamic LED

lights up when the Droplet detachment correction/arc force dynamic correction/arc force dynamic parameter is selected

(13) Welding voltage LED

lights up when the welding voltage parameter is selected

(14) Right digital display

(15) Job no. LED

lights up when the job number parameter is selected

(16) F3 indicator LED

lights up when the F3 indicator parameter is selected

No. Function

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

(17) Parameter selection button

for selecting the following parameters:

Arc length correction

for correcting the arc length

Droplet detachment correction/arc force dynamic correction/arc force dynamic

has a different function assigned to it, depending on the process being used. A description of the various functions can be found in the Welding chapter under the corresponding process.

Welding voltage

Welding voltage in V Before the start of welding, the machine automatically displays a standard value based on the programmed parameters. During welding, the actual value is displayed.

Job N

In the job mode process for retrieving parameter records stored under job numbers

F3 indicator

If the indicators are lit up on the parameter selection button (17) and on the adjusting dial (18), then the indicated / selected parameter can be altered using the adjusting dial (18).

(18) Adjusting dial

for altering welding parameters. If the indicator on the adjusting dial is lit up, then the selected parameter is one that can be altered.

(19) Process button(s)

for selecting the welding process

MIG/MAG pulse synergic welding

MIG/MAG standard synergic welding

CMT, CMT pulse

MIG/MAG standard manual welding

Job mode

Manual metal arc welding

When a process is selected, the LED on the relevant symbol lights up.

(20) Mode button

for selecting the mode

2-step mode

4-step mode

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

Spot welding mode

Operating mode

When a mode is selected, the LED behind the relevant symbol lights up.

No. Function

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

(21) Material button

for selecting the filler metal and shielding gas to be used. Parameters SP1 and SP2 are reserved for additional materials.

When a material is selected, the LED behind the relevant filler metal lights up.

(22) Diameter / Index (wire diameter) button

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

When a wire diameter is selected, the LED behind the relevant wire diameter lights up.

(23) CMT Pulse indicator

lights up when a CMT/pulse characteristic is selected

(24) Store button

for opening the Setup menu

(25) Purge (Gas test) button

Key combinations - special functions

Displaying the feeder inching speed

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

The following special functions can be called by pressing buttons simultaneously or repeatedly.

The set feeder inching speed is shown (e.g.: Fdi | 10 m/min or Fdi | 393.70 ipm).

Use the adjusting dial to change the feeder inching speed

Press the Store button to exit.

The set gas pre-flow time is displayed (e.g. GPr | 0.1 s)

Use the adjusting dial to change the gas pre-flow time

time setting (e.g. GPo | 0.5 s)

Then press the Process button (20) to display the gas post-flow

Use the adjusting dial to change the gas post-flow time

Press the Store button to exit.

Displaying the

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

software version

The software version is displayed

Press the Material button (24) to display the version number of the welding database (e.g.: 0 | 029 = M0029).

Press the Material button (24) again to display the number of the wire-feed unit (A or B in the case of twin-head mounts) and the software version of the wire-feed unit (e.g.: A 1.5 | 0.23).

Press the Material button (24) a third time to display the actual arc burning time since starting for the first time (e.g. "654 | 32.1" = 65,432.1 h = 65,432 h, 6 min)

NOTE! The arc burning time indicator is not suitable as a basis for

calculating hiring fees, guarantee, etc.

Press the Store button to exit.

Yard control panel

(14)(4)

(1)

(25)

(5)

(18)

(15)

(12)

(11)

(10)

(3)

(6)

(9)(7)

(16)(8)

(24)

(23)

(22)

(13)

(2)

(19)

(17)

(20)

(21)

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Yard control panel

No. Function

(1) Inch Forward (feeder inching) button

for feeding the wire electrode into the torch‑hosepack with no accompanying flow of gas or current

For information on the various wire feed sequences that are possible when the welder presses and holds the "Feeder inching" button, see the Fdi parameter in the Setup menu.

No. Function

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

(2) Parameter selection button

for selecting the following parameters:

Sheet thickness

Sheet thickness in mm or in.

Welding current

Welding current in A Before the start of welding, the machine automatically displays a standard value based on the programmed parameters. During welding, the actual value is displayed.

Wire feed speed

Wire feed speed in m/min or ipm.

F1 indicator

indicates that the PushPull drive is switched on

Wire-feed unit drive current-input indicator

indicates that the wire-feed unit drive is switched on

If the indicators are lit up on the parameter selection button (2) and on the adjusting dial (18), then the indicated / selected parameter can be altered using the adjusting dial (18).

(3) F1 indicator LED

lights up when the F1 indicator parameter is selected

(4) Wire-feed unit drive current-input indicator LED

lights up when the wire-feed unit drive current-input indicator parameter is selected

(5) Left digital display

(6) Sheet thickness LED

lights up when the sheet thickness parameter is selected

(7) Welding current LED

lights up when the welding current parameter is selected

(8) Wire feed speed LED

lights up when the wire feed speed parameter is selected

(9) Overtemperature indicator

lights up if the power source overheats (e.g. because the duty cycle has been exceeded). For more information on this, see the "Troubleshooting" section.

(10) HOLD indicator

every time a welding operation finishes, the actual values for welding current and welding voltage are stored, and the HOLD indicator lights up.

(11) Arc length correction LED

lights up when the arc length correction parameter is selected

(12) Droplet detachment correction/arc force dynamic correction/arc force

dynamic LED

lights up when the Droplet detachment correction/arc force dynamic correction/arc force dynamic parameter is selected

No. Function

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

(13) Welding voltage LED

lights up when the welding voltage parameter is selected

(14) Right digital display

(15) Job no. LED

lights up when the job number parameter is selected

(16) F3 indicator LED

lights up when the F3 indicator parameter is selected

(17) Parameter selection button

for selecting the following parameters:

Arc length correction

for correcting the arc length

Droplet detachment correction/arc force dynamic correction/arc force dynamic

has a different function assigned to it, depending on the process being used. A description of the various functions can be found in the Welding chapter under the corresponding process.

Welding voltage

Welding voltage in V Before the start of welding, the machine automatically displays a standard value based on the programmed parameters. During welding, the actual value is displayed.

Job N

In the job mode process for retrieving parameter records stored under job numbers

F3 indicator

If the indicators are lit up on the parameter selection button (17) and on the adjusting dial (18), then the indicated / selected parameter can be altered using the adjusting dial (18).

(18) Adjusting dial

for altering welding parameters. If the indicator on the adjusting dial is lit up, then the selected parameter is one that can be altered.

(19) Process button(s)

for selecting the welding process

MIG/MAG pulse synergic welding

MIG/MAG standard synergic welding

MIG/MAG standard manual welding

Job mode

TIG welding with touchdown ignition

Manual metal arc welding

When a process is selected, the LED on the relevant symbol lights up.

No. Function

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

(20) Mode button

for selecting the mode

2-step mode

4-step mode

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

Spot welding mode

Operating mode

When a mode is selected, the LED behind the relevant symbol lights up.

(21) Material button

for selecting the filler metal and shielding gas to be used. Parameters SP1 and SP2 are reserved for additional materials.

When a material is selected, the LED behind the relevant filler metal lights up.

(22) Diameter / Index (wire diameter) button

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

When a wire diameter is selected, the LED behind the relevant wire diameter lights up.

Key combinations - special functions

Displaying the feeder inching speed

(23) Intermediate arc indicator

a spatter-prone intermediate arc occurs between the short arc and the spray arc. The intermediate arc indicator lights up to alert you to this critical area

(24) Store button

for opening the Setup menu

(25) Purge (Gas test) button

The following special functions can be called by pressing buttons simultaneously or repeatedly.

The set feeder inching speed is shown (e.g.: Fdi | 10 m/min or Fdi | 393.70 ipm).

Use the adjusting dial to change the feeder inching speed

Press the Store button to exit.

Displaying the

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

gas pre-flow and gas post-flow time

The set gas pre-flow time is displayed (e.g. GPr | 0.1 s)

Use the adjusting dial to change the gas pre-flow time

time setting (e.g. GPo | 0.5 s)

Then press the Process button (20) to display the gas post-flow

Use the adjusting dial to change the gas post-flow time

Press the Store button to exit.

Displaying the software version

The software version is displayed

Press the Material button (24) to display the version number of the welding database (e.g.: 0 | 029 = M0029).

Press the Material button (24) again to display the number of the wire-feed unit (A or B in the case of twin-head mounts) and the software version of the wire-feed unit (e.g.: A 1.5 | 0.23).

Press the Material button (24) a third time to display the actual arc burning time since starting for the first time (e.g. "654 | 32.1" = 65,432.1 h = 65,432 h, 6 min)

NOTE! The arc burning time indicator is not suitable as a basis for

calculating hiring fees, guarantee, etc.

Press the Store button to exit.

“Remote” control panel

TransPuls Synergic 4000

(3)

(2)

(1)

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

General The Remote operating panel is fitted to the Remote power source. The Remote power

source is designed for automated and robot applications and is controlled exclusively via the LocalNet.

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

- Remote controls

- Robot interfaces

- Field bus systems

Remote control panel

No. Function

(1) Error indicator

lights up if an error has occurred. The corresponding error message is displayed on all devices connected to the LocalNet that have a digital display.

The error messages displayed are described in the section headed “Troubleshooting”.

(2) Robot interface indicator

lights up when the power source is switched on and a robot interface or field bus system is connected to the LocalNet

(3) Power source ON indicator

lights up for as long as the mains cable is plugged in and the mains switch is in the “I” position

CMT Remote control panel

CMT 4000 Advanced

(3)

(2)

(1)

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

General The CMT Remote control panel is fitted to the CMT Remote power source and CMT

Advanced power source. The CMT Remote power source and CMT Advanced power source are designed for automated and robot applications and are controlled exclusively via the LocalNet.

The CMT Remote power source and CMT Advanced power source can be operated via the following system add-ons:

- RCU 5000i remote control

- ROB 5000 robot interface

- Field bus systems

CMT Remote and CMT Advanced control panel

No. Function

(1) Error indicator

(2) Robot interface indicator

(3) Power source ON indicator

lights up if an error has occurred. The corresponding error message is displayed on all devices connected to the LocalNet that have a digital display.

The error messages displayed are described in the section headed “Troubleshooting”.

lights up when the power source is switched on and a robot interface or field bus system is connected to the LocalNet

lights up for as long as the mains cable is plugged in and the mains switch is in the “I” position

Connections, switches and mechanical compon-

(3)(4)(5)(6)

(7) (8)

)9()01(

)21()11(

(2)(1)

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

ents

TPS 2700 power source

Front view / Rear view / Side view

No. Function

(1) LocalNet connection

Standardised connection socket for system add-ons (e.g. remote control, JobMaster torch, etc.)

(2) (+) - Current socket with bayonet latch

for:

- connecting the grounding (earthing) cable during TIG welding

- connecting the electrode cable or grounding (earthing) cable during MMA welding (depending on the type of electrode used)

(3) Welding torch control connection

for the welding torch control plug

(4) Blanking cover

(5) (-) - Current socket with bayonet latch

for:

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

- the current connection for the TIG welding torch

- connecting the electrode cable or grounding (earthing) cable during MMA welding (depending on the type of electrode used)

(6) Welding torch connection

for connecting the welding torch

(7) Mains switch

for switching the power source on and off

(8) Blanking cover

reserved for a LocalNet connection

(9) Shielding gas connection

(10) Mains cable with strain relief device

(11) Wirespool holder with brake

for holding standard wirespools weighing up to 16 kg (35.27 lbs) and with a max. diameter of 300 mm (11.81 in)

No. Function

(3)(4)

(5)

(6)

(2)(1)

(7) (8)

(9)

(10)(11)

(13)(12)

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

TPS 2700 CMT power source

(12) 4 roller drive

Front view / Rear view / Side view

No. Function

(1) LocalNet connection

Standardised connection socket for system add-ons (e.g. remote control, JobMaster torch, etc.)

(2) Motor control connection

for connecting the control line from the CMT drive unit

(3) Welding torch control connection

for the welding torch control plug

(4) LHSB connection

for connecting the LHSB cable from the CMT drive unit (LHSB = LocalNet High-Speed Bus)

(5) (-) - Current socket with bayonet latch

for:

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

- the current connection for the TIG welding torch

- connecting the electrode cable or grounding (earthing) cable during MMA welding (depending on the type of electrode used)

(6) Welding torch connection

for connecting the welding torch

(7) Mains switch

for switching the power source on and off

(8) Blanking cover

reserved for a LocalNet connection

(9) Shielding gas connection

(10) (+) - Current socket with bayonet latch

for:

- connecting the grounding (earthing) cable during TIG welding

- connecting the electrode cable or grounding (earthing) cable during MMA welding (depending on the type of electrode used)

TS 4000 / 5000,

(2)(1)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

TPS 3200 / 4000 / 5000, TIME 5000 Digital power sources

No. Function

(11) Mains cable with strain relief device

(12) Wirespool holder with brake

for holding standard wirespools weighing up to 16 kg (35.27 lbs) and with a max. diameter of 300 mm (11.81 in)

(13) 4 roller drive

Front view / Rear view

No. Function

(1) (-) - Current socket with bayonet latch

for:

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

- the current connection for the TIG welding torch

- connecting the electrode cable or grounding (earthing) cable during MMA welding (depending on the type of electrode used)

(2) Mains switch

for switching the power source on and off

(3) Blanking cover

Reserved for LocalNet or LHSB (LocalNet High-Speed Bus) connection

(4) Blanking cover

Reserved for LocalNet or LHSB (LocalNet High-Speed Bus) connection

(5) LocalNet connection

for interconnecting hosepack

(6) Blanking cover

Reserved for LHSB (LocalNet High-Speed Bus) connection

The LHSB connection is provided as standard with CMT power sources.

(7) Mains cable with strain relief device

No. Function

CMT 4000 Advanced

(1)

(2)

LHSB

(3)

(4)

(5)

(7)

(8)

(6)

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

CMT 4000 Advanced power source

(8) Second (-) - Current socket with bayonet latch (optional) for:

- connecting the interconnecting hosepack in MIG/MAG welding for polarity reversal (e.g. for innershield and flux core wire welding)

- specially for automated and robot applications where the interconnecting hosepack and grounding (earthing) cable are to be connected to one side of the power source (e.g. in a switch cabinet)

Second (+) - Current socket with bayonet latch (optional)

for connecting a second current cable

Blanking cover

If the second (-) current socket with bayonet latch or second (+) current socket with bayonet latch options are not present on the power source.

(9) (+) - Current socket with bayonet latch for:

- connecting the current cable from the interconnecting hosepack during MIG/MAG welding

- connecting the grounding (earthing) cable during TIG welding

- connecting the electrode cable or grounding (earthing) cable during MMA welding (depending on the type of electrode used)

Front view / Rear view

No. Function

(1) Grounding (earthing) cable connection

for:

- connecting the grounding (earthing) cable in MIG/MAG welding, CMT welding and CMT Advanced welding

- connecting the electrode cable or grounding (earthing) cable during MMA welding (depending on the type of electrode used)

(2) Mains switch

for switching the power source on and off

No. Function

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

(3) Current socket with bayonet latch

for:

- connecting the current cable of the interconnecting hosepack in MIG/MAG welding, CMT welding and CMT Advanced welding

- connecting the electrode cable or grounding (earthing) cable during MMA welding (depending on the type of electrode used)

(4) Blanking cover

Reserved for LocalNet connection

(5) Blanking cover

Reserved for LocalNet connection

(6) LocalNet connection

for interconnecting hosepack

(7) LHSB (LocalNet High-Speed Bus) connection

(8) Mains cable with strain relief device

Installation and commissioning

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Minimum equipment needed for welding task

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

General Depending on which welding process you intend to use, a certain minimum equipment

level will be needed in order to work with the power source. The welding processes and the minimum equipment levels required for the welding task are then described.

MIG/MAG gascooled welding

MIG/MAG watercooled welding

MIG/MAG automated welding

- Power source

- Grounding (earthing) cable

- MIG/MAG welding torch, gas-cooled

- Gas connection (shielding gas supply)

- Wire-feed unit (TS 4000 / 5000, TPS 3200 / 4000 / 5000 only)

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

- Wire electrode

- Power source

- Cooling unit

- Grounding (earthing) cable

- MIG/MAG welding torch, water-cooled

- Gas connection (shielding gas supply)

- Wire-feed unit (TS 4000 / 5000, TPS 3200 / 4000 / 5000 only)

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

- Wire electrode

- Power source (TS 4000 / 5000, TPS 3200 / 4000 / 5000)

- Robot interface or field bus connection

- Grounding (earthing) cable

- MIG/MAG robot welding torch or MIG/MAG machine welding torch (a cooling unit is also required with water-cooled robot or machine welding torches)

- Gas connection (shielding gas supply)

- Wire-feed unit

- Interconnecting hosepack

- Wire electrode

CMT manual welding

- CMT power source

- Grounding (earthing) cable

- CMT welding torch with CMT drive unit and CMT wire buffer (a cooling unit is also required for water-cooled CMT applications)

- CMT wire-feed unit (TPS 3200 / 4000 / 5000 only)

- CMT interconnecting hosepack (TPS 3200 / 4000 / 5000 only)

- Wire electrode

- Gas connection (shielding gas supply)

CMT automated

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

welding

- CMT power source: TPS 3200 / 4000 / 5000 (or CMT remote power source with RCU 5000i remote control)

- Robot interface or field bus connection

- Grounding (earthing) cable

- CMT welding torch incl. CMT drive unit

- Cooling unit

- CMT wire-feed unit

- CMT interconnecting hosepack

- CMT wire buffer

- Wire electrode

- Gas connection (shielding gas supply)

CMT Advanced welding

- CMT 4000 Advanced power source

- RCU 5000i remote control

- Robot interface or field bus connection

- Grounding (earthing) cable

- CMT welding torch incl. CMT drive unit

- Cooling unit

- CMT wire-feed unit

- CMT interconnecting hosepack

- CMT wire buffer

- Wire electrode

- Gas connection (shielding gas supply)

TIG DC welding - Power source

- Grounding (earthing) cable

- TIG gas valve welding torch

- Gas connection (shielding gas supply)

- Filler metal (depending on the application)

Manual metal arc welding

- Power source

- Grounding (earthing) cable

- Electrode holder

- Rod electrodes

Before installation and commissioning

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Safety

Danger from incorrect operation.

Possible serious injury and damage to property.

▶ ▶

Proper use The power source may only be used for MIG/MAG, MMA and TIG welding. Any use

above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage.

Proper use also includes:

- following all the information in the operating instructions

- carrying out all the specified inspection and servicing work

Setup regulations The device is tested to IP 23 protection, meaning:

- protection against penetration by solid foreign bodies with diameters > 12.5 mm

- protection against direct sprays of water at any angle up to 60° from the vertical

WARNING!

(0.49 in.)

The device can be set up and operated outdoors in accordance with IP23. Avoid direct wetting (e.g. from rain).

WARNING!

If one of these devices topples over or falls it could cause serious or even fatal injury.

Place devices, upright consoles and trolleys on a solid, level surface in such a way

▶

that they remain stable.

The venting duct is a very important safety feature. When choosing the installation location, ensure that the cooling air can enter and exit unhindered through the air ducts on the front and back of the device. Any electroconductive metallic dust (e.g. from grinding work) must not be allowed to get sucked into the device.

Mains connection The devices are designed to run at the mains voltage specified on the rating plate. If your

version of the device does not come with mains cables and plugs ready-fitted, these must be fitted in accordance with national regulations and standards. For details of fuse protection of the mains lead, please see the Technical Data.

NOTE!

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Inadequately dimensioned electrical installations can cause serious damage.

The mains lead and its fuse must be dimensioned to suit the local power supply. The technical data shown on the rating plate applies.

Applies to TIME 5000 Digital power source: The standard mains plug allows the user to operate with a mains voltage of up to 400 V. For mains voltages up to 460 V, fit an approved mains plug or install the mains supply directly.

Connecting up the mains cable on US power

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

sources

General The US power sources are supplied without a mains cable. A mains cable appropriate

for the connection voltage must be fitted prior to commissioning. A strain-relief device for a cable cross-section AWG 10 is installed on the power source. Strain-relief devices for larger cable cross-sections must be designed accordingly.

Stipulated mains cables and strainrelief devices

Power source Mains voltage Cable cross-sec-

tion

TS 4000 / 5000, TPS 4000 / 5000, CMT 4000 Advanced

TPS 3200 3 x 460 V

AWG ... American Wire Gauge

3 x 460 V 3 x 230 V

3 x 230 V

AWG 10 AWG 6

AWG 10 AWG 8

Safety

Connecting the mains cable

WARNING!

Danger due to work that has been carried out incorrectly.

This can result in serious injury and damage to property.

The work described below must only be carried out by trained and qualified person-

▶

nel. Observe national standards and directives.

▶

CAUTION!

Danger due to improperly prepared mains cable.

This can cause short circuits and damage.

Fit ferrules to all phase conductors and the ground conductor of the stripped mains

▶

cable.

Remove the left side panel of the power source

Strip about 100 mm (4 in.) of insulation from the end of the mains cable

NOTE!

The ground conductor (green, or green with yellow stripes) should be approx. 10 - 15 mm (0.4 - 0.6 in.) longer than the phase conductors.

Fit ferrules to phase conductors and the ground conductor of the mains cable; crimp

V1 U1

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

ferrules with pliers

CAUTION!

Risk of short circuits!

If ferrules are not used, there is a risk of short circuits between the phase conductors or between phase conductors and the ground conductor.

Fit ferrules to all phase conductors and the ground conductor of the stripped

▶

mains cable.

Undo the screws (2 x) and clamping

nut (size 30) on the strain-relief device

Insert the mains cable into the strain-

relief device

NOTE!

Push the mains cable in far enough to make it possible to connect the ground conductor and the phase conductors to the block terminal properly.

Tighten the clamping nut (size 30 mm)

Tighten the screws (2 x)

Connect the mains cable to the block

terminal correctly:

- Ground conductor (green, or green with yellow stripes) to the PE connection

- Phase conductors to connections L1 - L3

Re-fit the left side panel of the power

source

Replacing the

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

strain-relief device

Remove the left side panel of the

power source

Remove the screws (2 x) from the

existing strain-relief device

Pull the existing strain-relief device

forwards to detach it

Remove the screws for the adapter

plate, and remove the adapter plate

Insert the hexagon nut (size 50 mm)

into the holding plate

NOTE!

To ensure a reliable earth connection to the housing of the power source, the points on the hexagon nut must be facing the holding plate.

Screw the front of the large strain-

relief device into the hexagon nut (size 50 mm). The hexagon nut (size 50 mm) now bites into the holding plate.

Slot the large strain-relief device into

the housing and fasten it with 2 screws

Connect the mains cable

Re-fit the left side panel of the power

source

Start-up

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Safety

Remarks on the cooling unit

WARNING!

An electric shock can be fatal.

If the power source is connected to the mains electricity supply during installation, there is a high risk of very serious injury and damage.

Before carrying out any work on the device make sure that the power source mains

▶

switch is in the "O" position Before carrying out any work on the device make sure that the power source is

▶

unplugged from the mains

WARNING!

Danger from electrical current due to electrically conductive dust in the device.

This can result in serious injury and damage to property.

Only operate the device with an air filter fitted. The air filter is a very important safety

▶

device for adhering to the IP 23 protection class.

We recommend using an FK 4000 R cooling unit for the following applications and situations:

- TS 4000 / 5000, TPS 3200 / 4000 / 5000 power sources

- JobMaster welding torch

- Push-pull welding torch

- Robot welding

- Hosepacks over 5 m long

- MIG/MAG pulse synergic welding

- In general, where welding is performed in higher power ranges

Information on system components

The cooling unit is powered from the power source. The cooling unit is ready for operation when the mains switch of the power source is in the - I - position.

More information on the cooling unit can be found in the operating instructions for the cooling unit.

The steps and activities described below include references to various system components, including:

- Trolleys

- Cooling units

- Wire-feed unit holders

- Wire-feed units

- Interconnecting hosepacks

- Welding torches

- etc.

For more detailed information about installing and connecting the system components, please refer to the appropriate operating instructions.

Overview "Commissioning" is composed of the following sections:

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

- Commissioning the TPS 2700

- Commissioning the TS 4000/5000, TPS 3200/4000/5000

- Commissioning the CMT 4000 Advanced

Commissioning the TPS 2700

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

General Commissioning the TPS 2700 power source is described by reference to a manual gas-

cooled MIG/MAG application.

Recommendation for water-cooled applications

Connecting the gas cylinder

- Use the PickUp trolley

- Fit the cooling unit to the PickUp trolley

- Fit the TPS 2700 power supply to the cooling unit

- Only use water-cooled welding torches with an external water connection

- Connect the water connections on the welding torch directly to the cooling unit

WARNING!

If gas cylinders topple over, there is a risk of very serious injury and damage.

Place gas cylinders on a solid, level surface so that they remain stable. Secure gas cylinders to prevent them from falling over.

Observe the safety rules of the gas cylinder manufacturer.

Place the gas cylinder on a solid, level

surface in such a way that it remains stable

Secure the gas cylinder to prevent it

from toppling over (but not around the neck of the cylinder)

Take the protective cap off the gas cyl-

inder

Briefly open the gas cylinder valve to

blow off any dust or dirt

Check the seal on the pressure regu-

lator

Screw the pressure regulator onto the

gas cylinder and tighten it

Connect the pressure regulator to the

Connecting the gas hose to the TPS 2700

shielding gas connection on the power source using the gas hose

NOTE!

US devices are supplied with an adapter for the gas hose:

Glue in or seal the adapter

▶

Test the adapter to ensure that it is gas tight.

▶

Establishing a

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

ground (earth) connection

Connecting the grounding (earthing) cable to the TPS

2700

Plug the grounding (earthing) cable

into the (-) current socket and twist to fasten it

Use the other end of the grounding

(earthing) cable to establish a connection to the workpiece

Connecting the welding torch

Connecting the welding torch to the TPS 2700

Check that the torch is correctly and

completely tooled up. Insert it - infeed tube first - into the torch connection

Tighten the union nut by hand to fix

the torch in place

Plug the control plug of the welding

torch into the torch control connection and latch it in place

NOTE!

When altering the length and/or crosssection of the welding torch hosepack, measure the welding circuit resistance r and the welding circuit inductivity L (see "Further settings").

Inserting/repla-

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

cing feed rollers

In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the diameter and alloy of the wire being welded.

NOTE!

Only use feed rollers that match the wire electrode.

An overview of the feed rollers available and their possible areas of use can be found in the spare parts lists.

US devices are supplied without feed rollers. After inserting the wirespool, insert the feed rollers.

Inserting the wirespool

CAUTION!

Risk of injury from springiness of spooled wire electrode.

While inserting the wirespool, hold the end of the wire electrode firmly to avoid injuries caused by the wire springing back.

CAUTION!

Risk of injury from falling wirespool.

Make sure the wirespool sits securely on the spool holder.

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Inserting the basket-type spool

CAUTION!

Risk of injury from springiness of spooled wire electrode.

While inserting the wirespool, hold the end of the wire electrode firmly to avoid injuries caused by the wire springing back.

CAUTION!

Risk of injury from falling wirespool.

Make sure the wirespool sits securely on the spool holder.

NOTE!

When working with basket-type spools, only use the basket-type spool adapter supplied with the device.

CAUTION!

Risk of injury from falling basket-type spool.

Place the basket-type spool on the adapter provided in such a way that the bars on the spool are inside the adapter guideways.

Feeding in the

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

wire electrode

CAUTION!

Risk of injury from springiness of spooled wire electrode.

When inserting the wire electrode into the 4-roller drive, hold the end of the wire electrode firmly to avoid injuries caused by the wire springing back.

CAUTION!

Risk of damage to the welding torch from sharp end of wire electrode.

Deburr the end of the wire electrode well before feeding in.

CAUTION!

Risk of injury from wire electrode emerging at speed.

Keep the welding torch away from face and body when pressing the feeder inching / inch forward button.

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Setting the contact pressure

NOTE!

Set the contact pressure in such a way that the wire electrode is not deformed but nevertheless ensures that the wire is transported properly.

Contact pressure standard values

Semi-cylindrical

rolls

Trapeze rolls Plastic rolls

Aluminium 1.5 - 3.5 - 4.5

Steel 3 - 4 1.5 -

CrNi 3 - 4 1.5 -

Adjusting the brake

NOTE!

After releasing the torch trigger the wirespool should stop unreeling.

Adjust brake if necessary.

STOP

PVC

KLEBER, GLUE, COLLE

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Design of the brake

CAUTION!

Risk of injury and damage from falling wirespool.

To ensure that the wirespool is properly in place and that the brake works properly, fit the brake according to the following diagram.

Commissioning the TS 4000 / 5000, TPS 3200 /

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

4000 / 5000, TIME 5000 Digital

General Commissioning the TS 4000 / 5000 and TPS 3200 / 4000 / 5000 power sources is

described by reference to a manual water-cooled MIG/MAG application.

Fitting the system components (overview)

The diagram below is intended to show you how to fit the individual system components. For detailed information about the individual steps, please refer to the operating instructions for the system components.

Fixing the strain-

(1)

(2) (3)

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

relief device in place

Fixing the strain-relief device to the trolley

Introduce the pin on the power source

strain-relief device for the interconnecting‑hosepack into the opening provided in the base of the trolley.

Use two screws supplied with the

interconnecting hosepack to fasten the strain-relief device to the base of the trolley.

A strain-relief device is not provided in the case of 1.2 m (4 ft.) interconnecting hosepacks.

Introduce the pin on the wire-feed unit

strain-relief device for the interconnecting hosepack into the opening provided in the wire-feed unit.

Use two screws supplied with the

interconnecting hosepack to fasten the strain-relief device to the wire-feed unit.

Connecting the interconnecting hosepack

Fitting the strain-relief device to the wire-feed unit

NOTE!

There is no cooling unit present in the case of gas-cooled systems.

There is no need to attach the water connections in the case of gas-cooled systems.

Plug the welding potential bayonet plug on the interconnecting hosepack into the (+)

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

socket and twist to fasten it

Plug the LocalNet plug on the interconnecting hosepack into the LocalNet connec-

tion and secure with a union nut

CMT power sources only:

Connect the LHSB plug to the LHSB connection

Connect the water feed hose (blue) (3) to the cooling unit

Connect the water return hose (red) (2) to the cooling unit

Connect the protective gas shield hose to the pressure regulator on the gas cylinder

(1)

Connect the interconnecting hosepack to the wire-feed unit

Connecting the gas cylinder

WARNING!

If gas cylinders topple over, there is a risk of very serious injury and damage.

Place gas cylinders on a solid, level surface so that they remain stable. Secure gas cylinders to prevent them from falling over.

Observe the safety rules of the gas cylinder manufacturer.

Place the gas cylinder on the base of

the trolley

Secure the gas cylinder by fixing the

cylinder strap around the upper part of the cylinder (but not around the neck) to prevent it from toppling over

Take the protective cap off the gas cyl-

inder

Briefly open the gas cylinder valve to

blow off any dust or dirt

Check the seal on the pressure regu-

lator

Screw the pressure regulator onto the

gas cylinder and tighten it

Connect the protective gas shield

Fixing the gas cylinder on the trolley

hose of the interconnecting hose pack to the pressure regulator using the gas hose

NOTE!

US devices are supplied with an adapter for the gas hose:

Glue in or seal the adapter

▶

Test the adapter to ensure that it is gas tight.

▶

Establishing a

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

ground (earth) connection

Plug the grounding (earthing) cable

into the (-) current socket and twist to fasten it

Use the other end of the grounding

(earthing) cable to establish a connection to the workpiece

Connecting the welding torch

Check that the torch is correctly and

completely tooled up. Insert it - infeed tube first - into the torch connection on the wire-feed unit

Tighten the union nut by hand to fix

the torch in place

Plug the control plug of the welding

torch into the torch control connection and latch it in place

NOTE!

When altering the length and/or crosssection of the welding torch hosepack,

Welding torch and torch control connections on the

VR 4000

measure the welding circuit resistance r and the welding circuit inductivity L (see "Further settings").

Other tasks Carry out the following steps in accordance with the wire-feed unit operating instructions:

Insert the feed rollers in the wire-feed unit

Insert the wirespool or basket-type spool with adapter in the wire-feed unit

Feed in the wire electrode

Set the contact pressure

Adjust the brake

Commissioning the CMT4000 Advanced

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Fitting the system components (overview)

WARNING!

If gas cylinders topple over, there is a risk of very serious injury and damage.

Place gas cylinders on a solid, level surface so that they remain stable. Secure gas cylinders to prevent them from falling over.

Observe the safety rules of the gas cylinder manufacturer.

Fitting the system components

Fasten the cooling unit and power source to the back of the machine as well using 2

screws in each case

Cylinder holder extension

Connecting the interconnecting hosepack, CMT welding torch and wire buffer

For detailed information about the individual steps, please refer to the relevant operating instructions for the system components.

Fasten the strain-relief devices of the CMT interconnecting hosepack to the trolley

and the wire-feed unit

Connect the CMT interconnecting hosepack to the power source and wire-feed unit

Connect the CMT hosepack to the CMT drive unit

Connect the wire buffer

Connect the CMT welding torch to the wire-feed unit

Installing the wire-feed unit and setting up the gas

cylinder

Other tasks

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Connect the wirefeeding hose

Establish a ground (earth) connection between the workpiece and power source

Connect the gas cylinder

Connect the RCU 5000i remote control

Make the connection to the robot control

Preparing the wire-feed unit

Carry out the following steps in accordance with the wire-feed unit operating instructions:

Insert the feed rollers in the wire-feed unit

Insert the wirespool or basket-type spool with adapter in the wire-feed unit

Feed in the wire electrode

Set the contact pressure

Adjust the brake

Welding

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

MIG/MAG modes

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

General

Symbols and their explanations

WARNING!

Danger from incorrect operation.

Possible serious injury and damage to property.

Do not use the functions described here until you have read and completely under-

▶

stood these Operating Instructions. Do not use the functions described here until you have fully read and understood all

▶

of the Operating Instructions for the system components, in particular the safety rules!

See the Setup menu for information on settings, setting range and units of measurement for the available parameters.

Press the torch trigger Hold the torch trigger Release the torch trigger

GPr

Gas pre-flow time

I-S

Starting-current phase: the base material is heated up rapidly, despite the high thermal dissipation that occurs at the start of welding

Slope: the starting current is continuously lowered as far as the welding current and the welding current as far as the final current

Welding-current phase: uniform thermal input into the base material, whose temperature is raised by the advancing heat

I-E

Crater-fill phase: to prevent any local overheating of the base material due to heat build-up towards the end of welding. This eliminates any risk of weld seam dropthrough.

GPo

Gas post-flow time

2-step mode

GPr

GPo

GPr GPo

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

"2-step mode" is suitable for

- Tacking work

- Short weld seams

- Automated and robot welding

4-step mode

"4-step mode" is suitable for longer weld seams.

Special 4-step

GPr GPoE-I LSS-I

+ +

SPt

GPr GPo

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

mode

“Special 4-step mode ” is particularly suitable for welding aluminium materials. The special pattern of the welding current curve takes account of the high thermal conductivity of aluminium.

Spot welding The “Spot welding” mode is suitable for welding joins on overlapped sheets.

Procedure for spot welding:

Hold welding torch in the vertical

Press and release the torch trigger

Keep the torch in the same position

Wait until the end of the gas post-flow time

Lift the torch off the workpiece

The welding operation can be aborted by pressing the torch trigger a second time.

MIG/MAG welding

Toowoomba Welding Supplies : tweld.com.au : Ph +61 7 4659 0044

Safety

General tasks before MIG/MAG welding

WARNING!

Danger from incorrect operation.

Possible serious injury and damage to property.

Do not use the functions described here until you have read and completely under-

▶

stood these Operating Instructions. Do not use the functions described here until you have fully read and understood all

▶

of the Operating Instructions for the system components, in particular the safety rules!

WARNING!

An electric shock can be fatal.

If the power source is connected to the mains electricity supply during installation, there is a high risk of very serious injury and damage.

Before carrying out any work on the device make sure that the power source mains

▶

switch is in the "O" position Before carrying out any work on the device make sure that the power source is

▶

unplugged from the mains

Only where a cooling unit and water-cooled welding torch are used:

- TPS 2700 with water cooling: Plug the water hoses of the welding torch to the correct connection sockets on the cooling unit

- TS 4000 / 5000, TPS 3200 / 4000 / 5000 with water cooling: Connect the water hoses of the welding torch to the correct connection sockets on the wire-feed unit

Plug in the mains plug

Move the mains switch to the "I" position:

- all the indicators on the control panel light up briefly

- where applicable, the cooling unit starts to run

NOTE!

Follow the safety rules and note the operating conditions in the cooling unit operating instructions.

Overview MIG/MAG welding is composed of the following sections:

- MIG/MAG synergic welding

- MIG/MAG standard manual welding

- CMT welding

- Special functions and options

- Robot welding

100

Fronius TransSynergic 4000, TransSynergic 5000 Operating instructions

Specifications and Main Features

Frequently Asked Questions

User Manual