Fronius TransPuls Synergic 3200 Source Manuals

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

Fronius TransPuls Synergic 3200 Operating Instructions Manual (212 pages)

MIG/MAG power source

Brand: Fronius | Category: Welding Accessories | Size: 5 MB

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 (212 pages)

MIG/MAG Power source

Brand: Fronius | Category: AC Power Distribution | Size: 27 MB

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 (140 pages)

MIG/MAG Power source

Brand: Fronius | Category: Power Supply | Size: 19 MB

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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Fronius TransPuls Synergic 3200 Source Manuals

Fronius TransPuls Synergic 3200 Operating Instructions Manual (212 pages)

Table of Contents

General Information

Control Elements and Connections

Installation and Commissioning

Welding

Setup Settings

Troubleshooting and Maintenance

Appendix

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

Table of Contents

General Information

Control Elements and Connections

Installation and Commissioning

Welding

Setup Settings

Troubleshooting and Maintenance

Appendix

Spare Parts List

Fronius TransPuls Synergic 3200 Service Manual (140 pages)

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