FRO­NIUS TransSynergic 4000 User manual

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
EN
Operating instructions
MIG/MAG power source
42,0426,0001,EN 023-17092020

Toowoomba Welding Supplies : tweld.com.au : Ph [phone]

Contents
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
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Key combinations - special functions 36
Displaying the feeder inching speed 36
Displaying the gas pre-flow and gas post-flow time 36
Displaying the software version 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
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Setup regulations 75
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
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Available parameters 104
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
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Protective gas shield setup menu for the standard control panel 139
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
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Special voltages 191
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
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Safety rules
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 com-
pany,
- 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 applic-
able 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.
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The device is intended solely for the welding processes specified on the rating plate.
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
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.)
Obligations of the
operator
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.
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