Fronius TransPuls Synergic 3200 Manuals

Manuals and User Guides for Fronius TransPuls Synergic 3200. We have 3 Fronius TransPuls Synergic 3200 manuals available for free PDF download: Operating Instructions Manual, Operating Instructions & Spare Parts, Service Manual

Fronius TransPuls Synergic 3200 Operating Instructions Manual

Fronius TransPuls Synergic 3200 Operating Instructions Manual (212 pages)

MIG/MAG power source

Brand: Fronius | Category: Welding Accessories | Size: 5.44 MB

Table of Contents

Parameters for Operating Power Sources in Parallel in the Setup Menu Level
2
Parameters for Timetwin Digital in the Setup Menu Level
2
Parameters for TIG Welding in the Setup Menu Level
2
Parameters for Rod Electrode (MMA) Welding in the Setup Menu Level
2
Table of Contents
3
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
Installation and Commissioning

71
- Minimum Equipment Needed for Welding Task
  73
  - General
    73
  - MIG/MAG Gas-Cooled Welding
    73
  - MIG/MAG Water-Cooled Welding
    73
  - MIG/MAG Automated Welding
    73
  - CMT Manual Welding
    73
  - CMT Automated Welding
    74
  - CMT Advanced Welding
    74
  - TIG DC Welding
    74
  - Manual Metal Arc Welding
    74
- Before Installation and Commissioning
  75
  - Safety
    75
  - Proper Use
    75
  - Setup Regulations
    75
  - 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
- Commissioning the CMT4000 Advanced
  93
Welding

95
- MIG/MAG Modes
  97
  - General
    97
  - Symbols and Their Explanations
    97
  - 2-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
  - Corrections During Welding
    102
  - Adjusting Parameters for Correction
    103
  - Remarks on the Standard Control Panel
    103
- MIG/MAG Standard Manual Welding
  104
  - General
    104
  - Available Parameters
    104
  - Corrections During Welding
    105
  - Adjusting Parameters for Correction
    106
- CMT Welding
  107
  - General
    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
Troubleshooting and Maintenance

173
- Troubleshooting
  175
  - General
    175
  - Safety
    175
  - Displayed Service Codes
    175
  - Power Source - Troubleshooting
    183
- Care, Maintenance and Disposal
  187
  - General
    187
  - Safety
    187
  - At Every Start-Up
    187
  - Every 2 Months
    187
  - Every 6 Months
    187
  - Disposal
    187
Appendix

189
- Technical Data
  191
  - Special Voltages
    191
  - 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

Fronius TransPuls Synergic 3200 Operating Instructions & Spare Parts

Fronius TransPuls Synergic 3200 Operating Instructions & Spare Parts (212 pages)

MIG/MAG Power source

Brand: Fronius | Category: AC Power Distribution | Size: 27.06 MB

Table of Contents

Table of Contents
5
Safety Rules
11
- Explanation of Safety Symbols
  11
- General
  11
- Intended Purpose
  12
- Environmental Conditions
  12
- Obligations of the Operator
  12
- Obligations of Personnel
  13
- Mains Connection
  13
- Protecting Yourself and Others
  13
- Noise Emission Values
  14
- Danger from Toxic Gases and Vapours
  14
- Danger from Flying Sparks
  15
- Risks from Mains Current and Welding Current
  15
- Meandering Welding Currents
  17
- EMC Device Classifications
  17
- EMC Measures
  17
- EMF Measures
  18
- Specific Hazards
  18
- Danger from Shielding Gas Cylinders
  20
- Safety Measures at the Installation Location and During Transport
  20
- Safety Measures in Normal Operation
  21
- Maintenance and Repair
  22
- Safety Inspection
  22
- Disposal
  22
- Safety Symbols
  22
- Data Protection
  23
- Copyright
  23
General Information

25
- General
  27
  - Device Concept
    27
  - Functional Principle
    27
  - Application Areas
    27
  - Warning Notices on the Device
    27
- Special Versions
  29
  - General
    29
  - Alu Edition
    29
  - Crni Edition
    29
  - CMT Variants
    29
  - CMT 4000 Advanced
    29
  - TIME 5000 Digital
    30
  - Yard Edition
    30
  - Steel Edition
    30
- System Components
  31
  - General
    31
  - Overview
    31
Control Elements and Connections

33
Installation and Commissioning

73
- Minimum Equipment Needed for Welding Task
  75
  - General
    75
  - MIG/MAG Gas-Cooled Welding
    75
  - MIG/MAG Water-Cooled Welding
    75
  - MIG/MAG Automated Welding
    75
  - CMT Manual Welding
    75
  - CMT Automated Welding
    76
  - CMT Advanced Welding
    76
  - TIG DC Welding
    76
  - Manual Metal Arc Welding
    76
- Before Installation and Commissioning
  77
  - Safety
    77
  - Proper Use
    77
  - Setup Regulations
    77
  - Mains Connection
    77
- Connecting up the Mains Cable on US Power Sources
  78
  - General
    78
  - Stipulated Mains Cables and Strain-Relief Devices
    78
  - Safety
    78
  - Connecting the Mains Cable
    78
  - Replacing the Strain-Relief Device
    79
- Start-Up
  81
  - Safety
    81
  - Remarks on the Cooling Unit
    81
  - Information on System Components
    81
  - 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
    83
  - Inserting the Wirespool
    84
  - Inserting the Basket-Type Spool
    84
  - Feeding in the Wire Electrode
    85
  - Setting the Contact Pressure
    86
  - Adjusting the Brake
    86
  - Design of the Brake
    87
- Commissioning the TS 4000 / 5000, TPS 3200 / 4000 / 5000, TIME 5000 Digital
  88
- Commissioning the CMT4000 Advanced
  92
Welding

95
- MIG/MAG Modes
  97
  - General
    97
  - Symbols and Their Explanations
    97
  - 2-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
  - Corrections During Welding
    102
  - Adjusting Parameters for Correction
    102
  - Remarks on the Standard Control Panel
    102
- MIG/MAG Standard Manual Welding
  103
  - General
    103
  - Available Parameters
    103
  - Corrections During Welding
    104
  - Adjusting Parameters for Correction
    104
- CMT Welding
  105
  - General
    105
  - Corrections During Welding
    106
  - Adjusting Parameters for Correction
    108
- Special Functions and Options
  109
  - Arc Break Watchdog Function
    109
  - Ignition Time-Out Function
    109
  - Spatter-Free Ignition Option
    109
  - Synchropulse Option
    110
- Robot Welding
  112
  - Prerequisite
    112
  - General
    112
  - Special 2-Step Mode for Robot Interface
    112
  - Wire-Stick Control Function
    113
  - Changing the Welding Process During CMT Advanced Welding
    113
- TIG Welding
  114
  - Safety
    114
  - Prerequisite
    114
  - Preparation
    114
  - Igniting the Arc
    115
  - Finishing Welding
    116
  - TIG Comfort Stop Option
    116
  - TIG Welding with TIG Comfort Stop
    118
- MMA Welding
  119
  - Safety
    119
  - Prerequisite
    119
  - Preparation
    119
  - Manual Metal Arc Welding
    119
  - Corrections During Welding
    120
  - Adjusting Parameters for Correction
    120
  - Hotstart Function
    120
  - Softstart Function
    121
  - Anti-Stick Function
    121
- Job Mode
  122
  - General
    122
  - Prerequisites
    122
  - Restrictions
    122
  - Job Mode Displays on the Left-Hand Digital Display
    122
  - Selecting Job Mode as the Process
    122
  - Creating a Job
    122
  - Retrieving a Job
    123
  - Copying/Overwriting a Job
    124
  - Deleting a Job
    125
Setup Settings

127
Troubleshooting and Maintenance

165
- Troubleshooting
  167
  - General
    167
  - Safety
    167
  - Displayed Service Codes
    167
  - Power Source - Troubleshooting
    175
- Care, Maintenance and Disposal
  179
  - General
    179
  - Safety
    179
  - At Every Start-Up
    179
  - Every 2 Months
    179
  - Every 6 Months
    179
  - Disposal
    179
Appendix

181
- Technical Data
  183
  - Special Voltages
    183
  - Tps 2700
    183
  - Tps 2700 MV
    184
  - Tps 3200
    185
  - Tps 3200 MV
    186
  - Tps 3200 460Vac
    187
  - Ts/Tps 4000
    188
  - Ts/Tps 4000 MV
    189
  - Ts/Tps 5000
    189
  - Ts/Tps 5000 MV
    190
  - Technical Data - US Devices
    191
  - Technical Data - Alu Edition, Crni Edition, Yard Edition and CMT Variants
    191
  - TIME 5000 Digital
    191
  - CMT 4000 Advanced
    192
  - CMT 4000 Advanced MV
    193
- Welding Program Databases
  195
  - Explanation of Symbols
    195
  - Setting up a Welding Program Database - Example
    195
- Terms and Abbreviations Used
  196
  - General
    196
  - Terms and Abbreviations a - C
    196
  - Terms and Abbreviations D - F
    196
  - Terms and Abbreviations G - I
    197
  - Terms and Abbreviations J - R
    197
  - Terms and Abbreviations S
    198
  - Terms and Abbreviations T - 2Nd
    198
Spare Parts List

201

Fronius TransPuls Synergic 3200 Service Manual

Fronius TransPuls Synergic 3200 Service Manual (140 pages)

MIG/MAG Power source

Brand: Fronius | Category: Power Supply | Size: 19.41 MB

Table of Contents

Table of Contents
3
Foreword and Safety Instructions
9
- Safety
  9
- Fronius Technical Support Center (TSC)
  9
- General Remarks
  9
- Function Overview
  10
- Fault Location Aid
  10
- Detailed Description
  10
- Changing Components
  10
- Terms and Abbreviations Used
  10
- Spare Parts List and Entire Circuit Diagram
  10
- Tools and Measuring Instruments
  10
Tools and Measuring Instruments
11
- General Remarks
  11
- Tools Required
  11
- Measuring and Inspection Equipment
  11
- Ancillary Materials
  11
Function Overview
12
- Principle of the Digital Family of Machines
  12
- Useful Information
  12
- Block Diagram
  13
- Block Diagram Legend
  13
Fault Location Aid
15
- General Remarks
  15
Fault Flowcharts
16
UST Service Codes
30
- Safety
  30
- Table of Service Codes
  30
- Special Displays Used with Service Codes
  36
Service Codes SR 4Xa
37
- Safety
  37
- Table of Service Codes
  37
Service Codes for Push-Pull Calibration
38
Detailed Description
41
- General Remarks
  41
- Position of Electronic Components
  41
- Overview
  41
ASU 27 - Additional PC Board
42
- General Remarks
  42
- Component Position in the Machine
  42
- Overview
  42
- Technical Data
  42
- Function Overview
  43
- Plug Layout
  43
- LED Checklist
  44
- Measuring Points
  44
ASU 40 - Additional PC Board
45
- General Remarks
  45
- Component Position in the Machine
  45
- Overview
  45
- Technical Data
  46
- Function Overview
  46
- Plug Layout
  46
- LED Checklist
  47
- Measuring Points
  48
BPS 25/BPT 27 - Power Module PC Board
49
- General Remarks
  49
- Component Position in the Machine
  49
- Overview
  49
- Technical Data
  50
- Function Overview
  50
- Plug Layout BPS 25/BPT 27
  50
- LED Checklist
  52
- Measuring Points
  52
BPS 32/40/42/43/50/53 - Power Module PC Board
54
- General Remarks
  54
- Component Position in the Machine
  54
- Overview
  54
- Technical Data
  55
- Function Overview
  55
- Plugs on the Power Module PC Boards
  56
- Plug Layout
  56
- LED Checklist of Power Module PC Boards
  58
- Measuring Points
  58
NT 24 - Switched Mode Power Supply 24 V
61
- General Remarks
  61
- Component Position in the Machine
  61
- Overview
  61
- Technical Data
  62
- Function Overview
  62
- Plug Layout
  62
- LED Checklist
  63
- Measuring Points
  63
NT 60 - Switched Mode Power Supply 60 V
65
- General Remarks
  65
- Component Position in the Machine
  65
- Overview
  65
- Technical Data
  66
- Function Overview
  66
- Plug Layout
  66
- LED Checklist
  67
- Measuring Points
  67
UST - Control and Regulation Unit
69
- General Remarks
  69
- Component Position in the Machine
  69
- Overview
  69
- Technical Data
  70
- Plug Layout
  70
- Function Overview
  70
- LED Checklist
  72
- Measuring Points
  72
- Changing UST PC Board
  72
NF 3160 - Line Filter
73
- General Remarks
  73
- Component Position in the Machine
  73
- Overview
  73
- Technical Data
  73
- Function Overview
  74
- Plug Layout
  74
- LED Checklist
  74
- Measuring Points
  74
NF 3400 - Line Filter/Line Filter 40 A/80 a
75
- General Remarks
  75
- Component Position in the Machine
  75
- Overview
  75
- Technical Data
  76
- Function Overview
  76
- Plug Layout NF 3400
  76
- Plug Layout Line Filter 40 A/80 a
  77
- LED Checklist
  77
- Measuring Points
  77
Shunt
78
- General Remarks
  78
- Component Position in the Machine
  78
- Overview
  78
- Technical Data
  79
- Function Overview
  79
- Plug Layout
  79
- LED Checklist
  79
- Measuring Points
  79
SR 41 - Wire-Feed Unit Regulation Unit
80
- General Remarks
  80
- Component Position in the Machine
  80
- Overview
  80
- Technical Data
  81
- Function Overview
  81
- Plug Layout
  81
- LED Checklist
  83
- Measuring Points
  84
Temperature Sensor TP 592S
85
- General Remarks
  85
- Component Position in the Machine
  85
- Technical Data
  86
- Function Overview
  86
- Plug Layout
  86
- Measuring Points
  86
Secondary Power Module TPS 2700
87
- General Remarks
  87
- Component Position in the Machine
  87
- Overview
  87
- Function Overview
  88
- Measuring Points
  88
Secondary Power Module TS 4000/5000, TPS 3200/4000/5000
89
- General Remarks
  89
- Component Position in the Machine
  89
- Overview
  90
- Function Overview
  90
- Measuring Points
  90
Primary Rectifier
91
- General Remarks
  91
- Component Position in the Machine
  91
- Overview
  91
- Function Overview
  91
- Plug Layout
  92
- Measuring Points
  92
Changing Components
93
- Safety
  93
- General Remarks
  93
- Overview
  93
Changing Throttle (TS 4000/5000, TPS 3200/4000/5000)
94
- Removing Throttle
  94
- Fitting Throttle
  95
Changing Throttle (TPS 2700)
97
- Removing Throttle
  97
- Fitting Throttle
  98
Changing Earth Current Watchdog
101
- Removing Earth Current Watchdog
  101
- Fitting Earth Current Watchdog
  102
Changing PC Board ASU 27 (TPS 2700 MV)
104
- Removing ASU 27
  104
- Fitting ASU 27
  104
Changing Shunt (TPS 2700)
105
- Removing Shunt
  105
- Fitting Shunt
  106
Changing Temperature Sensor TP 592S
108
- Notes
  108
Changing Transformer (TS 4000/5000, TPS 3200/4000/5000)
109
- Removing Transformer
  109
- Fitting Transformer
  110
Changing Transformer (TPS 2700)
112
- Removing Transformer
  112
- Fitting Transformer
  113
Changing Intermediate Circuit Capacitors (TS 4000/5000, TPS 3200/4000/5000)
115
- Removing Intermediate Circuit Capacitors
  115
- Fitting Intermediate Circuit Capacitors
  116
Safety Inspection
118
- General
  118
- Responsibility
  118
Visual Inspections
119
- General
  119
- General Conditions
  119
- Welding Torch/Electrode Holder/Welding Current Return Terminal
  119
- Mains Supply and Connecting Lines
  119
- Welding Circuit
  119
- Housing and Covers
  120
- Adjustment and Display Devices
  120
Electrical Tests
121
- Ground Conductor Resistance
  121
- Insulation Resistance
  122
- Open Circuit Voltage U0
  122
Function Tests
123
- General
  123
- Mains Power On/Off Equipment
  123
- Indicators and Controls
  123
- Gas Solenoid Valve
  123
- Earth Current Watchdog
  123
- Test Weld
  123
Documentation
124
- Test Record
  124
- Test Label
  124
Terms and Abbreviations Used
125
- General Remarks
  125
- Terms and Abbreviations
  125
Entire Circuit Diagram
127
- Storage Location
  127
Spare Parts List Circuit Diagram
129

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