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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13 SEP 12
/ 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-
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- Power Source
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-2
22
2-
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- Wire Feeder
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-3
33
3-
--
- Torch
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-4
44
4-
--
- Work Surface/Fixture
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-5
55
5-
--
- Main Power (230 or 460V AC⁄
-
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-6
66
6-
--
- Front Panel
-
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-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
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- 3
3 3
3 -
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13 SEP 12
/ Battery Charging Systems / Welding Technology / Solar Electronics
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
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Configurations

13 SEP 12
/ Battery Charging Systems / Welding Technology / Solar Electronics
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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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.