FRO­NIUS TPS 2700 MV Parts list manual

13 SEP 12
Fronius USA
Fronius USA Fronius USA
Fronius USA
Office: 1-877-376-6487 www.fronius-usa.com
/ Battery Charging Systems / Welding Technology / Solar Electronics
Operations Reference Guide
MIG Welding Equipment

13 SEP 12
/ Battery Charging Systems / Welding Technology / Solar Electronics
General Information
Table of Contents
Conversion Charts page 1
3d-Drawing page 2
Weld System
Component Layout page 3
Configurations page 4
Power Source
Models page 7
Nameplate page 9
Technical Specifications page 10
Connections and Controls page 11
Wire Feeder
Models page 15
Motor-plate page 17
Connections and Controls page 18
Welding Torch page 22
Cooler page 23
Weld Process
Overview page 24
MIG, short circuit page 26
MIG, pulse page 27
Gas Characteristics page 28
Torch Movement and Position page 32
Discontinuity page 33
Use and Operation
Initial Set-up and Turn-on page 35
Quick Reference Sheet, TPS page 36
Weld Correction Value page 41
Front Panel, TPS page 42
Front Panel, CMT page 45
Quick Reference Sheet, TsT page 55
Front Panel, TsT page 57
Processes
Synergic Lines page 48
Jobs page 49
Resistance Test page 50
Push-Pull Alignment page 51
Cooler Verification page 53
Output Tests page 54
Consumables
Drive Rolls page 61
Liners page 62
Contact Tips page 63
Torch Breakdown page 64
Changing a Liner page 67
Part Numbers page 69
Interface
Models page 76
General Information page 77
Inputs/Outputs page 78
Signal Interaction page 82
Fronius Xplorer page 85
Basic Troubleshooting page 87

13 SEP 12
/ Battery Charging Systems / Welding Technology / Solar Electronics
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- 1
1 1
1 -
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General Information
Conversion Charts
Fraction* Decimal* Millimeters Wire Guage**
2/64 .030 0.8 20
- - - .035 0.9 19
- - - .040 1.0 18
3/64 .045 1.2 17
- - - .052 1.4 16
1/16 .062 1.6 14
- - - .071 1.8 13
5/64 .078 2.0 12
3/32 .094 2.4 11
7/64 .109 2.8 9
¼ .250 6.4 2
1/2 .500 12.7 -
3/4 .750 19.1 -
1 1.00 25.4 -
Meters Feet
0.25 0.8
0.50. 1.6
0.75 2.5
1.00 3.1
1.25 4.1
1.50 4.9
1.75 5.7
2.0 6.6
2.5 8.2
3.0 9.8
3.5 11.5
4.0 13.1
4.5 14.8
5.0 16.4
10 32.8
15 49.2
20 65.6
25 82.0
30 98.4
35 114.8
40 131.2
45 147.6
50 164
55 180.4
60 196.8
65 213.3
70 229.6
75 246.0
Inch/min Mm/sec Cm/min
5 2.12 12.70
10 4.23 25.40
15 6.35 38.10
20 8.47 50.80
25 10.58 63.50
30 12.70 76.20
35 14.82 88.90
40 16.93 101.60
45 19.05 114.30
50 21.17 127.00
55 23.28 139.70
60 25.40 152.40
65 27.51 165.10
70 29.63 177.80
75 31.75 190.50
80 33.86 203.2
85 35.98 215.90
90 38.10 228.60
95 40.21 241.30
100 42.33 254.00
105 44.45 266.70
110 46.56 279.40
115 48.68 292.10
120 50.80 304.80
125 52.91 317.50
130 55.03 330.20
135 57.15 342.90
140 59.26 355.60
145 61.38 368.30
150 63.50 381.00
Conversion Factors
Inch/min to Mm/sec x 0.4233
Inch/min to Cm/min x 2.54
Mm/sec to Inch/min x 2.3622
Cm/min to Inch/min x 0.3937
Ft3/hour to L/min x 0.4719
L/min to Ft3/hour x 2.1189
Meter to Feet x 3.2808
Feet to Meter X 0.3048
Ft3/hour L/min
5 2.36
10 4.72
15 7.08
20 9.44
25 11.80
30 14.16
35 16.52
40 18.88
45 21.24
50 23.60
55 25.95
60 28.31
65 30.67
70 33.03
75 35.39
80 37.75
85 40.11
90 42.47
95 44.83
100 47.19
105 49.55
110 51.91
115 54.27
120 56.63
125 58.99
130 61.35
135 63.71

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/ Battery Charging Systems / Welding Technology / Solar Electronics
G
GG
G
H
HH
H
E
EE
E
F
FF
F
D
DD
D
I
II
I
J
JJ
J
F
FF
F
C
CC
C
J
JJ
J
D
DD
D
D
DD
D
A
AA
A
1
11
1
10
1010
10
2
22
23
33
3
4
44
4
9
99
9
8
88
8
5
55
5
D
DD
D
C
CC
C
7
77
7
D
DD
D
6
66
6
11
1111
11
B
BB
B
D
DD
D
Components consist of
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-1
11
1-
--
- Power Source
-
--
-2
22
2-
--
- Wire Feeder
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--
-3
33
3-
--
- Torch
-
--
-4
44
4-
--
- Work Surface/Fixture
-
--
-5
55
5-
--
- Main Power (230 or 460V AC⁄
-
--
-6
66
6-
--
- Front Panel
-
--
-7
77
7-
--
- Gas Tank
-
--
-8
88
8-
--
- Remote Control Unit (RCU⁄
-
--
-9
99
9-
--
- Robot Interface
-
--
-10
1010
10-
--
- Cooler
-
--
-11
1111
11-
--
- PC Interface Tool
Component Layout
Weld System
Component Management
Controlled by LocalNet (Fronius communication
protocol⁄.
Plug and play configuration
Provides both operating power and
communication to peripheral components.
Connections consist of
-
--
-A
AA
A-
--
- Ground Connection
-
--
-B
BB
B-
--
- Main Power (230 or 460V AC⁄
-
--
-C
CC
C-
--
- Gas
-
--
-D
DD
D-
--
- LocalNet
-
--
-E
EE
E-
--
- Motor Voltage (55V DC⁄
-
--
-F
FF
F-
--
- Main Current
-
--
-G
GG
G-
--
- Pump Voltage (230 or 400V AC⁄
-
--
-H
HH
H-
--
- Data Lines (non LocalNet⁄
-
--
-I
II
I-
--
- Coolant Out
-
--
-J
JJ
J-
--
- Coolant In
-
--
- 3
3 3
3 -
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Weld System
Data
Control Voltages
Welding Current
Coolant Lines
Data
Control Voltages
Welding Current
Shielding Gas
Wire
Coolant Lines
Power
PowerPower
Power-
--
-Source Mounted Wire Feeder
Source Mounted Wire FeederSource Mounted Wire Feeder
Source Mounted Wire Feeder
The wire feeder can be mounted directly on top of the welding power
source. This configuration can be applied with either robotic or manual
systems. This configuration allows for the following features.
The connections between the wire feeder to the power source, shielding
gas and coolant are made through the Interconnecting Hose Pack.
The connections between the wire feeder and welder can vary in
length. This allows the operator to relocate the wire feeder if
needed.
Length of the torch and the interconnecting hose pack must be
taken into consideration when determining if the system should be
a push or push/pull orientation.
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4 4
4 -
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-
Configurations

13 SEP 12
/ Battery Charging Systems / Welding Technology / Solar Electronics
Weld System
Data
Control Voltages
Welding Current
Shielding Gas
Wire
Coolant Lines
Remote Mounted Wire Feeder
Remote Mounted Wire FeederRemote Mounted Wire Feeder
Remote Mounted Wire Feeder
The wire feeder is placed between the welder and the torch location. This placement may or may not be permanent.
This configuration allow for:
Varying distances between the power source and wire feeder.
Enables the wire feeder to torch end distances to be reduced which can reduce the need for a push/pull system.
The wire feeder can be kept within a restricted area while the welder is easily accessible for parameter
monitoring and changes.
Data
Control Voltages
Welding Current
Coolant Lines
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5 5
5 -
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Configurations

13 SEP 12
/ Battery Charging Systems / Welding Technology / Solar Electronics
Weld System
Data
Control Voltages
Welding Current
Shielding Gas
Wire
Coolant Lines
Robot Mounted Wire Feeder
Robot Mounted Wire FeederRobot Mounted Wire Feeder
Robot Mounted Wire Feeder
The wire feeder can be mounted directly to the robot arm or automated system. This type of configuration has no built
in mechanism for manually starting the torch and is intended only for robotic/automated applications.
Interconnecting hose packs can vary in length. The length must be accommodate for the distance between the
power source and feeder but also for the motion of the robot.
This configuration allows for the wire feeder to be kept within a restricted area while the power source is left
accessible area for monitoring and adjusting parameters.
Data
Control Voltages
Welding Current
Coolant Lines
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- 6
6 6
6 -
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Configurations

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Power Source
Trans Synergic (TS) 3200/4000/5000
Three amp ranges available (320, 400, and 500⁄. Multi-voltage model is available
Fully digital, inverter based technology that provides stable, reproducible arc through ENTIRE arc
range.
Welder comes pre-loaded with over 30 standard synergic lines over a large variety of filler metal,
gas types, and wire diameters
Power source is equally suited to robotic, automated, and manual tasks based on application
demands.
Trans-Pulse Synergic (TPS) 3200/4000/5000
Three amp ranges available (320, 400, and 500⁄. Multi-voltage model is available
Welder is capable of pulse welding pre-loaded with pulse-designed synergic lines
Fully digital, inverter based technology that provides stable, reproducible arc through ENTIRE arc
range.
Welder comes pre-loaded with over 50 standard and pulse synergic lines over a large variety of
filler metal, gas types, and wire diameters
Power source is lightweight, easily updateable, and expanded through a plug and
play interface.
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7 7
7 -
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-
Models
TPS 2700
270-amp pulse machine with a built in wire feeder. Multi-voltage model is available
Fully digital, inverter based technology that provides stable, reproducible arc through ENTIRE arc
range.
Welder comes pre-loaded with over 50 standard and pulse synergic lines over a large variety of
filler metal, gas types, and wire diameters
Power source is lightweight, easily updateable, and expanded through a plug and play interface.

13 SEP 12
/ Battery Charging Systems / Welding Technology / Solar Electronics
Power Source
Trans-Steel (TsT) 3500/5000 Robotic
Two amp ranges available (350 and 500⁄. Multi-voltage model available.
Welder is designed specifically for steel welding, offering a large variety of options at a low price.
Fully digital, inverter based technology that provides stable, reproducible arc through ENTIRE arc
range.
Welder comes pre-loaded with over 30 standard synergic lines over a large variety of filler metal,
gas types, and wire diameters
Designed with robotic or automated welding in mind. -
--
- 8
8 8
8 -
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-
Models
Trans-Steel (TsT) 3500/5000 Manual
Two amp ranges available (350 and 500⁄. Multi-voltage model available.
Welder is designed specifically for steel welding, offering a large variety of options at a low price.
Fully digital, inverter based technology that provides stable, reproducible arc through ENTIRE arc
range.
Welder comes pre-loaded with over 30 standard synergic lines over a large variety of filler metal,
gas types, and wire diameters
Trans-Steel (TsT) 3500 Compact
350-amp pulse machine with a built in wire feeder. Multi-voltage model is NOT available
Fully digital, inverter based technology that provides stable, reproducible arc through ENTIRE arc
range.
Welder comes pre-loaded with multiple standard synergic lines over a large variety of filler metal,
gas types, and wire diameters
Power source is lightweight, easily updateable, and expanded through a plug and play interface.

13 SEP 12
/ Battery Charging Systems / Welding Technology / Solar Electronics
Power Source
Name Plate
The name plate is found on the top of the
machine just underneath the carrying handle.
This label includes identification, technical,
upgrade, and duty-cycle information about the
welding power supply.
The identification portion of the label will give a detailed
description of the welder, the full part number, and a unique
serial number.
Using the format below, the serial number can be used to
determine the approximate age of the welding power supply.
This technique can be used to age any Fronius product with an
8-digit serial number.
23080753
23 – subtract “11” to get the year of manufacture
08 – this is the week of manufacture (1 – 52)
0753 – this is the item number for the day of manufacture.
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- 9
99
9 -
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-
The middle portion of the label include technical that includes
duty cycle, amp drops, input and output voltage ranges, and
maximum outputs.

13 SEP 12
/ Battery Charging Systems / Welding Technology / Solar Electronics
Power Source
Tech Specs
TPS 2700 MV TPS 3200 MV TS/TPS 4000 MV TS/TPS 5000 MV CMT-A 4000 MV
Mains Voltage Range 3 x 240
3 x 460 200 – 240 V 380 – 460 V 200 – 240 V 380 – 460 V 200 – 240 V 380 – 460 V 200 – 240 V 380 – 460 V 200 – 240 V 380 – 460 V
Mains Tolerance +/-10% +/-10% +/- 10% +/- 10% +/- 10%
Mains Frequency 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz
Fuse Protection, slow-blow 3 x 460
3 x 240 25 A 16 A 35 A 35 A 63 A 35 A 63 A 35 A 63 A 35 A
Primary Continuous Current (100% dc) 6.4 – 14.2 A 10.6 – 31.2 A 15.3 – 34.4 A 10.1 – 36.1 A n/a
Primary Continuous Power (100% dc) 4.6 – 10.7 KVA 8.7 – 11.5 kVA 10.6 – 12.4 kVA 12.4 – 13.9 kVA 13.0 – 16.0 kVA
Electrical Efficiency 88 – 91% 90 – 91% 88 – 91% 88 – 91% n/a
Welding Current Range MIG Stick
TIG
3 – 270 A
10 – 270 A
3 – 270 A
3 – 320 A
10 – 320 A
3 – 320 A
3 – 400 A
10 – 400 A
3 – 400 A
3 – 500 A
10 – 500 A
3 – 500 A
3 – 400 A
10 – 400 A
n/a
Welding Voltage Range MIG Stick
TIG
14.2 – 27.5 V
20.4 – 30.8 V
10.1 – 20.8 V
14.2 – 30.0 V
20.4 – 32.8 V
10.1 – 22.8 V
14.2 – 34.0 V
20.4 – 36.0 V
10.1 – 26.0 V
14.2 – 30.0 V
20.4 – 40.0 V
10.1 – 30.0 V
14.2 – 34.0 V
20.4 – 36.0 V
n/a
Max Welding Voltage 34.6 V 49.1 – 63.1 V 48 V 49.2 V n/a
Open Circuit Voltage 50 V 64 – 67 V 68 – 78 V 68 – 78 V 90 V
Duty Cycle 77º F (25º C) 60% @ 270 A
100% @ 210 A 89% @ 320 A 100% @ 304 A 75% @ 400 A 100% @ 365 A 75% @ 500 A 100% @ 450 A 85% @ 400 A 100% @ 380 A
Duty Cycle 104º F (40º C) 60% @ 270 A
100% @ 170 A
40% @ 320 A
60% @ 260 A
100% @ 220 A
40% @ 400 A
60% @ 365 A
100% @ 320 A
40% @ 500 A
60% @ 450 A
100% @ 340 A
40% @ 400 A
60% @ 350 A
100% @ 290 A
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(
((
(-
--
-⁄ Current Socket Connection
⁄ Current Socket Connection⁄ Current Socket Connection
⁄ Current Socket Connection
The connection depends on the
operating mode of the power source
MIG Welding
MIG WeldingMIG Welding
MIG Welding: Connect the
welding ground to this socket.
TIG Welding
TIG WeldingTIG Welding
TIG Welding: Connect the
current connection on the torch
to this socket.
STICK Welding
STICK WeldingSTICK Welding
STICK Welding: Connect the
electrode cable to this socket
(depending on the type of
electrode being used⁄.
(+⁄ Current Socket Connection
(+⁄ Current Socket Connection(+⁄ Current Socket Connection
(+⁄ Current Socket Connection
The connection depends on the operating mode of the power source
MIG Welding
MIG WeldingMIG Welding
MIG Welding: Connect the current connection of the interconnection
hose pack to this socket.
TIG Welding
TIG WeldingTIG Welding
TIG Welding: Connect the welding ground to this socket.
STICK Welding
STICK WeldingSTICK Welding
STICK Welding: Connect the electrode cable to this socket (depending
on type of electrode being used⁄.
Power Switch
Power SwitchPower Switch
Power Switch
This switch turns the power source on
(1⁄ and off (0⁄.
Current Connection
Current Connection Current Connection
Current Connection
(
((
( optional ⁄
⁄⁄
⁄
This connection is reserved for
an optional current socket
Mains Connection
Mains ConnectionMains Connection
Mains Connection
This connection is for the 3-
phase input power.
LocalNet Connection
LocalNet ConnectionLocalNet Connection
LocalNet Connection
This connection is for the
LocalNet connection to the wire-
feeder and/or interface device.
Blanking Cover(s⁄
Blanking Cover(s⁄Blanking Cover(s⁄
Blanking Cover(s⁄
These connections are for
optional upgrades to the power
source.
Front Panel
Front PanelFront Panel
Front Panel
The front panel allows the welder to
control the power sources welding
characteristics.
Connections – TPS 3200/4000/5000
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11 11
11 -
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Power Source

13 SEP 12
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Current Connection
Current ConnectionCurrent Connection
Current Connection
Power Switch
Power SwitchPower Switch
Power Switch
Ground Connection (
Ground Connection (Ground Connection (
Ground Connection ( optional ⁄
⁄⁄
⁄
Mains Connection
Mains ConnectionMains Connection
Mains Connection
LocalNet Connection
LocalNet ConnectionLocalNet Connection
LocalNet Connection
Blanking Cover(s⁄
Blanking Cover(s⁄Blanking Cover(s⁄
Blanking Cover(s⁄
Front Panel
Front PanelFront Panel
Front Panel
Gas Connection (
Gas Connection (Gas Connection (
Gas Connection ( bottle ⁄
⁄⁄
⁄
Trigger Connection (
Trigger Connection (Trigger Connection (
Trigger Connection ( torch ⁄
⁄⁄
⁄
Carrying Strap
Carrying StrapCarrying Strap
Carrying Strap
Current Connection (
Current Connection (Current Connection (
Current Connection ( torch ⁄
⁄⁄
⁄Ground Connection
Ground ConnectionGround Connection
Ground Connection
Connections – TPS 2700
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12 12
12 -
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Power Source

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Current Connection
Current ConnectionCurrent Connection
Current Connection
Ground Connection
Ground ConnectionGround Connection
Ground Connection
Power Switch
Power SwitchPower Switch
Power Switch
Mains Connection
Mains ConnectionMains Connection
Mains Connection
LocalNet Connection
LocalNet ConnectionLocalNet Connection
LocalNet Connection
Optional Add
Optional AddOptional Add
Optional Add-
--
-ons
onsons
ons
Front Panel
Front PanelFront Panel
Front Panel
Connections – TsT 3500/5000
Power Source
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13 13
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Current
Current Current
Current
Connection
ConnectionConnection
Connection
Ground
Ground Ground
Ground
Connection
ConnectionConnection
Connection
Power
Power Power
Power
Switch
SwitchSwitch
Switch
Mains
Mains Mains
Mains
Connection
ConnectionConnection
Connection
LocalNet
LocalNet LocalNet
LocalNet
Connection
ConnectionConnection
Connection
Gas Purch / Wire
Gas Purch / Wire Gas Purch / Wire
Gas Purch / Wire
Feed Switch
Feed SwitchFeed Switch
Feed Switch
Front Panel
Front PanelFront Panel
Front Panel
Connections – TsT Compact
Power Source
Gas
Gas Gas
Gas
Connection
ConnectionConnection
Connection
Torch
Torch Torch
Torch
Connector
ConnectorConnector
Connector
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Wire Feeder
VR 4000
This wire feeder is designed specifically for manual applications.
This device has the trigger connections required for manual torches to operate.
A removable wire-spool holder is mounted to the rear of the feeder.
Robotic/automated connections and controls can easily be added to this wire feeder
A push/pull torch requires an additional, internally installed kit.
VR 7000 CMT
This wire feeder was developed specifically for the Cold Metal Transfer (CMT⁄ process.
The feeder is equally suited to both manual and robotic/automated needs.
A wire spool holder is integrated to the feeder allowing for both spool and drum use.
This feeder is designed to operate with either a push or a push/pull torch.
Models
VR 1500
This wire feeder is designed specifically for robotic or automated applications.
Using this wire feeder for manual welding is not feasible without special
modifications
A push/pull torch requires an additional, internally installed kit.
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15 15
15 -
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VR 1550
This wire feeder is designed specifically for robotic or automated applications.
Using this wire feeder for manual welding is not feasible without special
modifications
This feeder can be used for CMT and/or push/pull applications using a series of
specially designed kits.

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Wire Feeder
VR 5000 ROB
Newly developed wire feeder specifically designed for the robotic TransSteel Welding
system.
Designed to have the smallest profile of any Fronius wire feeder while maintaining a high
standard of durability and reliability.
Multiple versions available based on the robot type and design (PAP, standard, etc.⁄ with a
large range of options and fixtures to choose from. -
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16 16
16 -
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Models
VR 5000 Manual
Newly developed wire feeder designed specifically for the TransSteel Welding System.
Built with highly reliable, impact resistant materials. This provides reasonable protection
from dragging, dropping and hanging.
Multiple control options to handle both manual and synergic welding needs
Incredibly precise feed system allowing for perfect wire feed
Specialized current connection with data lines integrated to the connection simplifies setup
and keeps wiring to a minimum.
VR 1500 PAP
This wire feeder is designed specifically for robotic through-the-arm applications.
The size and weight was kept as small as possible, keeping only the mandatory components
in the feeder itself and moving the remainder to the welder.
Using this wire feeder for manual welding is not possible.
A push/pull torch requires an additional, internally installed kit.

13 SEP 12
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Wire Feeder
Fronius Connector (F++⁄
Fronius Connector (F++⁄Fronius Connector (F++⁄
Fronius Connector (F++⁄ Euro Connector (E⁄
Euro Connector (E⁄Euro Connector (E⁄
Euro Connector (E⁄ Tweeco Connector (T⁄
Tweeco Connector (T⁄Tweeco Connector (T⁄
Tweeco Connector (T⁄
Drive Rolls (
Drive Rolls (Drive Rolls (
Drive Rolls ( top ⁄
⁄⁄
⁄
Drive Rolls (
Drive Rolls (Drive Rolls (
Drive Rolls ( bottom ⁄
⁄⁄
⁄
Wire Guide Insert (
Wire Guide Insert (Wire Guide Insert (
Wire Guide Insert ( steel or synthetic ⁄
⁄⁄
⁄
Main Drive Roll
Main Drive RollMain Drive Roll
Main Drive Roll
Torch Connectors
Torch ConnectorsTorch Connectors
Torch Connectors
Tension Knobs
Tension KnobsTension Knobs
Tension Knobs
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- 17
17 17
17 -
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Motor Plate
Fronius System Connector (FSC⁄
Fronius System Connector (FSC⁄Fronius System Connector (FSC⁄
Fronius System Connector (FSC⁄