Name: Fronius TPS 5000 MV
Brand: Fronius
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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

Table of Contents3
General Information4
Conversion Charts4
Overview5
Weld System6
Component Layout6
Weld System Configurations7
Power Source Mounted Wire Feeder7
Remote Mounted Wire Feeder8
Robot Mounted Wire Feeder9
Power Source10
Name Plate12
Tech Specs13
Connections – TPS 3200/4000/500014
Connections – TPS 270015
Connections – Tst 3500/500016
Connections – Tst Compact17
Wire Feeder18
Motor Plate20
Connections & Controls – VR 150021
Connections & Controls – VR 700022
Connections & Controls – VR 5000 Rob23
Connections & Controls – VR 5000 Manual24
Welding Torch25
Manual Torches25
Robotic Torches25
Cooler26
Cooling Units26
Weld Process Overview27
Shielded Metal Arc Welding (SMAW)27
Gas Tungsten Arc Welding (GTAW)27
Gas Metal Arc Welding (GWAW)27
Synergic Welding28
Synergic Line28
Transsynergic and Transpulsesynergic28
MIG – Short Circuit Transfer29
Short Circuit Transfer29
Globular Transfer29
Spray Transfer29
MIG – Pulsed Current Welding (Pulse)30
Pulse Welding (GMAW-P)30
Note Concerning Synergic Welding30
Gas Characteristics31
Inert Gases - Inert Mixed Gases31
Active Gases31
Overview of Active Mixed Gas32
Impact of CO2 on the Arc33
Gas Flow34
Fronius Options34
Gas Pressure Sensor (4,100,343)34
Digital Gas Sensor (4,100,374)34
Torch Movement and Handling35
Neutral Travel Angle35
Push Travel Angle35
Drag Travel Angle35
Discontinuity36
Excessive Reinforcement36
Undercut36
Insufficient Throat36
Overlap / Weld Bead Rollover37
Slag Inclusions37
Excessive Spatter37
Porosity37
Use and Operation38
Initial Set-Up and Turn on38
TS/TPS Quick Reference Cards Mig/Mag39
Operating Mode Parameters Menu39
Program and Delete a Job40
Access Software Versions/Arc on Time41
Special 4-Step42
Synchropuls42
Special 2-Step Automated System42
Arc Length Correction43
Pulse Correction43
Arc Force Correction43
MIG Correction Values44
Front Panel – Controls (TPS)45
Front Panel – Indicators (TPS)46
Front Panel – Controls (CMT)48
Front Panel – Indicators (CMT)49
Select a Synergic Line51
Checking Software51
Job Programing and Editing52
Resistance Test53
Push Pull Alignment54
PPU - Additional Information55
PPU Number for Push Pull Torch55
PPU Error Codes55
Functional Tests56
Cooler Verification56
Motor Draw Test57
Output Voltage Test57
Tst Parameter Reference (MIG)58
Tst Parameter Reference (Stick)59
To Enter 1St Lever Setup Menu for MMA Select59
1St Level Menu Parameters59
Front Panel – (Tst - Manual)60
Front Panel – (Tst - Synergic)61
Drive Rolls63
Consumables64
Liners64
Teflon64
Graphite64
Contact Tips65
Torch Breakdown – no Drive66
Torch Breakdown – Whip Drive67
Torch Breakdown - CMT68
Liner Installation Procedure69
Graphite/Teflon Liner Tools69
Feeder End of Torch70
Feeder and Cooler71
Manual Torch-Body Consumables72
Torch Drive Consumables76
Interface78
General Information79
Major Signals80
Major Digital Inputs (Robot to the Power Source)81
Major Analog Inputs (Robot to the Power Source)81
Gas Test81
Wire Inching/Retracting81
Major Digital Outputs (Power Source to the Robot)82
Signal Interaction – Job Mode84
Signal Interaction – Program Mode85
Fronius Xplorer86
General Info86
Overview Tab87
Job and Docu Tab88
Troubleshooting89
Welder Error Codes90
Torches91
Wire Feeder Error Codes92

Brand	Fronius
Model	TPS 5000 MV
Category	Welding System
Language	English

Fronius TPS 5000 MV User Manual

Table of Contents

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Fronius TPS 5000 MV Specifications

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