Фрониус 5000 инструкция по применению

Page 5: Table Of Contents

Contents Safety rules …………………………Explanation of safety symbols ………………….General …………………………Intended purpose ……………………..Environmental conditions……………………Obligations of the operator……………………Obligations of personnel ……………………Mains connection ……………………..Protecting yourself and others ………………….Noise emission values …………………….. Danger from toxic gases and vapours ………………..Danger from flying sparks ……………………

Page 11: Safety Rules

Safety rules Explanation of DANGER! indicates immediate and real danger. If it is not avoided, death or se- safety symbols rious injury will result. WARNING! indicates a potentially dangerous situation. Death or serious injury may result if appropriate precautions are not taken. CAUTION! indicates a situation where damage or injury could occur.

Page 12: Intended Purpose

Intended purpose The device is to be used exclusively for its intended purpose. The device is intended for the welding process described on the rating plate only. Any use above and beyond this purpose is deemed improper. The manufac- turer shall not be liable for any damage resulting from such improper use. Utilisation in accordance with the «intended purpose»…

Page 13: Obligations Of Personnel

Obligations of Before using the device, all persons instructed to do so undertake: personnel 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 work area, ensure that people or property cannot come to any harm in your absence.

Page 14: Noise Emission Values

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 safety visor. wear stout footwear that provides insulation even in wet conditions. protect the hands with suitable gloves (electrically insulated and providing protection against heat).

Page 15: Danger From Flying Sparks

If there is any doubt about whether the extraction system is powerful enough, then the measured toxic emission values should be compared with the permis- sible limit values. The following components are responsible, amongst other things, for the de- gree of toxicity of welding fumes: Metals used for the workpiece Electrodes Coatings…

Page 17: Meandering Welding Currents

Meandering weld- If the following instructions are ignored, meandering welding currents can de- ing currents velop with the following consequences: Fire hazard Overheating of parts connected to the workpiece Irreparable damage to PE conductors Damage to device and other electrical equipment Ensure that the workpiece is held securely by the workpiece clamp.

Page 18: Emf Measures

Check for possible problems, and check and evaluate neighbouring devices’ resistance to interference according to national and international require- ments: Safety features power, signal and data transfer lines IT and telecommunications devices measuring and calibrating devices Supporting measures for avoidance of EMC problems: Mains supply if electromagnetic interference arises despite correct mains connec- tion, additional measures are necessary (e.g.

Page 20: Danger From Shielding Gas Cylinders

Danger from Shielding gas cylinders contain gas under pressure and can explode if dam- shielding gas cyl- aged. As the shielding gas cylinders are part of the welding equipment, they inders 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.

Page 21: Safety Measures In Normal Operation

When transporting the device, observe the relevant national and local guide- lines and accident prevention regulations. This applies especially to guidelines regarding the risks arising during transportation. Before transporting the device, allow coolant to drain completely and detach the following components: Wire-feed unit Wirespool Shielding gas cylinder…

Page 22: Maintenance And Repair

Maintenance and It is impossible to guarantee that bought-in parts are designed and manufac- repair tured to meet the demands made on them, or that they satisfy safety require- ments. Use only original replacement and wearing parts (also applies to standard parts).

Page 23: Data Protection

Data protection The user is responsible for the safekeeping of any changes made to the fac- tory settings. The manufacturer accepts no liability for any deleted personal settings. Copyright Copyright of these operating instructions remains with the manufacturer. The text and illustrations are all technically correct at the time of printing. We reserve the right to make changes.

Page 25: General Information

General information…

Page 27: General

General Device concept The TransSynergic (TS) 4000 and TS 5000 and TransPulsSynergic (TPS) 2700, TPS 3200, TPS 4000 and TPS 5000 power sour- ces are fully digitised microprocessor-con- trolled inverter power sources. The modular design and potential for sys- tem add-ons ensure a high degree of flexi- bility.

Page 29: Special Versions

Special versions General Professional processing of specific materials requires welding programs that are specially 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 weld- ing programs can be called up directly from the operating panel.

Page 30: Time 5000 Digital

ised 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…

Page 31: System Components

System components 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.

Page 33: Control Elements And Connections

Control elements and connections…

Page 35: Description Of The Control Panels

Description of the control panels 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 in- dividual parameter has been changed.

Page 36: Standard Control Panel

Standard control panel General NOTE! On the Standard control panel, only the MIG/MAG standard synergic welding process is available. The following processes and functions are not avail- able 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”…

Page 38: Key Combinations — Special Functions

Function (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.

Page 40: Comfort / Crni / Steel Control Panel

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

Page 43: Key Combinations — Special Functions

Function (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…

Page 44: Displaying The Gas Pre-Flow And Gas Post-Flow Time

Use the adjusting dial to change the feeder inching speed Press the Store button to exit. Displaying the gas pre-flow and The set gas pre-flow time is displayed (e.g. GPr | 0.1 s) gas post-flow time Use the adjusting dial to change the gas pre-flow time Then press the Process button (22) to display the gas post-flow time setting (e.g.

Page 45: Us Control Panel

US control panel US control panel (10) (12) (14) (16) (18) (11) (13) (15) (17) (19) (25) (23) (21) (26) (24) (22) (20) Function 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»…

Page 48: Key Combinations — Special Functions

Function (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.

Page 49: Displaying The Software Version

Displaying the In addition to the software version, these special functions can also be used to display the software version 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 (22) to display the version number of the welding database…

Page 50: Time 5000 Digital Control Panel

TIME 5000 Digital control panel TIME 5000 Digital control panel (10) (12) (14) (16) (18) (20) (11) (13) (15) (17) (19) (21) (27) (25) (23) (28) (26) (24) (22) Function 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»…

Page 53: Key Combinations — Special Functions

Function (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.

Page 54: Displaying The Gas Pre-Flow And Gas Post-Flow Time

Displaying the gas pre-flow and The set gas pre-flow time is displayed (e.g. GPr | 0.1 s) gas post-flow time Use the adjusting dial to change the gas pre-flow time Then press the Process button (20) to display the gas post-flow time setting (e.g.

Page 55: Cmt Control Panel

CMT control panel CMT control pan- (10) (12) (14) (16) (18) (11) (13) (15) (17) (24) (22) (20) (25) (23) (21) (19) Function 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»…

Page 58: Key Combinations — Special Functions

Function (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…

Page 60: Yard Control Panel

Yard control panel Yard control pan- (10) (12) (14) (16) (18) (11) (13) (15) (17) (24) (22) (20) (25) (23) (21) (19) Function 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»…

Page 63: Key Combinations — Special Functions

Function (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.

Page 64: Displaying The Software Version

Displaying the In addition to the software version, these special functions can also be used to display the software version 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 (24) to display the version number of the welding database…

Page 65: Remote» Control Panel

“Remote” control panel 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…

Page 66: Cmt Remote Control Panel

CMT Remote control panel General The CMT Remote control panel is fitted to the CMT Remote power source and CMT Ad- vanced 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.

Page 67: Connections, Switches And Mechanical Components

Connections, switches and mechanical components TPS 2700 power Front view Rear view Side view source (1) (2) (7) (8) Function LocalNet connection Standardised connection socket for system add-ons (e.g. remote control, Job- Master torch, etc.) (+) — Current socket with bayonet latch for: connecting the grounding (earthing) cable during TIG welding connecting the electrode cable or grounding (earthing) cable during MMA…

Page 68: Tps 2700 Cmt Power Source

TPS 2700 CMT Front view Rear view Side view power source (1) (2) (7) (8) (11) (10) (12) (13) Function LocalNet connection Standardised connection socket for system add-ons (e.g. remote control, Job- Master torch, etc.) Motor control connection for connecting the control line from the CMT drive unit Welding torch control connection for the welding torch control plug LHSB connection…

Page 69: Ts 4000 / 5000, Tps 3200 / 4000 / 5000, Time 5000 Digital Power Sources

TS 4000 / 5000, Front view Rear view TPS 3200 / 4000 / 5000, TIME 5000 Digital power sources Function (-) — 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) Mains switch…

Page 70: Cmt 4000 Advanced Power Source

Function Second (-) — Current socket with bayonet latch (optional) for: connecting the interconnecting hosepack in MIG/MAG welding for polarity re- versal (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.

Page 73: Installation And Commissioning

Installation and commissioning…

Page 75: Minimum Equipment Needed For Welding Task

Minimum equipment needed for welding task General Depending on which welding process you intend to use, a certain minimum equipment lev- el 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.

Page 76: Cmt Automated Welding

CMT automated CMT power source: TPS 3200 / 4000 / 5000 (or CMT remote power source with RCU welding 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…

Page 77: Before Installation And Commissioning

Before installation and commissioning Safety WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: these operating instructions all the operating instructions for the system components, especially the safe- ty rules Proper use The power source may only be used for MIG/MAG, MMA and TIG welding.

Page 78: Connecting Up The Mains Cable On Us Power Sources

Connecting up the mains cable on US power sourc- 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.

Page 79: Replacing The Strain-Relief Device

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 PE conductor and the phase conductors to the block ter- minal properly.

Page 81: Start-Up

Start-up Safety 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 in- jury and damage. Before carrying out any work on the device make sure that: the power source mains switch is in the «O»…

Page 82: Commissioning The Tps 2700

Commissioning the TPS 2700 General Commissioning the TPS 2700 power source is described by reference to a manual gas- cooled MIG/MAG application. Recommenda- Use the PickUp trolley tion for water- Fit the cooling unit to the PickUp trolley cooled applica- Fit the TPS 2700 power supply to the cooling unit tions Only use water-cooled welding torches with an external water connection…

Page 83: Establishing A Ground (Earth) Connection

Establishing a Plug the grounding (earthing) cable ground (earth) into the (-) current socket and twist to connection fasten it Use the other end of the grounding (earthing) cable to establish a connec- tion to the workpiece Connecting the grounding (earthing) cable to the TPS 2700 Connecting the Check that the torch is correctly and…

Page 84: Inserting The Wirespool

Inserting the wire- CAUTION! Risk of injury from springiness of spooled wire electrode. While insert- spool ing 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 se- curely on the spool holder.

Page 85: Feeding In The Wire Electrode

Feeding in the CAUTION! Risk of injury from springiness of spooled wire electrode. When insert- wire electrode ing 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.

Page 86: Setting The Contact Pressure

CAUTION! Risk of injury from wire electrode emerging at speed. Keep the weld- ing torch away from face and body when pressing the feeder inching / inch for- ward button. Setting the con- NOTE! Set the contact pressure in tact pressure such a way that the wire electrode is not deformed but nevertheless ensures that the wire is transport-…

Page 87: Design Of The Brake

STOP STOP Design of the CAUTION! Risk of injury and damage from falling wirespool. To ensure that the brake wirespool is properly in place and that the brake works properly, fit the brake ac- cording to the following diagram. KLEBER, GLUE, COLLE…

Page 88: Commissioning The Ts 4000 / 5000, Tps 3200 / 4000 / 5000, Time 5000 Digital

Commissioning the TS 4000 / 5000, TPS 3200 / 4000 / 5000, TIME 5000 Digital General Commissioning the TS 4000 / 5000 and TPS 3200 / 4000 / 5000 power sources is de- scribed by reference to a manual water-cooled MIG/MAG application. Fitting the system The diagram below is intended to show you how to fit the individual system components.

Page 89: Fixing The Strain-Relief Device In Place

Fixing the strain- Introduce the pin on the power source relief device in strain-relief device for the interconnec- place ting-hosepack into the opening provi- ded in the base of the trolley. Use two screws supplied with the inter- connecting hosepack to fasten the strain-relief device to the base of the trolley.

Page 90: Connecting The Gas Cylinder

Plug the welding potential bayonet plug on the interconnecting hosepack into the (+) socket and twist to fasten it Plug the LocalNet plug on the interconnecting hosepack into the LocalNet connection 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…

Page 91: Establishing A Ground (Earth) Connection

Establishing a Plug the grounding (earthing) cable ground (earth) into the (-) current socket and twist to connection fasten it Use the other end of the grounding (earthing) cable to establish a connec- tion to the workpiece Connecting the Check that the torch is correctly and welding torch completely tooled up.

Page 92: Commissioning The Cmt4000 Advanced

Commissioning the CMT4000 Advanced Fitting the system The diagram below is intended to show you how to fit the individual system components. components For detailed information about the individual steps, please refer to the operating instruc- (overview) tions for the system components. WARNING! If gas cylinders topple over, there is a risk of very serious injury and damage.

Page 93: Preparing The Wire-Feed Unit

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 Carry out the following steps in accordance with the wire-feed unit operating instructions: wire-feed unit Insert the feed rollers in the wire-feed unit Insert the wirespool or basket-type spool with adapter in the wire-feed unit…

Page 95: Welding

Welding…

Page 97: Mig/Mag Modes

MIG/MAG modes General WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: these operating instructions all the operating instructions for the system components, especially the safe- ty rules See the Setup menu for information on settings, setting range and units of measurement for the available parameters.

Page 98: 2-Step Mode

2-step mode “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.

Page 99: Special 4-Step Mode

Special 4-step “Special 4-step mode ” is particularly suitable for welding aluminium materials. The spe- mode cial 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…

Page 100: Mig/Mag Welding

MIG/MAG welding Safety WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: these operating instructions all the operating instructions for the system components, especially the safe- ty rules WARNING! An electric shock can be fatal.

Page 101: Mig/Mag Synergic Welding

MIG/MAG synergic welding General The inputs required for MIG/MAG synergic welding (pulse/standard) are described by ref- erence to the Comfort control panel. MIG/MAG syner- Press the Process button to select the desired welding process: gic welding MIG/MAG pulse synergic welding MIG/MAG standard synergic welding Press the Material button to select the filler metal and shielding gas used The assignment of SP1 and SP2 depends on the welding database used for the power…

Page 102: Corrections During Welding

CAUTION! Risk of injury and damage from electric shock and from the wire electrode emerging from the torch. When pressing the torch trigger: keep the torch away from your face and body do not point the welding torch at people make sure that the wire electrode does not touch any electrically conducting or earthed (grounded) parts, such as the housing, etc.

Page 103: Mig/Mag Standard Manual Welding

MIG/MAG standard manual welding General The MIG/MAG standard manual welding process is a MIG/MAG welding process with no Synergic function. Changing one parameter does not result in any automatic adjustments to the other param- eters. All of the variable parameters must therefore be adjusted individually, as dictated by the welding process in question.

Page 104: Corrections During Welding

All welding parameter set values that have been set using the adjusting dial or buttons on the welding torch remain stored until the next time they are changed. This is true even if the power source is switched off and on again in the meantime To display the actual welding current during welding: press the Parameter selection button and select the welding current parameter the actual welding current is displayed on the digital display during welding…

Page 105: Cmt Welding

CMT welding General The inputs required for CMT welding are described by reference to the CMT control panel. Settings for CMT applications with the CMT remote power source and the RCU 5000i re- mote control can be found in the operating instructions for the RCU 5000i remote control. CMT welding Press the Process button to select the CMT/CMT pulse process: Press the Material button to select the filler metal and shielding gas used…

Page 106: Corrections During Welding

Use the adjusting dial to set the selected parameter to the desired value. The param- eter value is displayed in the digital display located above it. The sheet thickness, welding current, wire feed speed and welding voltage parame- ters are directly interlinked. It is only necessary to alter one of the parameters, as the other parameters are immediately adjusted to match.

Page 108: Adjusting Parameters For Correction

Adjusting param- Press the Parameter selection button to select the parameter you wish to correct eters for correc- Use the adjusting dial to set the selected parameter to the desired value. The param- tion eter value is displayed in the digital display located above it.

Page 109: Special Functions And Options

Once the correct arc length has been reached, the wire starts being fed at the speed specified for this welding process. NOTE! The optimum function of the spatter-free ignition option can only be guar- anteed in aluminium applications in conjunction with Fronius push-pull wire-feed unit systems. System requirements: Firmware version on the power source: OFFICIAL UST V2.60.1…

Page 110: Synchropulse Option

Firmware version on the wire-feed unit: OFFICIAL SR 1 V1.40.15 NOTE! External enabling of the SynchroPulse option is possible from firmware version OFFICIAL UST V2.70.1 (power source) upwards. Only Fronius push-pull wire-feed unit systems are supported. NOTE! As long as the Standard manual welding process is selected, the Syn-…

Page 112: Robot Welding

Robot welding Prerequisite A robot interface or field bus system is needed in order to be able to control the power source from a robot control unit. General 2-step mode is selected automatically if a ROB 4000 / 5000 robot interface or field bus sys- tem is connected.

Page 113: Wire-Stick Control Function

Wire-stick control The wire-stick control function is available if a robot interface or field bus system is con- function nected to the LocalNet. After the end of welding, the wire-stick control function detects any “sticking” of the wire electrode in the solidifying weld pool. If a sticking wire electrode is detected within 750 ms after the end of welding, the error message “Err | 054”…

Page 114: Tig Welding

TIG welding Safety WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: these operating instructions all the operating instructions for the system components, especially the safe- ty rules WARNING! An electric shock can be fatal.

Page 115: Igniting The Arc

NOTE! Parameters that have been set on a system component control panel (e.g. wire feed unit or remote control) might not be able to be changed on the power source control panel. Press the Parameter selection button. The LED indicator on the button must light up. Use the adjusting dial to set the desired amperage.

Page 116: Finishing Welding

Raise the torch and pivot it into the nor- mal position — the arc ignites Carry out welding Arc ignited — welding commences Finishing welding NOTE! When the welding action is finished, the gas post-flow time required to protect the tungsten electrode and the weld seam depends on the welding cur- rent.

Page 118: Tig Welding With Tig Comfort Stop

Keep the torch in the same position The welding current is continuous- ly decreased (downslope) The arc goes out NOTE! The downslope is preset and cannot be adjusted. Raise the torch from the workpiece. Keeping the torch at the same height and then remo- ving it TIG welding with Welding current curve with the TIG Comfort Stop option activated:…

Page 119: Mma Welding

MMA welding Safety WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: these operating instructions all the operating instructions for the system components, especially the safe- ty rules WARNING! An electric shock can be fatal.

Page 120: Corrections During Welding

NOTE! Parameters that have been set on a system component control panel (e.g. wire feed unit or remote control) might not be able to be changed on the power source control panel. Press the Parameter selection button. The LED indicator on the button must light up. Use the adjusting dial to set the desired amperage.

Page 121: Softstart Function

Legend Hti ..Hot-current time, 0 — 2 s, factory set- I (A) ting: 0.5 s HCU … Hot-start current, 0 — 200%, factory HCU > I setting 150 % ..Main current = set welding current Function: during the specified hot-current time (Hti), the welding current is increased to a certain value.

Page 122: Job Mode

Job mode General Job mode enhances the quality of welding engineering fabrication, both in manual and au- tomated welding. Up to 100 common jobs (operating points) can be reproduced in job mode, avoiding the need to document parameters by hand. Prerequisites Job mode is only available on power sources with the following control panels: Comfort control panel…

Page 123: Retrieving A Job

Briefly press the Store button to change to the job menu The first vacant program location for the job is indicated. Select the desired program location with the adjusting dial, or else leave the suggest- ed program location unchanged Press and hold the Store button NOTE! If the selected program location already has a job stored in it, then this existing job will be overwritten with the new job.

Page 124: Copying/Overwriting A Job

MIG/MAG jobs can also be selected via the JobMaster or Up/Down welding torches. When you retrieve a job directly from the power source, you can also select vacant program locations (symbolised by “- — -”). Only pre-programmed program locations can be selected via the JobMaster or Up/Down torches, however.

Page 125: Deleting A Job

Release the Store button. Briefly press the Store button to exit from the Job menu The power source switches to the setting selected before the job was copied. Deleting a job NOTE! Jobs are deleted in the Job menu, not in the job mode process. Stored jobs can also be deleted again.

Page 127: Setup Settings

Setup settings…

Page 129: Job Correction

Job correction General In the Job correction menu, setup parame- ters can be adapted to the specific require- ments of individual jobs. Job correction menu: Overview Opening the Job Press and hold the Store button correction menu Press the parameter selection button (left) Release the Store button The power source is now in the Job correction menu.

Page 130: Parameters In The Job Correction Menu

Parameters in the There are two types of parameter in the job correction menu: job correction menu permanently settable parameters: cannot be altered apart from in the job correction menu. can only be corrected in the job correction menu. parameters that can be corrected at a later time: with boundary values for which an adjusting range can be defined within this adjusting range, these parameters can be corrected from the following con- trol elements:…

Page 132: Parameters That Can Be Corrected At A Later Time

Factory setting time — End current — Final current duration Unit Setting range OFF or 0.1 — 9.9 Factory setting Spot welding time Unit Setting range 0.1 — 5.0 Factory setting Frequency — for SynchroPulse option Unit Setting range OFF or 0.5 — 5 Factory setting delta Feeder — Welding power offset for the SynchroPulse option (defined by the wire feed speed)

Page 135: Shielding Gas Setup Menu

Shielding gas setup menu General The Protective gas shield setup menu provides easy access to the protective gas shield settings. Protective gas Opening the Protective gas shield setup menu shield setup menu for the Press and hold the Store button standard control Press the Gas test button panel…

Page 137: Setup Menu For The Standard Control Panel

Setup menu for the standard control panel General The Setup menu provides easy access to expert knowledge in the power source and to additional functions. The Setup menu can be used to make simple adjustments of the weld- ing parameters to suit the various job settings. Setup menu for Opening the Protective gas shield setup menu the standard con-…

Page 140: Process Setup Menu

Process setup menu General The Process setup menu provides simple access to expert knowledge in the power source and to additional functions. The Process setup menu can be used to make simple adjust- ments of the parameters to the various job settings. The Process setup menu can be accessed using the Comfort, US, TIME 5000 Digital and CMT control panels.

Page 143: Parameters For Tig Welding In The Process Setup Menu

NOTE! When the power source is reset, all the customised settings in the Setup menu are lost. When the power source is reset, jobs are not deleted but are retained in the memory. The functions in the second level of the Setup menu (2nd) are also not deleted. Exception: Ig- nition time-out welding parameter (ito).

Page 144: Mode Setup Menu

Mode setup menu General The Mode setup menu provides simple access to expert knowledge in the power source and to additional functions. The Mode setup menu can be used to make simple adjust- ments of the parameters to the various job settings. The Process setup menu can be accessed using the Comfort, US, TIME 5000 Digital and CMT control panels.

Page 145: Welding Parameters For «Special 4-Step Mode» In The Mode Setup Menu

I (current) — End — Final current Unit % (of starting current) Setting range 0 — 200 Factory setting time — Starting current — Starting current duration Unit Setting range OFF or 0.1 — 9.9 Factory setting time — End current — Final current duration Unit Setting range OFF or 0.1 — 9.9…

Page 146: Setup Menu — Level 2

Setup menu — Level 2 General The following functions are located in a second menu level: PPU (push-pull unit) r (welding circuit resistance measure- C-C (cooling unit cut-out) ment) Stc (wire-stick — only where there is a L (welding circuit inductivity display) robot interface) Eln (characteristic selection — not on Ito (ignition time-out)

Page 147: Setup Menu Level 2 For The Comfort, Us, Time 5000 Digital And Cmt Control Panels

Setup menu level Changing to the second menu level 2 for the Comfort, (2nd) US, TIME 5000 Open the Process setup menu Digital and CMT Select «2nd» welding parameter control panels Press and hold the Store button Press the Process button Release the Store button The power source is now in the second menu level (2nd) of the Setup menu.

Page 150: Parameters For Operating Power Sources In Parallel In The Setup Menu Level2

NOTE! Please refer to «Digital gas control» operating instructions for more de- tailed explanations of the «COr» parameter. Real Energy Input – electrical energy of the arc relative to the welding speed Unit Setting range ON/OFF Factory setting Since the full range of values (1 kJ — 99999 kJ) cannot be displayed on the three-digit dis- play, the following display format has been selected: Value in kJ Indicator on display…

Page 152: Parameters For Rod Electrode (Mma) Welding In The Setup Menu Level 2

Parameters for rod electrode Electrode line — characteristic selection (MMA) welding in Unit the Setup menu level 2 Setting range CON or 0.1 — 20 or P Factory setting Load line for rod electrode Load line for rod electrode where arc length is in- con — 20 A / V U (V) creased…

Page 154: Notes On The Use Of The Fac Parameter

U (Voltage) cut-off — Welding voltage limitation: Unit Setting range OFF or 5 — 95 Factory setting NOTE! The arc length depends on the welding voltage. To end the welding proc- ess, it is usually necessary to significantly lift the rod electrode away from the workpiece.

Page 155: Calibrating Push-Pull Unit

Calibrating push-pull unit General The push-pull unit must be calibrated before it is started up for the first time and whenever the wirefeed software is updated. If the push-pull unit is not calibrated, standard parame- ters will be used — which may lead to an unsatisfactory welding result. Calibrating the Access Setup menu: Level 1 push-pull unit -…

Page 159: Service Codes For Push-Pull Calibration

Service codes for push-pull calibration Safety WARNING! An electric shock can be fatal. Before opening the device Turn the mains switch to the «O» position Unplug the machine from the mains Prevent it from being switched on again Using a suitable measuring instrument, check to make sure that electrically charged components (e.g.

Page 160: Service Codes When The Drive Units Are Engaged («Engaged» Calibration)

Service codes St1 | E 16 when the drive Cause: Push-pull calibration was interrupted: Quick-stop was activated by pressing units are engaged the torch trigger. («engaged» cali- Remedy: Repeat push-pull calibration bration) St2 | E 7 Cause: «Push-pull calibration — open-circuit» has not been carried out Remedy: Carry out «push-pull calibration — open-circuit»…

Page 162: Measuring Welding Circuit Resistance R

Measuring welding circuit resistance r General Measuring the welding circuit resistance “r” makes it possible to have a constant welding result at all times, even with hosepacks of different lengths. The welding voltage at the arc is then always precisely regulated, regardless of the length and cross-sectional area of the hosepack.

Page 164: Displaying Welding Circuit Inductivity L

Displaying welding circuit inductivity L General The way that the interconnecting hosepack is arranged has a very significant effect on the weld properties. In MIG/MAG pulse synergic welding in particular, high welding circuit in- ductivity may occur, depending on the length of the interconnecting hosepack and the way it is arranged.

Page 165: Troubleshooting And Maintenance

Troubleshooting and maintenance…

Page 167: Troubleshooting

Troubleshooting General The digital power sources are equipped with an intelligent safety system. This means that apart from the fuse for the coolant pump, it has been possible to dispense with melting-type fuses entirely. After a possible malfunction or error has been remedied, the power source can be put back into normal operation again without any fuses having to be replaced.

Page 175: Power Source — Troubleshooting

Power source — tSt | xxx troubleshooting Note: xxx is a temperature value Cause: Overtemperature in the control circuit Remedy: Allow power source to cool down Power source has no function Mains switch is on, but indicators are not lit up Cause: There is a break in the mains lead;…

Page 179: Care, Maintenance And Disposal

Care, maintenance and disposal General Under normal operating conditions, the power source requires only a minimum of care and maintenance. However, it is vital to observe some important points to ensure the welding system remains in a usable condition for many years. Safety WARNING! An electric shock can be fatal.

Page 181: Appendix

Appendix…

Page 183: Technical Data

Technical data Special voltages For devices designed for special voltages, the technical data on the rating plate applies. For all machines with a permitted mains voltage of up to 460 V: 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 a mains plug permitted for such use or install the mains supply directly.

Page 184: Tps 2700 Mv

Wirespool types all standardised wirespools Max. permitted wirespool weight 16 kg 35.27 lb Wirespool diameter 300 mm 11.81 in. Wire diameter 0.8 — 1.6 mm 0.03 — 0.06 in. Drive 4 roller drive Maximum shielding gas pressure 7 bar 101 psi. The wire-feed unit for the TPS 2700 is integrated in the power source.

Page 185: Tps 3200

Dimensions l x w x h 641.5 x 297.4 x 476.5 mm 25.26 x 11.71 x 18.76 in. Weight 27 kg 59.5 lb. Supply voltage in wire-feed unit 55 V DC Nominal current in wire-feed unit Wire feed speed 0.5 — 22 m/min 19.69 — 866.14 ipm Wirespool types all standardised wirespools…

Page 186: Tps 3200 Mv

Open circuit voltage 65 V Degree of protection IP 23 Type of cooling Insulation class EMC emission class Marks of conformity Safety symbol Dimensions l x w x h 626 x 287 x 477 mm 24.65 x 11.30 x 18.78 in. Weight 34.6 kg 76.3 lb.

Page 187: Tps 3200 460Vac

Dimensions l x w x h 626 x 287 x 477 mm 24.65 x 11.30 x 18.78 in. Weight 34.6 kg 76.3 lb. connected to public grid at 230/400 V and 50 Hz d.c. = Duty cycle TPS 3200 Mains voltage 3 x 380-460 V 460 V AC Mains voltage tolerance…

Page 188: Ts/Tps 4000

Safety symbol Dimensions l x w x h 626 x 287 x 477 mm 24.65 x 11.30 x 18.78 in. Weight 34.6 kg 76.3 lb. connected to public grid at 230/400 V and 50 Hz d.c. = Duty cycle TS/TPS 4000 Mains voltage 3 x 400 V Mains voltage tolerance…

Page 189: Ts/Tps 4000 Mv

TS/TPS 4000 MV Mains voltage 3 x 200-240 V 3 x 380-460 V Mains voltage tolerance +/- 10 % Mains frequency 50 / 60 Hz Mains fuse protection 63/35 A slow-blow Mains connection Restrictions possible Primary continuous current 100% d.c. 15.3 — 34.4 A Primary continuous power 10.6 — 12.4 kVA…

Page 190: Ts/Tps 5000 Mv

Cos phi 0.99 Efficiency 90 % Welding current range MIG/MAG 3 — 500 A Rod electrode 10 — 500 A 3 — 500 A Welding current at 10 min / 40 °C (104 °F) 40 % d.c. 500 A 60 % d.c. 450 A 100% d.c.

Page 191: Technical Data — Us Devices

60 % d.c. 450 A 100% d.c. 320 — 340 A Welding voltage range according to standard characteristic MIG/MAG 14.2 — 39.0 V Rod electrode 20.4 — 40.0 V 10.1 — 30.0 V Max. welding voltage 49.2 V Open circuit voltage 68 — 78 V Degree of protection IP 23…

Page 192: Cmt 4000 Advanced

3 — 500 A Welding current at 10 min / 40 °C (104 °F) 40 % d.c. 500 A 60 % d.c. 450 A 100% d.c. 360 A Welding voltage range according to standard characteristic TIME 28.0 — 48.0 V MIG/MAG 14.2 — 39.0 V Rod electrode…

Page 193: Cmt 4000 Advanced Mv

Max. welding voltage Open circuit voltage 90 V Degree of protection IP 23 Type of cooling Insulation class EMC emission class Marks of conformity Safety symbol Dimensions l x w x h 625 x 290 x 705 mm 24.61 x 11.42 x 27.76 in. Weight 54.2 kg 119.49 lb.

Page 195: Welding Program Databases

Welding program databases Explanation of The key symbols for the welding program databases are explained below. The databases symbols contain the welding programs depending on the following settings on the control panel: Mode: P = Pulse synergic welding S = Standard synergic welding CMT = Cold Metal Transfer C-P = CMT/pulse characteristic Welding programs that support the SFi (spatter free ignition) option have a grey back-…

Page 196: Terms And Abbreviations Used

Terms and abbreviations used General The terms and abbreviations listed here are used in connection with functions that are ei- ther included in the standard scope of supply or that are available as optional extras. Terms and abbre- AL.c viations A — C Arc length correction Up and down correction limits for the arc length (job correction) AL.1…

Page 197: Terms And Abbreviations G — I

Electrode line Characteristic selection (MMA welding) Frequency Frequency for SynchroPulse option Factory Reset welding system Feeder control Wire-feed unit cut-out (wire-end sensor option) Feeder creep Feeder creep speed Feeder inching Feeder inching speed Terms and abbre- viations G — I Gasflow Set value for shielding gas flow («Digital gas control»…

Page 198: Terms And Abbreviations S

L (inductivity) Displays welding circuit inductivity Power-correction Welding power correction (defined by the wire feed speed, job correction function) Power-Control For defining the Master or Slave power sources when two power sources are operated in parallel Power correction High Correction boundary (high) for the welding power (job correction) Power correction Low Correction boundary (low) for the welding power (job correction) Push-pull unit…

Page 201: Spare Parts List

Spare parts list…

Page 202: Spare Parts List: Transpuls Synergic 2700

Spare parts list: TransPuls Synergic 2700…

Page 205: Spare Parts List: Ts/Tps 3200/4000/5000, Time 5000

Spare parts list: TS/TPS 3200/4000/5000, TIME 5000…

Page 208: Spare Parts List: Cmt 4000 Advanced

Spare parts list: CMT 4000 Advanced…

Elgar CW 1251M

ELGAR ELECTRONICS CORPORATION 9250 Brown Deer Road San Diego, CA 92121-2294 1-800-733-5427 Tel: (858) 450-0085 Fax: (858) 458-0267 Email: [email protected] www.elgar.com CW-M SERIES AC POWER SOURCE Operation Manual This manual covers models: CW 801M CW 1251M CW 2501M ©2002 by Elgar Electronics Corporation This do …

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A Merit Series Power Conditioner is the perfect low-cost AC power solution for any rack mount system. Install an M-8x², M-8Lx, or M-8Dx in to the top slot of your rack, and the eight switched outlets in the rear panel will power up and protect all your equipment up to a 15-amp load. The M-8Lx and M-8Dx feature two sli …

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