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EN
Operating Instructions
TPS 320i / 400i / 500i / 600i
TPS 400i LSC ADV
MIG/MAG Power source
42,0426,0114,EN 026-11092018
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Dear reader,
EN
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.
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Contents
EN
Safety rules ..................................................................................................................................................... 11
Explanation of safety symbols ................................................................................................................... 11
General ...................................................................................................................................................... 11
Proper use ................................................................................................................................................. 11
Mains connection ....................................................................................................................................... 12
Environmental conditions .......................................................................................................................... 12
Obligations of the operator ........................................................................................................................ 12
Obligations of personnel ............................................................................................................................ 13
Residual current protective device ............................................................................................................ 13
Protecting yourself and others ................................................................................................................... 13
Noise emission values ............................................................................................................................... 13
Danger from toxic gases and vapours ....................................................................................................... 14
Danger from flying sparks.......................................................................................................................... 14
Risks from mains current and welding current .......................................................................................... 14
Meandering welding currents .................................................................................................................... 15
EMC Device Classifications....................................................................................................................... 15
EMC measures .......................................................................................................................................... 16
EMF measures .......................................................................................................................................... 16
Specific hazards ........................................................................................................................................ 16
Factors affecting welding results ............................................................................................................... 17
Danger from shielding gas cylinders ......................................................................................................... 18
Danger from escaping shielding gas ......................................................................................................... 18
Safety measures at the installation location and during transport ............................................................. 18
Safety measures in normal operation ........................................................................................................ 19
Commissioning, maintenance and repair .................................................................................................. 19
Safety inspection ....................................................................................................................................... 20
Disposal ..................................................................................................................................................... 20
Safety symbols .......................................................................................................................................... 20
Data protection .......................................................................................................................................... 20
Copyright ................................................................................................................................................... 20
General information 21
General ........................................................................................................................................................... 23
Device concept .......................................................................................................................................... 23
Functional principle .................................................................................................................................... 23
Application areas ....................................................................................................................................... 23
FCC / RSS Compliance ............................................................................................................................. 24
Warning notices on the device .................................................................................................................. 25
Welding processes, procedures and welding characteristics for MIG/MAG welding ..................................... 26
General ...................................................................................................................................................... 26
Welding characteristics .............................................................................................................................. 26
Summary of MIG/MAG pulse synergic welding ......................................................................................... 27
Summary of MIG/MAG standard synergic welding ....................................................................................28
Summary of the PMC process .................................................................................................................. 28
Summary of the LSC / LSC Advanced process ........................................................................................ 28
Summary of SynchroPulse welding ........................................................................................................... 28
Summary of the CMT process ................................................................................................................... 29
Short description of the CMT Cycle Step welding process ........................................................................29
System components ....................................................................................................................................... 30
General ...................................................................................................................................................... 30
Overview .................................................................................................................................................... 30
Options ...................................................................................................................................................... 30
OPT/i Safety Stop PL d option .................................................................................................................. 32
Controls, connections and mechanical components 33
Control panel .................................................................................................................................................. 35
General ...................................................................................................................................................... 35
Safety......................................................................................................................................................... 35
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Control panel ............................................................................................................................................. 35
Connections, switches and mechanical components ..................................................................................... 37
TPS 320i / 400i / 500i / 600i, TPS 400i LSC ADV power source .............................................................. 37
Operating concept 39
Input options ................................................................................................................................................... 41
General ...................................................................................................................................................... 41
Turning/pressing the adjusting dial ............................................................................................................ 41
Pressing buttons ........................................................................................................................................ 42
Pressing on the display ............................................................................................................................. 42
Display and status line .................................................................................................................................... 43
Display ....................................................................................................................................................... 43
Status bar .................................................................................................................................................. 44
Status bar – Current limit reached ............................................................................................................. 45
Installation and commissioning 47
Minimum equipment needed for welding task ................................................................................................ 49
General ...................................................................................................................................................... 49
MIG/MAG gas-cooled welding ................................................................................................................... 49
MIG/MAG water-cooled welding ................................................................................................................ 49
MIG/MAG automated welding ................................................................................................................... 49
Manual CMT welding ................................................................................................................................. 49
Automated CMT welding ........................................................................................................................... 50
TIG DC welding ......................................................................................................................................... 50
MMA welding ............................................................................................................................................. 50
Before installation and commissioning ........................................................................................................... 51
Safety......................................................................................................................................................... 51
Proper use ................................................................................................................................................. 51
Setup regulations ....................................................................................................................................... 51
Mains connection ....................................................................................................................................... 51
Generator-powered operation ................................................................................................................... 52
Information on system components .......................................................................................................... 52
Connecting the mains cable ........................................................................................................................... 53
General ...................................................................................................................................................... 53
Stipulated mains cables............................................................................................................................. 53
Connecting the mains cable - general ....................................................................................................... 53
Commissioning the TPS 320i / 400i / 500i / 600i, TPS 400i LSC ADV .......................................................... 56
Safety......................................................................................................................................................... 56
General ...................................................................................................................................................... 56
TPS 320i / 400i / 500i / 600i: Fitting the system components (overview) .................................................. 57
TPS 400i LSC ADV: Fitting the system components (overview)............................................................... 58
Fixing the strain-relief device for the interconnecting hosepack ................................................................59
Connecting the interconnecting hosepack ................................................................................................ 59
Correct arrangement of the interconnecting hosepack ..............................................................................60
Connecting the gas cylinder ...................................................................................................................... 61
Establishing a ground earth connection .................................................................................................... 61
Connecting MIG/MAG welding torches to the wire-feed unit .....................................................................62
Other tasks ................................................................................................................................................ 63
Locking and unlocking the power source using the NFC key ..........................................................................64
General remarks ........................................................................................................................................ 64
Locking and unlocking the power source using the NFC key ................................................................... 64
Welding 67
MIG/MAG modes ............................................................................................................................................ 69
General ...................................................................................................................................................... 69
Symbols and their explanations ................................................................................................................ 69
2-step mode ............................................................................................................................................... 70
4- step mode ............................................................................................................................................... 70
Special 4-step mode .................................................................................................................................. 70
Special 2-step mode .................................................................................................................................. 70
Spot welding .............................................................................................................................................. 70
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MIG/MAG and CMT welding ........................................................................................................................... 71
EN
Safety......................................................................................................................................................... 71
MIG/MAG and CMT welding – overview ................................................................................................... 71
Switching on the power source ................................................................................................................. 71
Setting the welding process and operating mode ..................................................................................... 72
Selecting the filler metal and shielding gas ............................................................................................... 73
Setting the welding parameters ................................................................................................................. 74
Setting the shielding gas flow rate ............................................................................................................. 75
MIG/MAG or CMT welding ........................................................................................................................ 75
MIG/MAG and CMT welding parameters ....................................................................................................... 76
Welding parameters for MIG/MAG pulse synergic welding, for CMT welding and PMC welding ............. 76
Welding parameters for MIG/MAG standard synergic welding and LSC welding ..................................... 77
Welding parameters for MIG/MAG standard manual welding ................................................................... 78
Explanation of footnotes ............................................................................................................................ 78
EasyJob mode ................................................................................................................................................ 79
General ...................................................................................................................................................... 79
Activating EasyJob mode .......................................................................................................................... 79
Storing EasyJob operating points .............................................................................................................. 80
Retrieving EasyJob operating points ......................................................................................................... 80
Deleting EasyJob operating points ............................................................................................................ 81
Job mode ........................................................................................................................................................ 82
General ...................................................................................................................................................... 82
Storing settings as a job ............................................................................................................................ 82
Job welding - retrieving a job ..................................................................................................................... 83
Renaming a job ......................................................................................................................................... 84
Deleting a job ............................................................................................................................................. 85
Loading a job ............................................................................................................................................. 86
Optimise job ............................................................................................................................................... 87
Setting correction limits for a job ............................................................................................................... 88
Pre-settings for "Save as Job" ................................................................................................................... 90
Spot welding ................................................................................................................................................... 92
Spot welding .............................................................................................................................................. 92
TIG welding ..................................................................................................................................................... 94
Safety......................................................................................................................................................... 94
Preparations .............................................................................................................................................. 94
TIG welding ............................................................................................................................................... 95
Igniting the arc ........................................................................................................................................... 97
Finishing welding ....................................................................................................................................... 98
MMA welding .................................................................................................................................................. 99
Safety......................................................................................................................................................... 99
Preparations .............................................................................................................................................. 99
MMA welding ........................................................................................................................................... 100
Welding parameters for manual metal arc welding ................................................................................. 102
Process parameters 103
Overview ....................................................................................................................................................... 105
Overview - Process parameters, Common ............................................................................................. 105
Overview – components and monitoring process parameters ................................................................ 105
Overview – Process parameters, Job ..................................................................................................... 105
Process parameters, General ....................................................................................................................... 106
Process parameters for start of welding/end of welding.......................................................................... 106
Process parameters for gas setup .......................................................................................................... 108
Process parameters for process control .................................................................................................. 109
Penetration stabiliser ............................................................................................................................... 109
Arc length stabilizer ................................................................................................................................. 111
Combination of penetration stabiliser and arc length stabiliser ............................................................... 112
Process parameters for SynchroPulse .................................................................................................... 113
Process parameters for Process mix ...................................................................................................... 115
Process parameters for spot welding ...................................................................................................... 117
Process parameters for CMT Cycle Step ................................................................................................ 118
R/L-check / alignment .............................................................................................................................. 119
Process parameters for TIG / MMA/SMAW Setup ...................................................................................120
Components and monitoring process parameters ....................................................................................... 125
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Process parameters for components ...................................................................................................... 125
System calibration ................................................................................................................................... 126
Setting process parameters for arc break monitoring ............................................................................. 127
Process parameters for wire stick contact tip .......................................................................................... 129
Process parameters for wire stick work piece ......................................................................................... 130
Process parameter for wire end monitoring ............................................................................................ 132
Process parameters for gas monitoring .................................................................................................. 133
Process parameters, Job .............................................................................................................................. 135
Optimising job process parameters ......................................................................................................... 135
Process parameters for correction limits ................................................................................................. 137
Process parameters for "Save as Job" pre-settings ................................................................................ 138
Defaults 141
Defaults ......................................................................................................................................................... 143
General remarks ...................................................................................................................................... 143
Overview .................................................................................................................................................. 143
Defaults - view .............................................................................................................................................. 144
Setting the language ................................................................................................................................ 144
Setting Units/Standards ........................................................................................................................... 145
Setting the time and date......................................................................................................................... 146
Retrieving system data ............................................................................................................................ 147
Displaying characteristics ........................................................................................................................ 149
Defaults - System ......................................................................................................................................... 150
Retrieving device information .................................................................................................................. 150
Restoring factory settings ........................................................................................................................ 150
Restoring the website password ............................................................................................................. 151
Mode Setup: Activating the special 4-step mode "Guntrigger", special display for JobMaster and torch
trigger job selection...............................................................................................................................
152
Setting network parameters manually ..................................................................................................... 154
Power source configurations ................................................................................................................... 155
Wire feeder setup .................................................................................................................................... 156
Interface setup ......................................................................................................................................... 157
Defaults - Documentation ............................................................................................................................. 158
Setting the sampling rate ......................................................................................................................... 158
Viewing the logbook ................................................................................................................................ 159
Activate/deactivate limit value monitoring ............................................................................................... 160
Defaults - Administration .............................................................................................................................. 161
General remarks ...................................................................................................................................... 161
Explanation of terms used ....................................................................................................................... 161
Pre-defined roles and users .................................................................................................................... 161
Overview .................................................................................................................................................. 162
Administrator and creating roles ................................................................................................................... 163
Recommendation for creating roles and users........................................................................................ 163
Create administrator key ......................................................................................................................... 163
Creating roles .......................................................................................................................................... 165
Copy roles ............................................................................................................................................... 169
Creating a user ............................................................................................................................................. 171
Creating a user ........................................................................................................................................ 171
Copying users .......................................................................................................................................... 172
Editing roles / users, deactivating user management ................................................................................... 174
Editing roles ............................................................................................................................................. 174
Deleting roles ........................................................................................................................................... 175
Editing users ............................................................................................................................................ 176
Deleting users .......................................................................................................................................... 178
Deactivating user management ............................................................................................................... 179
SmartManager - The power source website 181
SmartManager - The power source website ................................................................................................ 183
General remarks ...................................................................................................................................... 183
Opening and logging into the power source SmartManager ................................................................... 183
Help function, should you be unable to log in .......................................................................................... 184
Changing password / logging off ............................................................................................................. 184
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Settings .................................................................................................................................................... 185
EN
Language selection ................................................................................................................................. 185
Status indicator ........................................................................................................................................ 186
Fronius ..................................................................................................................................................... 186
Current system data ..................................................................................................................................... 187
Current system data ................................................................................................................................ 187
Documentation, logbook ............................................................................................................................... 188
Documentation ........................................................................................................................................ 188
Job-Data ....................................................................................................................................................... 189
Job data ................................................................................................................................................... 189
Job overview ............................................................................................................................................ 189
Editing a job ............................................................................................................................................. 189
Importing a job ......................................................................................................................................... 190
Exporting a job ......................................................................................................................................... 190
Exporting job(s) as… ............................................................................................................................... 190
Power source settings .................................................................................................................................. 191
Power source settings ............................................................................................................................. 191
Backup & Restore ......................................................................................................................................... 192
General remarks ...................................................................................................................................... 192
Backup & Restore .................................................................................................................................... 192
Automatic backup .................................................................................................................................... 193
User management ........................................................................................................................................ 194
User management ................................................................................................................................... 194
Signal visualisation ....................................................................................................................................... 195
Signal visualisation .................................................................................................................................. 195
Overview ....................................................................................................................................................... 196
Overview .................................................................................................................................................. 196
Expand all groups / Reduce all groups .................................................................................................... 196
Save as XML-file ..................................................................................................................................... 196
Update .......................................................................................................................................................... 197
Update ..................................................................................................................................................... 197
Searching for an update file (performing the update) .............................................................................. 197
Fronius WeldConnect .............................................................................................................................. 198
Function Packages ....................................................................................................................................... 199
Function Packages .................................................................................................................................. 199
Welding Packages ................................................................................................................................... 199
Special characteristics ............................................................................................................................. 199
Options .................................................................................................................................................... 199
Installing a function package ................................................................................................................... 199
Synergic lines overview ................................................................................................................................ 200
Characteristics overview .......................................................................................................................... 200
Show /hide filter ....................................................................................................................................... 200
Screenshot .................................................................................................................................................... 201
Screenshot .............................................................................................................................................. 201
Interface ........................................................................................................................................................ 202
Interface ................................................................................................................................................... 202
Troubleshooting and maintenance 203
Troubleshooting ............................................................................................................................................ 205
General .................................................................................................................................................... 205
Safety....................................................................................................................................................... 205
MIG/MAG welding – Current limit ............................................................................................................ 205
Power source troubleshooting ................................................................................................................. 205
Care, maintenance and disposal .................................................................................................................. 209
General .................................................................................................................................................... 209
Safety....................................................................................................................................................... 209
At every start-up ...................................................................................................................................... 209
Every 2 months ........................................................................................................................................ 209
Every 6 months ........................................................................................................................................ 209
Updating firmware ................................................................................................................................... 209
Disposal ................................................................................................................................................... 209
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Appendix 211
Technical data .............................................................................................................................................. 213
Explanation of the term "duty cycle" ........................................................................................................ 213
Special voltages ...................................................................................................................................... 213
TPS 320i .................................................................................................................................................. 214
TPS 320i /nc ............................................................................................................................................ 215
TPS 320i /600V/nc ................................................................................................................................... 216
TPS 320i /MV/nc ...................................................................................................................................... 217
TPS 400i .................................................................................................................................................. 218
TPS 400i /nc ............................................................................................................................................ 219
TPS 400i /600V/nc ................................................................................................................................... 220
TPS 400i /MV/nc ...................................................................................................................................... 221
TPS 400i LSC ADV ................................................................................................................................. 222
TPS 400i LSC ADV /nc .......................................................................................................................... 223
TPS 400i LSC ADV /600V/nc ................................................................................................................ 224
TPS 400i LSC ADV /MV/nc ................................................................................................................... 225
TPS 500i .................................................................................................................................................. 226
TPS 500i /nc ............................................................................................................................................ 227
TPS 500i /600V/nc ................................................................................................................................... 228
TPS 500i /MV/nc ...................................................................................................................................... 229
TPS 600i .................................................................................................................................................. 230
TPS 600i /nc ............................................................................................................................................ 231
TPS 600i /600V/nc ................................................................................................................................... 232
Spare parts list: TPS 320i / 400i / 500i / 600i .............................................................................................. 233
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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. If it is not
avoided, minor injury and/or damage to property may result.
Safety rules
DANGER! Indicates immediate and real danger. If it is not avoided, death or se-
rious injury will result.
EN
Explanation of
safety symbols
NOTE! Indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT! Indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.
If you see any of the symbols depicted in the "Safety rules" chapter, special care is re-
quired.
General The device is manufactured using state-of-the-art technology and according to recognised
safety standards. If used incorrectly or misused, however, it can cause:
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operating company,
- inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing the device
must:
- be suitably qualified,
- have sufficient knowledge of welding and
- read and follow these operating instructions carefully.
The operating instructions must always be at hand wherever the device is being used. In
addition to the operating instructions, attention must also be paid to any generally applicable and local regulations regarding accident prevention and environmental protection.
All safety and danger notices on the device
- must be in a legible state,
- must not be damaged,
- must not be removed,
- must not be covered, pasted or painted over.
For the location of the safety and danger notices on the device, refer to the section headed
"General" in the operating instructions for the device.
Before switching on the device, rectify any faults that could compromise safety.
This is for your personal safety!
Proper use The device is to be used exclusively for its intended purpose.
The device is intended solely for the welding processes specified on the rating plate.
Any use above and beyond this purpose is deemed improper. The manufacturer shall not
be held liable for any damage arising from such usage.
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Proper use includes:
NOTE! Ensure that the mains connection is earthed properly
- carefully reading and following all the instructions given in the operating instructions
- studying and obeying all safety and danger notices carefully
- performing all stipulated inspection and maintenance work.
Never use the device for the following purposes:
- Thawing out pipes
- Charging batteries
- Starting engines
The device is designed for use in industry and the workshop. The manufacturer accepts
no responsibility for any damage caused through use in a domestic setting.
The manufacturer likewise accepts no liability for inadequate or incorrect results.
Mains connection Devices with a higher rating may affect the energy quality of the mains due to their current
consumption.
This may affect a number of types of device in terms of:
- connection restrictions
- criteria with regard to the maximum permissible mains impedance
- criteria with regard to the minimum short-circuit power requirement
*)
at the interface with the public grid
see Technical Data
In this case, the plant operator or the person using the device should check whether the
device may be connected, where appropriate by discussing the matter with the power supply company.
*)
*)
Environmental
conditions
Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage.
Ambient temperature range:
- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
Relative humidity:
- up to 50% at 40 °C (104 °F)
- up to 90% at 20 °C (68 °F)
The surrounding air must be free from dust, acids, corrosive gases or substances, etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)
Obligations of the
operator
The operator must only allow persons to work with the device who:
- are familiar with the fundamental instructions regarding safety at work and accident
prevention and have been instructed in how to use the device
- have read and understood these operating instructions, especially the section "safety
rules", and have confirmed as much with their signatures
- are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are working in a
safety-conscious manner.
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EN
Obligations of
personnel
Before using the device, all persons instructed to do so undertake:
- 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 workplace, ensure that people or property cannot come to any harm in
your absence.
Residual current
protective device
Local regulations and national guidelines may require a residual current protective device
when connecting equipment to the public grid.
The type of residual current protective device recommended by the manufacturer for the
equipment is indicated in the technical data.
Protecting yourself and others
Anyone working with the device exposes themselves to numerous risks, e.g.
- flying sparks and hot pieces of metal
- Arc radiation, which can damage eyes and skin
- Hazardous electromagnetic fields, which can endanger the lives of those using cardiac pacemakers
- Risk of electrocution from mains current and welding current
- Greater noise pollution
- Harmful welding fumes and gases
Suitable protective clothing must be worn when working with the device. The protective
clothing must have the following properties:
- Flame-resistant
- Insulating and dry
- Covers the whole body, is undamaged and in good condition
- Safety helmet
- Trousers with no turn-ups
Protective clothing refers to a variety of different items. Operators should:
- 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 protective visor
- Wear stout footwear that provides insulation even in wet conditions
- Protect the hands with suitable gloves (electrically insulated and providing protection
against heat)
- Wear ear protection to reduce the harmful effects of noise and to prevent injury
Keep all persons, especially children, out of the working area while any devices are in operation or welding is in progress. If, however, there are people in the vicinity:
- Make them aware of all the dangers (risk of dazzling by the arc, injury from flying
sparks, harmful welding fumes, noise, possible risks from mains current and welding
current, etc.)
- Provide suitable protective equipment
- Alternatively, erect suitable safety screens/curtains.
Noise emission
values
The device generates a maximum sound power level of <80 dB(A) (ref. 1pW) when idling
and in the cooling phase following operation at the maximum permissible operating point
under maximum rated load conditions according to EN 60974-1.
It is not possible to provide a workplace-related emission value during welding (or cutting)
as this is influenced by both the process and the environment. All manner of different welding parameters come into play, including the welding process (MIG/MAG, TIG welding), the
type of power selected (DC or AC), the power range, the type of weld metal, the resonance
characteristics of the workpiece, the workplace environment, etc.
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Danger from toxic
gases and vapours
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that may, under certain circumstances, cause birth de-
fects or cancer.
Keep your face away from welding fumes and gases.
Fumes and hazardous gases
- must not be breathed in
- must be extracted from the working area using appropriate methods.
Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/hour.
Otherwise, a protective mask with an air supply must be worn.
Close the shielding gas cylinder valve or main gas supply if no welding is taking place.
If there is any doubt about whether the extraction capacity is sufficient, the measured toxic
emission values should be compared with the permissible limit values.
Amongst others, the following components are responsible for the degree of toxicity of
welding fumes:
- Metals used for the workpiece
- Electrodes
- Coatings
- Cleaners, degreasers, etc.
The relevant material safety data sheets and manufacturer's specifications for the listed
components should therefore be studied carefully.
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation area.
Danger from flying sparks
Flying sparks may cause fires or explosions.
Never weld close to flammable materials.
Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the arc, or al-
ternatively covered with an approved cover.
A suitable, tested fire extinguisher must be available and ready for use.
Sparks and pieces of hot metal may also get into adjacent areas through small gaps or
openings. Take appropriate precautions to prevent any danger of injury or fire.
Welding must not be performed in areas that are subject to fire or explosion or near sealed
tanks, vessels or pipes unless these have been prepared in accordance with the relevant
national and international standards.
Do not carry out welding on containers that are being or have been used to store gases,
propellants, mineral oils or similar products. Residues pose an explosive hazard.
Risks from mains
current and weld-
ing current
An electric shock is potentially life threatening and can be fatal.
Do not touch live parts either inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed rollers
and all pieces of metal that are in contact with the welding wire are live.
Always set the wirefeeder up on a sufficiently insulated surface or use a suitable, insulated
wirefeeder holder.
Make sure that you and others are protected with an adequately insulated, dry temporary
backing or cover for the earth or ground potential. This temporary backing or cover must
extend over the entire area between the body and the earth or ground potential.
All cables and leads must be secured, undamaged, insulated and adequately dimensioned. Replace loose connections and scorched, damaged or inadequately dimensioned
cables and leads immediately.
15
Use the handle to ensure the power connections are tight before every use.
EN
In the case of power cables with a bayonet connector, rotate the power cable around the
longitudinal axis by at least 180° and pre-load.
Do not wrap cables or leads around the body or parts of the body.
The electrode (rod electrode, tungsten electrode, welding wire, etc.) must
- never be immersed in liquid for cooling
- Never touch the electrode when the power source is switched on.
Double the open circuit voltage of a power source can occur between the welding electrodes of two power sources. Touching the potentials of both electrodes at the same time
may be fatal under certain circumstances.
Arrange for the mains cable to be checked regularly by a qualified electrician to ensure the
ground conductor is functioning properly.
The device must only be operated on a mains supply with a ground conductor and a socket
with a ground conductor contact.
Operating the device on a grid without a ground conductor and in a socket without a ground
conductor contact will be deemed gross negligence. The manufacturer shall not be held
liable for any damage arising from such usage.
If necessary, provide an adequate earth connection for the workpiece.
Switch off unused devices.
Wear a safety harness if working at height.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to prevent any-
one from plugging the mains plug back in and switching it on again.
After opening the device:
- Discharge all live components
- Ensure that all components in the device are de-energised
If work on live parts is required, appoint a second person to switch off the main switch at
the right moment.
Meandering welding currents
If the following instructions are ignored, meandering welding currents can develop with the
following consequences:
- Fire hazard
- Overheating of parts connected to the workpiece
- Irreparable damage to ground conductors
- Damage to device and other electrical equipment
Ensure that the workpiece is held securely by the workpiece clamp.
Attach the workpiece clamp as close as possible to the area that is to be welded.
If the floor is electrically conductive, the device must be set up with sufficient insulating ma-
terial to insulate it from the floor.
If distribution boards, twin-head mounts, etc., are being used, note the following: The elec-
trode of the welding torch / electrode holder that is not used is also live. Make sure that the
welding torch / electrode holder that is not used is kept sufficiently insulated.
In the case of automated MIG/MAG applications, ensure that only an insulated wire electrode is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeed unit.
EMC Device Classifications
Devices in emission class A:
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
16
Devices in emission class B:
- Satisfy the emissions criteria for residential and industrial areas. This is also true for
residential areas in which the energy is supplied from the public low-voltage mains.
EMC device classification as per the rating plate or technical data.
EMC measures In certain cases, even though a device complies with the standard limit values for emis-
sions, it may affect the application area for which it was designed (e.g. when there is sensitive equipment at the same location, or if the site where the device is installed is close to
either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rectify the situation.
Check and evaluate the immunity to interference of nearby devices according to national
and international regulations. Examples of equipment that may be susceptible to interference from the device include:
- Safety devices
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite correct mains connection, addition-
al measures are necessary (e.g. use a suitable line filter).
2. Welding power leads
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
5. Shielding, if necessary
- Shield off other nearby devices
- Shield off entire welding installation
EMF measures Electromagnetic fields may pose as yet unknown risks to health:
- effects on the health of others in the vicinity, e.g. wearers of pacemakers and hearing
aids
- wearers of pacemakers must seek advice from their doctor before approaching the device or any welding that is in progress
- for safety reasons, keep distances between the welding cables and the welder's head/
torso as large as possible
- do not carry welding cables and hosepacks over the shoulders or wind them around
any part of the body
Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example:
- Fans
- Cogs
- Rollers
- Shafts
- Wirespools and welding wires
Do not reach into the rotating cogs of the wire drive or into rotating drive components.
Covers and side panels may only be opened/removed while maintenance or repair work is
being carried out.
17
During operation
NOTE! There is an increased risk of soiling if ring mains are being used
EN
- Ensure that all covers are closed and all side panels are fitted properly.
- Keep all covers and side panels closed.
The welding wire emerging from the welding torch poses a high risk of injury (piercing of
the hand, injuries to the face and eyes, etc.).
Therefore always keep the welding torch away from the body (devices with wire-feed unit)
and wear suitable protective goggles.
Never touch the workpiece during or after welding - risk of burns.
Slag can jump off cooling workpieces. The specified protective equipment must therefore
also be worn when reworking workpieces, and steps must be taken to ensure that other
people are also adequately protected.
Welding torches and other parts with a high operating temperature must be allowed to cool
down before handling.
Special provisions apply in areas at risk of fire or explosion - observe relevant
national and international regulations.
Power sources for work in areas with increased electric risk (e.g. near boilers) must carry
the "Safety" sign. However, the power source must not be located in such areas.
Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting coolant flow or return lines.
Observe the information on the coolant safety data sheet when handling coolant. The coolant safety data sheet may be obtained from your service centre or downloaded from the
manufacturer's website.
Use only suitable load-carrying equipment supplied by the manufacturer when transporting
devices by crane.
- Hook chains and/or ropes onto all suspension points provided on the load-carrying
equipment.
- Chains and ropes must be at the smallest angle possible to the vertical.
- Remove gas cylinder and wire-feed unit (MIG/MAG and TIG devices).
If the wire-feed unit is attached to a crane holder during welding, always use a suitable,
insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).
If the device has a carrying strap or handle, this is intended solely for carrying by hand. The
carrying strap is not to be used if transporting with a crane, counterbalanced lift truck or
other mechanical hoist.
All lifting accessories (straps, handles, chains, etc.) used in connection with the device or
its components must be tested regularly (e.g. for mechanical damage, corrosion or changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national standards
and directives as a minimum.
Odourless and colourless shielding gas may escape unnoticed if an adapter is used for the
shielding gas connection. Prior to assembly, seal the device-side thread of the adapter for
the shielding gas connection using suitable Teflon tape.
Factors affecting
welding results
The following requirements with regard to shielding gas quality must be met if the welding
system is to operate in a correct and safe manner:
- Size of solid matter particles < 40 μm
- Pressure dew point < -20 °C
- Max. oil content < 25 mg/m³
Filters must be used if necessary.
18
Danger from
shielding gas cylinders
Shielding gas cylinders contain gas under pressure and can explode if damaged. As the
shielding gas cylinders are part of the welding equipment, they 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.
Mount the shielding gas cylinders vertically and secure according to instructions to prevent
them falling over.
Keep the shielding gas cylinders well away from any welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.
Only use shielding gas cylinders suitable for the application in hand, along with the correct
and appropriate accessories (regulator, hoses and fittings). Only use shielding gas cylinders and accessories that are in good condition.
Turn your face to one side when opening the valve of a shielding gas cylinder.
Close the shielding gas cylinder valve if no welding is taking place.
If the shielding gas cylinder is not connected, leave the valve cap in place on the cylinder.
The manufacturer's instructions must be observed as well as applicable national and inter-
national regulations for shielding gas cylinders and accessories.
Danger from escaping shielding
gas
Risk of suffocation from the uncontrolled escape of shielding gas
Shielding gas is colourless and odourless and, in the event of a leak, can displace the ox-
ygen in the ambient air.
- Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/hour.
- Observe safety and maintenance instructions on the shielding gas cylinder or the main
gas supply.
- Close the shielding gas cylinder valve or main gas supply if no welding is taking place.
- Check the shielding gas cylinder or main gas supply for uncontrolled gas leakage before every start-up.
Safety measures
at the installation
location and during transport
A device toppling over could easily kill someone. Place the device on a solid, level surface
such that it remains stable
- The maximum permissible tilt angle is 10°.
Special regulations apply in rooms at risk of fire or explosion
- Observe relevant national and international regulations.
Use internal directives and checks to ensure that the workplace environment is always
clean and clearly laid out.
Only set up and operate the device in accordance with the degree of protection shown on
the rating plate.
When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft. 7.69 in.)
to ensure that cooling air can flow in and out freely.
When transporting the device, observe the relevant national and local guidelines and accident prevention regulations. This applies especially to guidelines regarding the risks arising during transport.
Do not lift or transport operational devices. Switch off devices before transport or lifting.
19
Before transporting the device, allow coolant to drain completely and detach the following
EN
components:
- Wirefeeder
- Wirespool
- Shielding gas cylinder
After transporting the device, the device must be visually inspected for damage before
commissioning. Any damage must be repaired by trained service technicians before commissioning the device.
Safety measures
in normal operation
Only operate the device when all safety devices are fully functional. If the safety devices
are not fully functional, there is a risk of
- injury or death to the operator or a third party
- damage to the device and other material assets belonging to the operator
- inefficient operation of the device
Any safety devices that are not functioning properly must be repaired before switching on
the device.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper functioning of safety
devices.
Always fasten the shielding gas cylinder securely and remove it beforehand if the device
is to be transported by crane.
Only the manufacturer's original coolant is suitable for use with our devices due to its prop-
erties (electrical conductibility, anti-freeze agent, material compatibility, flammability, etc.).
Only use suitable original coolant from the manufacturer.
Do not mix the manufacturer's original coolant with other coolants.
Only connect the manufacturer's system components to the cooling circuit.
The manufacturer accepts no liability for damage resulting from use of other system com-
ponents or a different coolant. In addition, all warranty claims will be forfeited.
Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under cer-
tain conditions. Transport the coolant only in its original, sealed containers and keep well
away from any sources of ignition.
Used coolant must be disposed of properly in accordance with the relevant national and
international regulations. The coolant safety data sheet may be obtained from your service
centre or downloaded from the manufacturer's website.
Check the coolant level before starting to weld, while the system is still cool.
Commissioning,
maintenance and
repair
It is impossible to guarantee that bought-in parts are designed and manufactured to meet
the demands made of them, or that they satisfy safety requirements.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without the manufacturer's consent.
- Components that are not in perfect condition must be replaced immediately.
- When ordering, please give the exact designation and part number as shown in the
spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the housing
parts.
Only use original housing screws in the correct number and tightened to the specified
torque.
20
Safety inspection The manufacturer recommends that a safety inspection of the device is performed at least
once every 12 months.
The manufacturer recommends that the power source be calibrated during the same 12-
month period.
A safety inspection should be carried out by a qualified electrician
- after any changes are made
- after any additional parts are installed, or after any conversions
- after repair, care and maintenance has been carried out
- at least every twelve months.
For safety inspections, follow the appropriate national and international standards and directives.
Further details on safety inspection and calibration can be obtained from your service centre. They will provide you on request with any documents you may require.
Disposal Do not dispose of this device with normal domestic waste! To comply with the European
Directive on Waste Electrical and Electronic Equipment and its implementation as national
law, electrical equipment that has reached the end of its life must be collected separately
and returned to an approved recycling facility. Any device that you no longer require must
either be returned to your dealer or given to one of the approved collection and recycling
facilities in your area. Ignoring this European Directive may have potentially adverse affects on the environment and your health!
Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage and elec-
tromagnetic compatibility directives (e.g. relevant product standards of the EN 60 974 series).
Fronius International GmbH hereby declares that the device is compliant with Directive
2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following
address: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant standards
for Canada and the USA.
Data protection The user is responsible for the safekeeping of any changes made to the factory 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. The contents of the operating instructions shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for
improvement, or can point out any mistakes that you have found in the instructions, we will
be most grateful for your comments.
General information
23
General
EN
Device concept
The MIG/MAG power sources TPS 320i,
TPS 400i, TPS 500i and TPS 600i are completely digitised, microprocessor-controlled
inverter power sources.
The modular design and potential for system add-ons ensure a high degree of flexibility. The devices can be adapted to any
specific situation.
Functional principle
The central control and regulation unit of the power sources is coupled with a digital signal
processor. The central control and regulation unit and the signal processor control the entire welding process.
During the welding process, the actual data is measured continuously and the device responds immediately to any changes. Control algorithms ensure that the desired target
state is maintained.
This results in:
- a precise welding process
- exact reproducibility of all results
- excellent weld properties.
Application areas The devices are used in workshops and industry for manual and automated applications
with classical steel, galvanised sheets, chrome/nickel and aluminium.
The power sources are designed for:
- Automobile and component supply industry
- Machine manufacturing and rail vehicle construction
- Chemical plant construction
- Equipment construction
- Shipyards, etc.
24
FCC / RSS Com-
pliance
FCC
Note: This equipment has been tested and found to comply with the limits
for a Class A digital device, pursuant to part 15 of the FCC Rules.
These limits are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial environment.
This equipment generates, uses, and can radiate radio frequency energy
and, if not installed and used in accordance with the instruction manual,
may cause harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interference in
which case the user will be required to correct the interference at his own
expense.
FCC ID: QKWSPBMCU2
Industry Canada RSS
This device contains licence-exempt transmitter(s)/receiver(s) that comply
with Innovation, Science and Economic Development Canada’s licenceexempt RSS(s). Operation is subject to the following two conditions:
(1) This device may not cause interference
(2) This device must accept any interference, including interference
that may cause undesired operation of the device.
L’émetteur/récepteur exempt de licence contenu dans le présent appareil
est conforme aux CNR d’Innovation, Sciences et Développement
économique Canada applicables aux appareils radio exempts de licence.
L’exploitation est autorisée aux deux conditions suivantes :
(1) L’appareil ne doit pas produire de brouillage;
(2) L’appareil doit accepter tout brouillage radioélectrique subi, même
sile brouillage est susceptible d’en compromettre le
fonctionnement.
IC: 12270A-SPBMCU2
The antenna(s) used for this transmitter must be installed to provide a separation
distance of at least 20 cm from all persons and must not be co-located or operating
in conjunction with any other antenna or transmitter. OEM integrators and End-Users
must be provided with transmitter operation conditions for satisfying RF exposure
compliance.
25
EN
Warning notices
on the device
Warning notices and safety symbols are affixed to power sources with the CSA test mark
for use in North America (USA and Canada). These warnings and safety symbols must not
be removed or painted over. They warn against operating the device incorrectly, as this
may result in serious injury and damage.
Safety symbols on the rating plate:
Welding is dangerous. The following basic requirements must be met:
- Welders must be sufficiently qualified
- Suitable protective equipment must be used
- All persons not involved in the welding process must be kept at a safe distance
Do not use the functions described here until you have thoroughly read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safety
rules.
26
Welding processes, procedures and welding characteristics for MIG/MAG welding
General TPSi power sources contain a selection of welding processes, procedures and welding
characteristics that enable a wide range of materials to be processed in the most effective
way.
Welding characteristics
Depending on the welding process and shielding gas mix, various process-optimised welding characteristics are available when selecting the filler metal.
Examples of welding characteristics:
- MIG/MAG 3700 PMC Steel 1,0mm M21 - arc blow (*)
- MIG/MAG 3450 PMC Steel 1,0mm M21 - dynamic (*)
The additional designation (*) next to the welding process provides information about the
special properties and use of the welding characteristic:
Special welding characteristic properties
arc blow Characteristics with improved arc break properties by deflecting the
arcing Characteristics for a special type of hardfacing on a wet or dry surface
braze Characteristics for brazing processes (high brazing speed, reliable
braze+ Optimised characteristics for brazing processes with special "Braze+"
cladding Characteristics for cladding with low penetration, low dilution and
dynamic Characteristics for high welding speeds with concentrated arc
galvanized Characteristics for galvanised sheet surfaces (low zinc pore risk, re-
gap bridging Characteristics with very low heat input for optimum gap-bridging abil-
multi arc Characteristics for components being welding by several interfering
pipe Characteristics for pipe applications and positional welding on narrow
root Characteristics for root passes with powerful arc
universal Characteristics for conventional welding tasks
TWIN Synchronised characteristics for two wire electrodes in a single weld
external magnetic fields
(e.g. grinding rollers in the sugar and ethanol industries)
wetting and good flow of braze material)
gas nozzle (narrow gas nozzle opening, high shielding gas flow rate)
wide weld seam flow for improved wetting
duced zinc melting loss)
ity
arcs
gap applications
pool (TANDEM welding process)
27
Mixed process characteristics
EN
mix Characteristics with process switch between pulsed and dip transfer
arc
Specifically for welding vertical-up seams with cyclic change between
a hot and cold supporting process phase.
PCS Pulse Controlled Spray Arc
Direct transition from the concentrated pulsed arc to a short spray arc.
The advantages of pulsed and standard arcs combined in a single
characteristic.
Special welding characteristic properties provided by additional hardware
ADV Additional hardware for the CMT welding process:
Inverter module for alternating current processes
Negatively poled process phase with low heat input and high deposi-
tion rate
Additional hardware for the MIG/MAG LSC welding process:
Electronic switch for interrupting power
Maximum reduction in current caused by opening the circuit in each
required process phase
Only in combination with TPS 400i LSC ADV
CMT mix Additional hardware:
CMT drive unit
Characteristics with process switch between pulsed and CMT, where
the CMT process is initiated by wire movement reversal.
mix drive Additional hardware:
PushPull drive unit
Characteristics with process switch between pulsed and dip transfer
arc, where the dip transfer arc is initiated by wire movement reversal.
ripple drive Additional hardware:
CMT drive unit, RA Drive
Characteristics that behave like interval mode for clear weld rippling,
especially with aluminium
Summary of MIG/
MAG pulse synergic welding
MIG/MAG pulse synergic
MIG/MAG pulse synergic welding is a pulsed-arc process with controlled material transfer.
In the base current phase, the energy supply is reduced to such an extent that the arc is
only just stable and the surface of the workpiece is preheated. In the pulsing current phase,
a precise current pulse ensures the targeted detachment of a droplet of welding material.
This principle guarantees a low-spatter weld and precise working across the entire power
range, as unwelcome short circuits with simultaneous droplet explosion and uncontrolled
welding spatter are virtually eliminated.
28
Summary of MIG/
MAG standard
synergic welding
MIG/MAG standard synergic
The MIG/MAG standard synergic welding process is a MIG/MAG welding process across
the entire power range of the power source with the following arc types:
Short circuit arc
Droplet transfer takes place during a short circuit in the lower power range.
Intermediate arc
The droplet increases in size on the end of the wire electrode and is transferred in the midpower range during the short circuit.
Spray arc
A short circuit-free transfer of material in the high power range.
Summary of the
PMC process
PMC = Pulse Multi Control
PMC is a pulsed arc welding process with high-speed data processing, precise recording
of the process status and improved droplet detachment. Faster welding possible with a stable arc and even fusion penetration.
Summary of the
LSC / LSC Ad-
vanced process
LSC = Low Spatter Control
LSC is a new, low-spatter dip transfer arc process.
The current is reduced before breaking the short-circuit bridge; re-ignition takes place at
significantly lower welding current values.
LSC Advanced
The TPS 400i LSC ADV is required for the LSC Advanced process.
The TPS 400i LSC ADV accelerates the reduction in current and improves the LSC properties. The LSC Advanced process is predominantly used when the welding circuit inductivity is higher.
Summary of SynchroPulse welding
SynchroPulse is available for all processes (standard/pulsed/LSC/PMC).
Due to the cyclical change of welding power between two operating points, SynchroPulse
achieves a flaking seam appearance and non-continuous heat input.
29
EN
Summary of the
CMT process
CMT = Cold Metal Transfer
A special CMT drive unit is required for the CMT process.
The reversing wire movement in the CMT process results in a droplet detachment with im-
proved dip transfer arc properties.
The advantages of the CMT process are as follows
- Low heat input
- Less spattering
- Reduced emissions
- High process stability
The CMT process is suitable for:
- Joint welding, cladding and brazing – particularly in the case of high requirements in
terms of heat input and process stability
- Welding on light-gauge sheet with minimal distortion
- Special connections, such as copper, zinc, and steel/aluminium
NOTE! A CMT reference book is available complete with typical applications; see
ISBN 978-3-8111-6879-4.
Short description
of the CMT Cycle
Step welding process
CMT Cycle Step is the next step in the development of the CMT welding process. A special
CMT drive unit is also required for this process.
CMT Cycle Step is the welding process with the lowest heat input.
The CMT Cycle Step welding process switches cyclically between CMT welding and pauses of an adjustable duration.
These pauses in the welding process lower the heat input; the continuity of the weld seam
is maintained.
Individual CMT cycles are also possible. The size of the CMT spot welds is determined by
the number of CMT cycles.
30
System components
(1)
(2a)
(7)
(4)
(3)
(2)
(6)
(5)
General The power sources can be operated 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.
Overview
(1) Cooling units also:
(2) Power sources
(2a) TPS 400i LSC ADV power source
(3) Robot accessories
(4) Interconnecting hosepacks
(max. 50 m)*
(5) Wirefeeders
(6) Wirefeeder holder
(7) Trolley and gas cylinder holders
- Welding torch
- Grounding (earthing) cable and electrode cable
- Dust filter
- Additional current sockets
Options
* Interconnecting hosepacks > 50 m only in combination with optional
OPT/i SpeedNet Repeater
OPT/i TPS 2.SpeedNet Connector
Optional second SpeedNet connection socket
Factory-installed on the rear of the power source (but can also be installed on the front of
the power source).
OPT/i TPS 4x Switch SpeedNet
Option if more than one additional SpeedNet connection socket is required.
IMPORTANT! The OPT/i TPS 4x Switch SpeedNet option cannot be operated in conjunc-
tion with the OPT/i TPS 2. SpeedNet Connector option. If the OPT/i TPS 2.SpeedNet
Connector option is installed in the power source, it must be removed.
31
EN
OPT/i TPS SpeedNet Connector
Expansion of the OPT/i TPS 4x Switch SpeedNet option
Can only be used in conjunction with the OPT/i TPS 4x Switch SpeedNet option, maxi-
mum of 2 per power source
OPT/i TPS 2nd NT241 CU 1400i
Where a CU 1400 cooling unit is used, the OPT/i TPS 2nd NT241 CU1400i option must
be installed in TPS 320i - 600i power sources. .
OPT/i TPS motor supply +
If three or more drive motors are to be operated in the welding system, the OPT/i TPS
motor supply + option must be installed in the TPS320i - 600i power sources.
OPT/i TPS dust filter
IMPORTANT! Use of the OPT/i TPS dust filter option on TPS 320i - 600i power sources
shortens the duty cycle.
OPT/i TPS 2nd plus socket PC
2nd (+) current socket (Power Connector) on the front of the power source (option)
OPT/i TPS 2nd earth socket
Optional 2nd (-) current socket (Dinse) on the rear of the power source
OPT/i TPS 2nd DINSE plus socket
2nd (+) current socket (Dinse) on the front of the power source (option)
OPT/i TPS 2nd earth socket PC
Optional 2nd (-) current socket (Power Connector) on the rear of the power source (option)
OPT/i SpeedNet Repeater
Signal amplifier if interconnecting hosepacks or connections from the power source to the
wirefeeder are more than 50 m in length
OPT/i Synergic Lines
Option for enabling all special characteristics available on TPSi power sources;
this also automatically enables special characteristics created in future.
OPT/i GUN Trigger
Option for special functions in conjunction with the torch trigger
OPT/i Jobs
Option for Job mode
OPT/i Documentation
Option for the documentation function
OPT/i Interface Designer
Option for individual interface configuration
OPT/i WebJobEdit
Option for editing jobs via the SmartManager for the power source
OPT/i Limit Monitoring
Option for specifying the limit values for the welding current, welding voltage and wire
speed
OPT/i Custom NFC - ISO 14443A
Option to use a customer-specific frequency band for key cards
OPT/i CMT Cycle Step
Option for adjustable, cyclical CMT welding process
32
OPT/i Safety Stop
PL d option
IMPORTANT! The safety function OPT/i Safety Stop PL d has been designed according
to EN ISO 13849-1:2008 + AC:2009 as category 3.
This requires two-channel feel of the input signal.
Bridging of two-channel operation (e.g. with a shorting bar) is not permitted and will result
in loss of PL d.
Functional description
The OPT/i Safety Stop PL d option guarantees a safety stop of the power source according
to PL d with controlled end of welding in less than one second.
Every time the power source is switched on, the safety function Safety Stop PL d performs
a self-test.
IMPORTANT! This self-test must be performed at least once a year to check the operation
of the safety shutdown.
If the voltage drops on at least one of 2 inputs, Safety Stop PL d halts the current welding
operation; the wirefeeder motor and the welding voltage are switched off.
The power source outputs an error code. Communication via the robot interface or the bus
system remains unaffected.
To re-start the welding system, the power must be re-connected. An error must be acknowledged via the torch trigger, display or interface and Weld-Start must be carried out
again.
A non-simultaneous shutdown of both inputs (> 750 ms) is output by the system as a critical, non-resettable error.
The power source is permanently switched off.
A reset is carried out by switching the power source off and on again.
Controls, connections and mechani-
cal components
35
Control panel
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 safety rules
(1) (2) (3) (4) (5) (6)
EN
General Welding parameters can be easily changed and selected using the adjusting dial.
The parameters are shown on the display while welding is in progress.
The synergic function ensures that other welding parameters are also adjusted whenever
an individual parameter is changed.
NOTE! As a result of firmware updates, you may find that your device has certain
functions that are not described in these operating instructions, or vice versa. Certain illustrations may also differ slightly from the actual controls on your device,
but these controls function in exactly the same way.
Safety
Control panel
36
No. Function
(1) USB port
For connecting USB flash drives (such as service dongles and licence keys).
IMPORTANT! The USB port is not electrically isolated from the welding circuit.
Therefore, devices that establish an electrical connection with another device
must not be connected to the USB port.
(2) Adjusting dial with turn/press function
For selecting elements, setting values and scrolling through lists
(3) Display (touchscreen)
- For operating the power source directly by pressing the buttons on the display
- For displaying values
- For navigating in the menu
(4) Key card reader for NFC keys
- For locking/unlocking the power source using NFC keys
- For logging on different users (with active user management and assigned
NFC keys)
NFC key = NFC card or NFC key ring
(5) Wire threading button
For threading the wire electrode into the torch hosepack with no accompanying
flow of gas or current
(6) Gas-test button
For setting the required gas flow rate on the gas pressure regulator.
After pressing this button, gas flows for 30 seconds. Press the button again to
stop the gas flow prematurely.
37
(4)
(5)
(6)
(1)
(3)
(2)
(12)
(13)
(11)
(10)
(9)
(8)
(7)
EN
Connections, switches and mechanical components
TPS 320i / 400i /
500i / 600i, TPS
400i LSC ADV
power source
Front Rear
No. Function
(1) Mains switch
for switching the power source on and off
(2) Control panel cover
for protecting the control panel
(3) Control panel with display
for operating the power source
(4) (-) Current socket with bayonet latch
for:
- connecting the grounding (earthing) cable during MIG/MAG welding
(5) Blanking cover
reserved for the second (+) current socket option with bayonet latch
(6) Blanking cover
reserved for the second SpeedNet connection socket option
(7) Blanking cover
reserved for the second SpeedNet connection socket option
(8) (+) Current socket with fine-pitch thread (Power Connector)
for:
- connecting the current cable from the interconnecting hosepack during MIG/
MAG welding
(9) SpeedNet connection socket
for connecting the interconnecting hosepack
(10) Ethernet port
(11) Mains cable with strain relief device
(12) Blanking cover
reserved for the second (-) current socket option with bayonet latch
The second (-) current socket is for:
- connecting the interconnecting hosepack during MIG/MAG welding for polarity reversal (e.g. for flux-cored wire welding)
(13) Blanking cover
reserved for the second SpeedNet connection socket option or robot interface
RI FB Inside/i
38
Operating concept
41
Input options
WARNING! Incorrect operation may result in serious injury or damage. Do not
use the functions described here until you have thoroughly read and understood
the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safety rules
EN
General
The following input options are available on the power source control panel:
- Turning/pressing the adjusting dial
- Pressing buttons
- Pressing on the display
Turning/pressing
the adjusting dial
Turn/press the adjusting dial to select elements, change values and scroll through lists.
NOTE! As a result of firmware updates, you may find that there are functions
available on your device that are not described in these operating instructions or
vice versa. Certain illustrations may also differ slightly from the actual controls on
your device, but these controls function in exactly the same way.
Turn the adjusting dial to:
Select elements from the main area of the display:
- Turning right highlights the next element in the sequence.
- Turning left highlights the preceding element in the sequence.
- In vertical lists, turn right to scroll down and turn left to scroll up.
Change values:
- Turning to the right increases the value.
- Turning to the left decreases the value.
- Slowly turning the adjusting dial changes the value in very small stages,
i.e. for precision adjustments.
- Turning the adjusting dial quickly changes the value in disproportionately large stages, i.e. large value changes can be made quickly.
For certain parameters (wire speed, welding current, arc length correction,
etc.), a value changed by turning the adjusting dial is applied automatically
without having to press the adjusting dial.
Press the adjusting dial to:
Apply highlighted elements, e.g. to change the welding parameter value.
Apply certain welding parameter values.
42
Pressing buttons
Pressing buttons triggers the following functions:
When the feeder inching button is pressed, the wire electrode is fed into the
torch hosepack with no accompanying flow of gas or current.
When the gas test button is pressed, gas will flow out for 30 seconds. Press
the button again to stop the gas test flow before the end of this period.
Pressing on the
display
The display can be touched in order to
- navigate,
- trigger functions,
- select options
Pressing on (and therefore selecting) an element on the display highlights this element.
43
Display and status line
(4)
(3)
(5)
(2)
(6)
(1)
EN
Display
No. Function
(1) The status line
provides details on:
- The current welding process
- The current operating mode
- The current welding program (material, shielding gas and wire diameter)
- Active faults
- Time and date
(2) Left-hand ribbon
The left-hand ribbon contains the following buttons:
- Welding
- Welding process
- Process parameters
- Defaults
The buttons in the left-hand ribbon are actuated by touching the display.
(3) Actual value display
Welding current, welding voltage, wire speed
(4) Main area
The welding parameters, graphics, lists or navigation elements are shown in the
main area. The structure of the main area and the elements shown in it vary according to the application.
The main area is operated
- using the adjusting dial
- by touching the display
(5) Right-hand ribbon
Depending on the buttons selected in the left-hand ribbon, the right-hand ribbon
may be used as follows:
- As a function ribbon containing application and function buttons
- For navigating through the 2nd menu level
The buttons in the right-hand ribbon are actuated by touching the display.
(6) HOLD indicator
At the end of each welding operation, the actual values for the welding current
and voltage are stored - HOLD lights up.
44
Status bar
(1) (2) (3)
The status bar is divided into segments and contains the following information:
(4)
(5)
(6)
(1) Current welding process
(2) Current operating mode
(3) Current welding program (material, shielding gas, characteristic and wire diameter)
(4) Stabilizers/CMT Cycle Step active indicator
Arc length stabilizer
Penetration stabilizer
CMT Cycle Step (only in combination with the CMT welding process)
Symbol lights up green:
Stabilizer/CMT Cycle Step is active
Symbol is grey:
Stabilizer/CMT Cycle Step is available, but is not being used for welding
(5) Current logged-on user (with active user management)
or
the key symbol when the power source is locked (e.g. when the "locked" profile/
role is active)
(6) Time and date
45
1
Current limit exceeded!
1
2
3
EN
Status bar – Current limit reached
If the characteristic-dependent current limit is reached while MIG/MAG welding, a corresponding message appears in the status bar.
For detailed information, select the status bar
The information appears.
Select "Hide information" to exit
Reduce the wire speed, welding current, welding voltage or material thickness
or
Increase the distance between the contact tip and the workpiece
Further information on the current limit can be found in the Troubleshooting section on
page 205.
46
Installation and commissioning
49
Minimum equipment needed for welding task
EN
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.
MIG/MAG gascooled welding
MIG/MAG watercooled welding
MIG/MAG automated welding
Manual CMT
welding
- Power source
- Grounding (earthing) cable
- MIG/MAG welding torch, gas-cooled
- Shielding gas supply
- Wire-feed unit
- Interconnecting hosepack
- Wire electrode
- Power source
- Cooling unit
- Grounding (earthing) cable
- MIG/MAG welding torch, water-cooled
- Shielding gas supply
- Wire-feed unit
- Interconnecting hosepack
- Wire electrode
- Power source
- Robot interface or field bus connection
- Grounding cable
- MIG/MAG robot welding torch or automatic MIG/MAG welding torch
A cooling unit is also required with water-cooled robot or machine welding torches.
- Gas connection (shielding gas supply)
- Wirefeeder
- Interconnecting hosepack
- Wire electrode
- Power source
- Standard, Pulse and CMT welding packages enabled on the power source
- Grounding cable
- PullMig CMT welding torch incl. CMT drive unit and CMT wire buffer
IMPORTANT! For water-cooled CMT applications, a cooling unit is also required!
- OPT/i PushPull
- Wirefeeder
- CMT interconnecting hosepack
- Wire electrode
- Gas connection (shielding gas supply)
50
Automated CMT
welding
- Power source
- Standard, Pulse and CMT welding packages enabled on the power source
- Robot interface or field bus connection
- Grounding cable
- CMT welding torch incl. CMT drive unit
- Cooling unit
- Unreeling wirefeeder (WFi REEL)
- Interconnecting hosepack
- Torch hosepack
- Wirefeeding hose
- Media splitter (e.g. SB 500i R, SB 60i R)
- CMT wire buffer (included with SB 60i R)
- Wire electrode
- Gas connection (shielding gas supply)
TIG DC welding - Power source with built-in OPT/i TPS 2nd plus socket option
- Grounding (earthing) cable
- TIG gas-valve torch
- Gas connection (shielding gas supply)
- Filler metal (depending on the application)
MMA welding - Power source with built-in OPT/i TPS 2nd plus socket option
- Grounding (earthing) cable
- Electrode holder with welding cable
- Rod electrodes
51
Before installation and commissioning
WARNING! If one of these devices topples over or falls it could cause serious or
even fatal injury. Place devices, upright consoles and trolleys on a solid, level sur-
face in such a way that they remain stable.
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 safety rules
EN
Safety
Proper use The power source may only be used for MIG/MAG, MMA and TIG welding. Any use above
and beyond this purpose is deemed improper. The manufacturer shall not be held liable for
any damage arising from such usage.
Proper use also includes:
- following all the information in the operating instructions
- carrying out all the specified inspection and servicing work
Setup regulations The device is tested to IP 23 protection, meaning:
- protection against penetration by solid foreign bodies with diameters > 12.5 mm (0.49
in.)
- protection against direct sprays of water at any angle up to 60° from the vertical
The device can be set up and operated outdoors in accordance with IP23. Avoid direct wetting (e.g. from rain).
The venting duct is a very important safety feature. When choosing the installation location,
ensure that the cooling air can enter and exit unhindered through the air ducts on the front
and back of the device. Any electroconductive metallic dust (e.g. from grinding work) must
not be allowed to get sucked into the device.
Mains connection - The devices are designed for the mains voltage specified on the rating plate.
- Devices with a nominal voltage of 3 x 575 V must be operated on three-phase systems
with earthed star point.
- If your version of the appliance does not come with mains cables and mains plugs
ready-fitted, these must be fitted by a qualified person in accordance with national
standards.
- The fuse protection for the mains cable is indicated in the technical data.
NOTE! An inadequately dimensioned electrical installation can cause serious
damage. The mains cable and its fuse protection must be dimensioned to suit the
local power supply. The technical data shown on the rating plate applies.
52
Generator-powered operation
The power source is generator-compatible.
The maximum apparent power S
of the power source must be known in order to select
1max
the correct generator output.
The maximum apparent power S
of the power source is calculated as follows:
1max
3-phase devices:
S
= I
1max
1max
x U1 x √3
Single-phase devices:
S
1max
= I
1max
x U
1
See device rating plate or technical data for I
The generator apparent power S
needed is calculated using the following rule of
GEN
and U1 values
1max
thumb:
S
GEN
= S
1max
x 1.35
A smaller generator may be used when not welding at full power.
IMPORTANT! The generator apparent power S
mum apparent power S
of the power source.
1max
When using single-phase devices with a 3-phase generator, note that the specified generator apparent power is often only available as a whole across all three phases of the generator. If necessary, obtain further information on the single-phase power of the generator
from the generator manufacturer.
NOTE! The voltage delivered by the generator must never exceed the upper or
lower limits of the mains voltage tolerance range. Details of the mains voltage tolerance can be found in the "Technical data" section.
Information on
system components
The steps and activities described below include references to various system components, including:
- Trolleys
- Cooling units
- Wire-feed unit holders
- Wire-feed units
- Interconnecting hosepacks
- Welding torches
- etc.
For more detailed information about installing and connecting the system components,
please refer to the appropriate operating instructions.
must always be higher than the maxi-
GEN
53
Connecting the mains cable
USA / Canada *
Europe
TPS 320i /nc
3 x 400 V
AWG 12
4 G 2.5
3 x 460 V
AWG 14
4 G 2.5
TPS 320i /MV/nc
3 x 230 V
AWG 10
4 G 4
3 x 460 V
AWG 14
4 G 2.5
TPS 320i /600V/nc **
3 x 575 V
AWG 14
-
TPS 400i /nc
3 x 400 V
AWG 10
4 G 4
3 x 460 V
AWG 12
4 G 4
TPS 400i /MV/nc
3 x 230 V
AWG 6
4 G 6
3 x 460 V
AWG 10
4 G 4
TPS 400i /600V/nc **
3 x 575 V
AWG 12
-
TPS 500i /nc
3 x 400 V
AWG 8
4 G 4
3 x 460 V
AWG 10
4 G 4
TPS 500i /MV/nc
3 x 230 V
AWG 6
4 G 10
3 x 460 V
AWG 10
4 G 4
TPS 500i /600V/nc **
3 x 575 V
AWG 10
-
TPS 600i /nc
3 x 400 V
AWG 6
4 G 10
3 x 460 V
AWG 6
4 G 10
TPS 600i /600V/nc **
3 x 575 V
AWG 6
-
CAUTION! Risk of injury and material damage due to short circuits.
Short circuits can occur between the phase conductors or between the phase
conductors and the ground conductor unless ferrules are used.
Fit ferrules to all phase conductors in an exposed mains cable as well as the
ground conductor.
EN
General If no mains cable is connected, a mains cable that is suitable for the connection voltage
must be fitted before commissioning.
A universal strain-relief device for cable diameters from 12 - 30 mm (0.47 - 1.18 in.) is fitted
to the power source.
Strain-relief devices for other cable cross-sections must be designed accordingly.
Stipulated mains
cables
Power source Mains voltage Cable cross-section
Connecting the
mains cable general
* Cable type for USA / Canada: Extra-hard usage
** Power source without CE mark; not available in Europe
AWG = American wire gauge
NOTE! Mains cables must be connected to devices in compliance with national
standards and guidelines and the work must be carried out by a qualified person.
54
IMPORTANT! The ground conductor should be approx. 30 mm (1.18 in.) longer than the
1
2
3 4 5
6
phase conductors.
55
7
EN
56
Commissioning the TPS 320i / 400i / 500i / 600i, TPS
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 injury and damage. Before carrying out any work on the device make sure that:
- the power source mains switch is in the "O" position
- the power source is unplugged from the mains
400i LSC ADV
Safety
General A manual water-cooled MIG/MAG application is used to describe how to commission the
TPS 320i / 400i / 500i / 600i and TPS 400i LSC ADV power sources.
The following illustrations provide an overview of the structure of the individual system
components.
Refer to the respective system component operating instructions for detailed information
about the various work steps involved.
57
EN
TPS 320i / 400i /
500i / 600i:
Fitting the system
components
(overview)
58
TPS 400i LSC
ADV:
Fitting the system
components
(overview)
59
2 1
2
1
2
EN
Fixing the strainrelief device for
the interconnecting hosepack
Fixing the strain-relief device to the trolley Fixing the strain-relief device to the wire-feed unit
Connecting the
interconnecting
hosepack
NOTE! There is no cooling unit present in the case of gas-cooled systems. There
is no need to attach the water connections in the case of gas-cooled systems.
Connecting the interconnecting hosepack to the power
source and cooling unit
Connecting the interconnecting hosepack to the wirefeed unit
* (only if coolant connections are installed in the wirefeed unit and a water-cooled interconnecting hosepack is being used)
60
CAUTION! Risk of damage to components due to overheating posed by laying
the interconnecting hosepack incorrectly.
- Lay the interconnecting hosepack without loops
- Do not put anything on top of the interconnecting hosepack
- Do not wind up the interconnecting hosepack next to gas cylinders and do
not wind it around gas cylinders
Correct arrangement of the interconnecting
hosepack
Correct arrangement of the interconnecting hosepack
IMPORTANT:
- The duty cycle value (D.C.) for the interconnecting hosepack can only be attained
when the interconnecting hosepacks are laid correctly.
- Carry out R/L calibration if the arrangement of an interconnecting hosepack changes
(see page 119).
- Magnetically compensated interconnecting hosepacks make it possible to change the
arrangement without affecting the welding circuit inductivity.
Magnetically compensated interconnecting hosepacks are available from Fronius with
a minimum length of 10 m.
61
WARNING! If gas cylinders topple over, there is a risk of very serious injury and
damage. Place gas cylinders on a solid, level surface so that they remain stable.
Secure gas cylinders to prevent them from toppling over.
Observe the safety rules of the gas cylinder manufacturer.
1 2
3
4
5 6 7
1
2
EN
Connecting the
gas cylinder
Fixing the gas cylinder on the trolley
Establishing a
ground earth connection
Place the gas cylinder on the base of
the trolley
Secure the gas cylinder by fixing the
cylinder strap around the upper part of
the cylinder (but not around the neck)
to prevent it from toppling over
Take the protective cap off the gas
cylinder
Briefly open the gas cylinder valve to
blow off any dust or dirt
Check the seal on the pressure regulator
Screw the pressure regulator onto the
gas cylinder and tighten it
Connect the shielding gas hose of the
interconnecting hose pack to the pressure regulator using the gas hose
Plug the grounding (earthing) cable
into the (-) current socket and twist to
fasten it
Use the other end of the grounding
(earthing) cable to establish a connection to the workpiece
IMPORTANT! For optimum weld properties, route the grounding cable as close as
possible to the interconnecting hosepack.
62
1
2
3
*
4 5 6 7
8
9
Connecting MIG/
MAG welding
torches to the
wire-feed unit
Check that all cables, leads and hosepacks are undamaged and correctly insulated
Open the wire drive cover
Open the clamping lever on the wire
drive
Check that the welding torch is correctly and completely tooled up. Insert it marking at the top first - into the welding torch connection on the wire-feed
unit
Close the clamping lever on the wire
drive
* On water-cooled welding torches:
Connect the coolant flow hose to the
coolant flow connection (blue)
Connect the coolant return hose to the
coolant return connection (red)
Close the wire drive cover
Check that all connections are connec-
ted properly
63
1
2
3
4
5
EN
Other tasks Carry out the following steps in accordance with the wirefeeder operating instructions:
Insert the feed rollers into the wirefeeder
Insert the wirespool or basket-type spool with adapter into the wirefeeder
Feed in the wire electrode
Set the contact pressure
Adjust the brake
IMPORTANT! For optimum welding results, the manufacturer recommends performing an
R/L alignment when starting the device for the first time and when any changes are made
to the welding system.More information about the R/L alignment can be found under "R/L
alignment" in the "Process parameters" section of the "Welding mode" chapter“ (page
119).
64 1
1
Locking and unlocking the power source using the
universal
NFC key
General remarks NFC key = NFC card or NFC key ring
The power source can be locked using an NFC key, e.g. to prevent unauthorised access
or welding parameters being changed without permission.
A contactless system on the control panel allows the power source to be locked and unlocked.
The power source must be switched on before it can be locked or unlocked.
Locking and unlocking the power
source using the
NFC key
Locking the power source
Hold the NFC key on the NFC key reader
The key symbol appears on the display.
The key symbol is then displayed in the status bar.
The power source is now locked.
Only the welding parameters can be viewed and adjusted using the adjusting dial.
Any attempt to call a locked function will result in a notification being displayed.
Unlocking the power source
Hold the NFC key on the NFC key reader
The crossed-out key symbol appears on the display.
The key symbol no longer appears in the status bar.
All power source functions are now available again without restrictions.
65
NOTE! More information about locking and unlocking the power source can be
EN
found in the "Defaults - Administration" section on page 161.
66
Welding
69
MIG/MAG modes
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 safety rules
Press the torch trigger
Hold the torch trigger
Release the torch trigger
EN
General
See the Setup menu for information on settings, setting range and units of measurement
for the available parameters.
Symbols and
their explanations
GPr
Gas pre-flow
I-S
Starting-current phase: the base material is heated up rapidly, despite the high thermal
dissipation that occurs at the start of welding
t-S
Starting current time
S
Start arc length correction
SL1
Slope 1: the starting current is steadily lowered until it reaches the welding current
I
Welding-current phase: uniform thermal input into the base material, whose temperature
is raised by the advancing heat
I-E
Final current phase: to prevent any local overheating of the base material due to heat
build-up towards the end of welding. This eliminates any risk of weld seam drop-through.
t-E
Final current time
E
End arc length correction
SL2
Slope 2: the welding current is steadily lowered until it reaches the final current
GPo
Gas post-flow
A detailed explanation of the parameters can be found in the section headed "Process parameters"
70
+ I t
GPr
GPo
+ + I
t
GPr
GPo
+ I GPr
SPt
GPo
t
I
I
SL2 t-E GPo
GPr t-S SL1
t
I-E
E
I
+
+
I I-S
S
I-E
E
SL2 t-E GPo t
I-S
S
GPr t-S SL1
I
I
+
I
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.
Special 4-step
mode
"Special 4-step mode" is particularly suitable for welding aluminium materials. The
special slope of the welding current curve
takes account of the high thermal conductivity of aluminium.
Special 2-step
mode
"Special 2-step mode" is ideal for welding in
the higher power range. In special 2-step
mode, the arc starts at a low power, which
makes it easier to stabilise.
Spot welding
The "Spot welding" mode is suitable for
welded joints on overlapped sheets.
71
MIG/MAG and CMT welding
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 injury and damage. Before carrying out any work on the device make sure that:
- the power source mains switch is in the "O" position
- the power source is unplugged from the mains
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 safety rules
1
2
EN
Safety
MIG/MAG and
CMT welding –
overview
Switching on the
power source
The "MIG/MAG and CMT welding" section comprises the following steps:
- Switching on the power source
- Selecting the welding process and operating mode
- Selecting the filler metal and shielding gas
- Setting the welding and process parameters
- Setting the shielding gas flow rate
- MIG/MAG or CMT welding
NOTE! If using a cooling unit, follow the safety rules and note the operating conditions in the cooling unit Operating Instructions.
Connect the mains cable
Move the mains switch to the "I" position
A cooling unit connected to the system will begin to operate.
IMPORTANT! For optimum welding results, the manufacturer recommends performing an
R/L alignment when starting the device for the first time and when any changes are made
to the welding system.
More information about the R/L alignment can be found under "R/L alignment" in the "Process parameters" section of the "Welding mode" chapter (page 119).
72
3
1
*
2
5 4
1
2
3
4
Setting the welding process and
Setting the welding process
operating mode
* next page: Electrode, TIG
Select "Welding process"
Select "Process"
An overview of the welding process is displayed.
Various welding processes are available depending on the power source type or function
package installed.
Select the desired welding process
Setting the operating mode
Select "Mode"
73
An overview of the operating modes is displayed:
5
1
2
3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EN
- 2-step mode
- 4-step mode
- Special 2-step mode
- Special 4-step mode
Select the desired operating mode
Selecting the filler
metal and shielding gas
Select "Welding process"
Select "Filler metal"
Select "Change material settings"
Turn the adjusting dial and select the desired filler metal
Select "Next" / press the adjusting dial
Turn the adjusting dial and select the desired wire diameter
Select "Next" / press the adjusting dial
Turn the adjusting dial and select the desired shielding gas
Select "Next" / press the adjusting dial
NOTE! The available characteristics per welding process are not displayed if only
one characteristic is available for the selected filler metal. In this case, the confirmation step of the filler metal wizard follows immediately; steps 10 - 14 do not apply.
Turn the adjusting dial and select the desired welding process
To select the desired characteristic, press the adjusting dial (blue background)
Turn the adjusting dial and select the desired characteristic
Press the adjusting dial and apply the selected characteristic (white background)
Select "Next"
74 15
4
The confirmation step of the filler metal wizard is displayed:
4
1
2
3
1
2
3
Select "Save" / press the adjusting dial
The selected filler metal and associated characteristics per welding process will be saved.
Setting the welding parameters
Select "Welding"
Select the desired welding parameter by turning the adjusting dial
Press the adjusting dial to change the welding parameter
The value of the welding parameter is displayed as a horizontal scale:
e.g. wire speed parameter
The value of the selected parameter can now be changed.
Turn the adjusting dial to change the welding parameter
The adjusted value of the welding parameter is applied immediately.
If one of the "Wire speed", "Material thickness", "Current" or "Voltage" parameters is
changed during synergic welding, the other welding parameters are immediately adjusted
accordingly.
Press the adjusting dial to call up the welding parameters overview
5
Adjust the process parameters accordingly to make user- or application-specific set-
6
tings on the welding system
75
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.
1
2
3
4 1 1
2
EN
Setting the
shielding gas
flow rate
Open the gas cylinder valve
Press the gas test button
Shielding gas flows out
Turn the adjusting screw on the underside of the pressure regulator until the pressure
gauge shows the required shielding gas flow rate
Press the gas test button
The flow of gas stops.
MIG/MAG or CMT
welding
Select "Welding" to display the welding parameters
Press the torch trigger and start welding
Whenever welding ends, the actual values for the welding current, welding voltage and
wire speed are stored, and HOLD appears on the display.
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.
76
MIG/MAG and CMT welding parameters
Unit
mm
in.
Setting range
0.1 - 30.0 mm
2)
0.004 - 1.18
2)
Wire speed
1)
Unit
m/min
ipm
Setting range
0.5 - max.
2) 3)
19.69 - max
2) 3)
Welding parameters for MIG/MAG
pulse synergic
welding, for CMT
welding and PMC
welding
The following welding parameters for MIG/MAG pulse synergic welding, CMT welding and
PMC welding can be set and displayed by pressing the "Welding" button:
Current
1)
Unit A
Setting range Depends on the welding process and welding program selected
Before the start of welding, the machine automatically displays a standard value based
on the programmed parameters. The actual value is displayed during welding.
Voltage
1)
Unit V
Setting range Depends on the welding process and welding program selected
Before the start of welding, the machine automatically displays a standard value based
on the programmed parameters. The actual value is displayed during welding.
Material thickness
1)
Arc length correction
For correcting the arc length
Setting range -10 - +10
Factory setting 0
- shorter arc length
0 neutral arc length
+ longer arc length
Pulse/dynamic correction
For correcting the pulsing energy of a pulsed arc
Setting range --------------- 10 - +10
Factory setting 0
- lower droplet detachment force
0 neutral droplet detachment force
+ higher droplet detachment force
77
EN
Welding parameters for MIG/MAG
standard synergic welding and
LSC welding
The following welding parameters for MIG/MAG standard synergic welding and LSC welding can be set and displayed by selecting the "Welding" menu button:
Current
1)
Unit A
Setting range Depends on the welding process and welding program selected
Before the start of welding, the device automatically displays a standard value based on
the programmed parameters. During welding, the actual value is displayed.
Voltage
1)
Unit V
Setting range Depends on the welding process and welding program selected
Before the start of welding, the device automatically displays a standard value based on
the programmed parameters. During welding, the actual value is displayed.
Material thickness
1)
Unit mm in.
Setting range 0.1 - 30.0 mm
Feeder command value
1)
2)
0.004 - 1.18
2)
for setting a harder, more stable arc
Unit m/min ipm.
Setting range 0.5 -max.
2)
19.69 -max.
2)
Arc length correction
For correcting the arc length, which is preset by the characteristic or the synergic program;
Setting range -10 - +10
Factory setting 0
- Shorter arc length
0 Neutral arc length
+ Longer arc length
Pulse/dynamic correction
For influencing the short-circuiting dynamic at the instant of droplet transfer
Setting range---------------- 10 - +10
Factory setting 0
- Harder, more stable arc
0 Neutral arc
+ Soft, low-spatter arc
78
Unit
m/min
ipm.
Setting range
0.5 -max.
2)
19.69 -max.
2)
Welding parameters for MIG/MAG
standard manual
welding
The following welding parameters for MIG/MAG standard manual welding can be set and
displayed by selecting the "Welding" menu button:
Voltage
Unit V
Setting range Depends on the welding process and welding program selected
Dynamic
For influencing the short-circuiting dynamic at the instant of droplet transfer
Setting range 0 - 10
Factory setting 0
0 Harder, more stable arc
10 Soft, low-spatter arc
Feeder command value
for setting a harder, more stable arc
Explanation of
footnotes
1) Synergic parameter
When a synergic parameter is changed, the synergic function automatically changes all other synergic parameters to match.
The real setting range depends on power source and wire feeder used and on the
welding programm.
2) The real setting range depends on the welding program.
3) The maximum value depends on the wire feeder used.
79
EasyJob mode
2 3 1
1
2
3
4
5 6
EN
General If EasyJob mode has been activated, 5 additional buttons appear on the display. These
enable up to 5 operating points to be saved at the touch of a button.
The current welding settings are saved.
Activating EasyJob mode
Select "Defaults"
Select "View"
Select "EasyJobs"
The overview to activate/deactivate EasyJob mode is displayed.
Select "EasyJobs on"
Select "OK"
EasyJob mode is activated and the default settings are displayed.
Select "Welding"
Five "EasyJob" buttons are displayed for the welding parameters.
80
1
~ 3 sec.
1
< 3 sec.
1
2
1 1 81
Storing EasyJob
operating points
NOTE! EasyJobs are saved under job numbers 1 - 5 and can also be called up in
Job mode.
Storing an EasyJob overwrites any other job saved under the same number!
To store the current welding settings, touch one of the EasyJob buttons for about three
seconds
The size and colour of the button changes. After about three seconds, the button is displayed green with a frame.
The settings have now been stored. The most recently stored settings will be active. An
active EasyJob is indicated by a tick on the EasyJob button.
Retrieving EasyJob operating
points
To retrieve a saved EasyJob operating point, touch the corresponding EasyJob button
briefly (< 3 seconds)
The size and colour of the button changes briefly; it is then displayed with a tick.
If a tick is not displayed after touching an EasyJob button, this means that there is no operating point saved under this button.
1
1
> 5 sec.
*
EN
Deleting EasyJob
operating points
To delete an EasyJob operating point, touch the relevant EasyJob button for approximately 5 seconds
The button
- first changes its size and colour;
- is displayed with a frame after about 3 seconds.
The saved operating point is overwritten with the latest settings.
- is highlighted in red (= delete) after a total of 5 seconds.
The EasyJob operating point has been deleted.
* ... highlighted in red
82 2
3
Job mode
2 1
4
5
General Up to 1000 jobs can be stored and retrieved in the power source.
This eliminates the need for manual documenting of the welding parameters.
"Job mode" enhances the quality of automated and manual applications.
Jobs can only be stored when in welding mode. When storing jobs, the process parameters
and certain machine defaults are taken into account in addition to the present welding settings.
Storing settings
as a job
Set the parameters that are to be stored as a job:
- Welding parameters
- Welding process
- Process parameters
- Machine defaults (if necessary)
Select "Save as Job"
The job list is displayed.
To overwrite an existing job, select it by turning and pressing the adjusting dial (or selecting
"Next").
The selected job can be overwritten after acknowledging the confirmation prompt.
Select "Create a new Job" to create a new job
Press the adjusting dial / select "Next"
The next free job number is displayed.
Turn the adjusting dial and select the desired storage location
Press the adjusting dial / select "Next"
The keyboard is displayed.
83
Enter a job name
2 1 3
6
7 8
1
2
3
4
5
6
7
8
9
EN
Select "OK" and confirm the job name / press the adjusting dial
The name is saved and a confirmation that the job has been stored is displayed.
To exit, select "Finish" / press the adjusting dial
Job welding - retrieving a job
NOTE! Before retrieving a job, make sure that the welding system has been in-
stalled and set up for the job.
Select "Welding process"
Select "Process"
Select "Job mode"
Job mode is activated.
"Job welding" and the data from the most recently retrieved job are displayed.
Select "Job welding"
Turn the adjusting dial and select "Job number" (white background)
To select the desired job, press the adjusting dial (blue background)
Turn the adjusting dial to select the desired job number (blue background)
The name of the selected job is displayed above the actual value display.
Press the adjusting dial and accept the selected job number (white background)
Start welding
IMPORTANT! "Job number" is the only parameter that can be altered in Job mode; all the
others are read-only.
84
4
5
universal
3 2 1 1
2
3
6
Renaming a job
Select "Save as Job"
(also works in Job mode)
The job list is displayed.
Turn the adjusting dial and select the job to be renamed
Select "Rename Job"
The keyboard is displayed.
Change the job name using the keyboard
Select "OK" and confirm the amended job name / press the adjusting dial
The job name is changed and the job list is displayed.
To exit, select "Cancel"
85
4
universal
3 2
1
1
2
3
5
EN
Deleting a job
Select "Save as Job"
(also works in Job mode)
The job list is displayed.
Turn the adjusting dial and select the job to be deleted
Select "Delete Job"
A confirmation prompt asking whether you really want to delete the job is displayed.
Select "Yes" to delete the selected job
The job is deleted, the job list is displayed.
To exit, select "Cancel"
86
universal
1
1
2
3 4 87
Loading a job The load job function can be used to load the data for a saved job or an EasyJob to the
welding screen. The relevant data from the job is displayed in the welding parameters and
can be changed, saved as a new job or EasyJob, or used to start welding.
Select "Save as Job"
(also works in Job mode)
The job list is displayed.
Turn the adjusting dial and select the job to be loaded
Select "load Job"
The load job information is shown.
Select "Yes"
The data for the selected job is loaded onto the welding screen.
The data for the loaded job can now be used for welding (no job mode), changed, or be
saved as a new job or an EasyJob.
3
1
*
2
1
2
3
4
EN
Optimise job
* Only displayed if the OPT/i CMT Cycle Step option is present on the power source.
Select "Process parameters"
Select "JOB"
An overview of the job functions is displayed.
Select "Optimize Job"
The overview of the most recently optimised job is displayed.
Turn the adjusting dial and select either the job or the job welding parameters to be
modified
88
The choice between the job and the job welding parameters can also be made by
1
*
2
5
1
2
touching the "Job number / Job parameter" button.
Select job:
- Press the adjusting dial
The job number is highlighted in blue and can now be changed.
- Turn the adjusting dial to select the job to be altered
- Press the adjusting dial to change the job
Select job welding parameters:
- Turn the adjusting dial and select the parameter to be changed
- Press the adjusting dial
The value of the parameter is highlighted in blue and can now be changed.
- Turn the adjusting dial; the amended value is applied immediately
- Press the adjusting dial to select other parameters
Select "Finish"
Setting correction
limits for a job
Individual correction limits for welding power and arc length can be defined for each job.
If correction limits are defined for a job, the welding power and arc length for the job in
question can be corrected within the defined limits while welding.
* Only displayed if the OPT/i CMT Cycle Step option is present on the power source.
Select "Process parameters"
Select "JOB"
An overview of the job functions is displayed.
89
3 3 4
5
EN
Select "Correction limits"
A list of the job correction limits for the last job opened is displayed.
Turn the adjusting dial and select either the job or the job limits to be modified
The choice between the job and the job limits can also be made by touching the "Job
number / Job parameter" button.
Select job:
- Press the adjusting dial
The job number is highlighted in blue and can now be changed.
- Turn the adjusting dial to select the job to be altered
- Press the adjusting dial to change the job
Select job limits:
- Turn the adjusting dial and select the desired limit group
- Press the adjusting dial
The selected limit group opens.
- Turn the adjusting dial and select the top or bottom limit
- Press the adjusting dial
The value of the limit parameter is highlighted in blue and can now be changed.
- Turn the adjusting dial; the amended value is applied immediately
- Press the adjusting dial to select other limit parameters
Select "Finish"
90
1
*
2 3
1
2
3
4
5
6
Pre-settings for
"Save as Job"
"Pre-settings for "Save as Job" is for setting the default values that are assumed for every
newly created job.
* Only displayed if the OPT/i CMT Cycle Step option is present on the power source.
Select "Process parameters"
Select "JOB"
An overview of the job functions is displayed.
Select "Pre-settings for "Save as Job"
Confirm the displayed information
The default settings for saving new jobs are displayed.
Turn the adjusting dial and select the desired parameter
Press the adjusting dial
91
Turn the adjusting dial and change the value
7
8
9
EN
Press the adjusting dial
Select "Finish"
92
Spot welding
4
6 5
3
1
*
2
1
2
3
4
5
6
Spot welding
Select "Welding process"
Select "Process"
Select the desired welding process
Select "Mode"
Select "Spot welding"
Select "Process parameters"
93
* Only displayed if the OPT/i CMT Cycle Step option is present on the power source.
7
*
8
CAUTION! Risk of injury and damage from electric shock and from the wire elec-
trode emerging from the torch. When pressing the torch trigger
- Keep the welding torch away from your face and body
- wear suitable protective goggles
- Do not point the welding torch at people
- make sure that the wire electrode does not touch any conductive or earthed
parts (e.g. housing)
7
8 9
10
11
12
13
14
1
2
3
4
5
EN
Select "General"
Select "Spot welding"
The spot welding time parameter is displayed.
Enter the desired value for the spot welding time: Press and turn the adjusting dial
Setting range: 0.1 - 10.0 s
Factory setting: 1.0 s
Apply value by pressing OK
Select the filler metal, wire diameter and shielding gas
Open the gas cylinder valve
Setting the shielding gas flow rate
Spot welding
Procedure for welding a spot:
Hold the welding torch vertical
Press and release the torch trigger
Keep the torch in the same position
Wait for the gas post-flow time
Lift the torch off the workpiece
94
TIG welding
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 injury and damage. Before carrying out any work on the device make sure that:
- the power source mains switch is in the "O" position
- the power source is unplugged from the mains
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 safety rules
1
2
3
4
5
6
7
8
9
10
Safety
Preparations IMPORTANT! For TIG welding, the OPT/i TPS 2nd plus socket option must be installed on
the power source.
Move the mains switch to the "O" position
Disconnect the mains plug
Remove the MIG/MAG welding torch
Disconnect the grounding (earthing) cable from the (-) current socket
Plug the grounding (earthing) cable into the 2nd (+) current socket and twist to fasten it
Use the other end of the grounding (earthing) cable to establish a connection to the
workpiece
Plug the bayonet current plug on the TIG gas-valve torch into the (-) current socket
and twist it clockwise to fasten it
Screw the pressure regulator onto the (argon) gas cylinder and tighten it
Connect the gas hose of the TIG gas-valve torch to the pressure regulator
Plug in the mains plug
95
3
2
*
4
CAUTION! Risk of injury and damage from electric shock. As soon as the mains
switch is in the "I" position, the tungsten electrode of the welding torch is live.
Make sure that the tungsten electrode does not touch any persons or electrically
conductive or earthed parts (e.g. housing, etc.)
1
2
3 4
EN
TIG welding
Move the mains switch to the "I" position
* next page: Electrode, TIG
Select "Welding process"
Select "Process"
An overview of the welding process is displayed.
Various welding processes are available depending on the power source type or function
package installed.
Select "Next page"
The 2nd page of the welding process overview is displayed.
96
**
6 5
7
5 6
7
** previous page: MIG/MAG pulse synergic, MIG/MAG standard synergic, MIG/MAG
PMC, MIG/MAG LSC, MIG/MAG standard manual, CMT and Job mode
Select TIG
The welding voltage is applied to the welding socket with a three second time lag.
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.
Select "TIG welding"
The TIG welding parameters are shown.
Press the adjusting dial to change the welding parameter
The value of the welding parameter is displayed as a horizontal scale:
97
8
8
9
10
11
12 1 2
EN
The value of the selected parameter can now be changed.
Turn the adjusting dial and change the parameter
Adjust the process parameters accordingly to make user- or application-specific set-
tings on the welding system
Open the gas stop valve on the TIG gas-valve torch
Set the desired shielding gas flow rate on the pressure regulator
Start welding (ignite the arc)
Igniting the arc The welding arc is ignited by touching the workpiece with the tungsten electrode.
Place the gas nozzle on the ignition location so that
there is a gap of 2-3 mm (0.08 - 0.12 in.) between
the tip of the tungsten electrode and the workpiece
Placing the gas nozzle down
Gradually tilt the welding torch up until the tungsten
electrode touches the workpiece
Arc ignites when electrode is touched
down on workpiece
98
1
3 4 2 99
Raise the welding torch and pivot it into the normal
position - the arc ignites
Carry out welding
Arc ignited - welding commences
Finishing welding Lift the TIG gas-valve torch away from the workpiece until the arc goes out.
IMPORTANT! To protect the tungsten electrode, ensure that the shielding gas at the
end of welding flows for long enough to allow the tungsten electrode to cool sufficiently.
Close the gas stop valve on the TIG gas-valve torch
MMA welding
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 injury and damage. Before carrying out any work on the device make sure that:
- the power source mains switch is in the "O" position
- the power source is unplugged from the mains
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 safety rules
1
2
3
4 5 6
7
EN
Safety
Preparations IMPORTANT! For MMA welding a grounding (earthing) cable with a Power Connector is
required. For other grounding (earthing) cables the OPT/i TPS 2nd plus socket option must
be installed on the power source.
Move the mains switch to the "O" position
Disconnect the mains plug
Remove the MIG/MAG welding torch
NOTE! Check the rod electrode packaging or labelling to determine whether
the rod electrodes are for positive pole or negative pole welding.
Plug the grounding (earthing) cable into either the (-) or the (+) current socket depending on the type of electrode, and twist to fasten it
Use the other end of the grounding (earthing) cable to establish a connection to the
workpiece
Plug the bayonet current plug of the electrode holder cable into the free current socket
with the opposite polarity, according to the type of electrode, and twist it clockwise to
latch it in place
Plug in the mains plug
100
3
2
*
4
CAUTION! Risk of injury and damage from electric shock. As soon as the mains
switch is in the "I" position, the rod electrode in the electrode holder is live. Make
sure that the rod electrode does not touch any persons or electrically conductive
or earthed parts (e.g. housing, etc.)
1
2
3 4
MMA welding
Move the mains switch to the "I" position
* next page: Electrode, TIG
Select "Welding process"
Select "Process"
An overview of the welding process is displayed.
Various welding processes are available depending on the power source type or function
package installed.
Select "Next page"
The 2nd page of the welding process overview is displayed.
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