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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.
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