Fronius TPS 270i C Operating Instruction [EN]

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TPS 270i C

Operating instructions

MIG/MAG power source

42,0426,0206,EN 015-17112020

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Contents

Safety rules 7

Explanation of safety notices 7 General 7 Proper use 7 Environmental conditions 8 Obligations of the operator 8 Obligations of personnel 8 Mains connection 8 Residual current protective device 9 Protecting yourself and others 9 Noise emission values 9 Danger from toxic gases and vapours 10 Danger from flying sparks 10 Risks from mains current and welding current 11 Meandering welding currents 12 EMC Device Classifications 12 EMC measures 12 EMF measures 13 Specific hazards 13 Requirement for the shielding gas 14 Danger from shielding gas cylinders 14 Danger from escaping shielding gas 15 Safety measures at the installation location and during transport 15 Safety measures in normal operation 15 Commissioning, maintenance and repair 16 Safety inspection 16 Disposal 17 Safety symbols 17 Data protection 17 Copyright 17

General information 19

General 21

Device concept 21 Functional principle 21 Application areas 21 Warning notices on the device 22 Description of Warning Notices on the Device 24

Welding packages, welding characteristics and welding processes 26

General 26 Welding characteristics 26 Summary of MIG/MAG pulse synergic welding 28 Summary of MIG/MAG standard synergic welding 28 Summary of the PMC process 29 Summary of the LSC process 29 Summary of SynchroPulse welding 29 Summary of the CMT process 30

System components 31

General 31 Overview 31 Options 31

Controls, connections and mechanical components 33

Control panel 35

General 35 Safety 35 Control panel 35 Displaying plain text for parameters 40

F1/F2 special function parameters, Favourites button 41

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F1 and F2 special function parameters 41 The Favourites button 42

Connections, switches and mechanical components 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 Manual CMT welding 49 TIG DC welding 49 MMA welding 49

Before installation and commissioning 50

Safety 50 Proper use 50 Setup regulations 50 Mains connection 50 Generator-powered operation 51 Information on system components 51

Connecting the mains cable 52

Safety 52 General 52 Stipulated mains cables 52 Connecting the mains cable - general 53

Start-up 55

Safety 55 General 55 Connecting the gas cylinder 55 Establishing a ground earth connection 56 Connecting the welding torch 56 Inserting/replacing feed rollers 57 Inserting the wirespool 58 Inserting the basket-type spool 59 Feeding in the wire electrode 60 Setting the contact pressure 61 Adjusting the brake 63 Design of the brake 63 Performing R/L alignment 64

Welding 65

MIG/MAG modes 67

General 67 Symbols and their explanations 67 2-step mode 68 4-step mode 68 Special 4-step mode 68 Special 2-step mode 68

MIG/MAG and CMT welding 69

Safety 69 MIG/MAG and CMT welding – overview 69 Switching on the power source 69 Setting the welding process and operating mode 69 Retrieving the currently set filler metal 70 Selecting the filler metal 70 Setting the welding parameters 72 Setting the shielding gas flow rate 72 MIG/MAG or CMT welding 73

MIG/MAG and CMT welding parameters 74

Welding parameters for MIG/MAG pulse synergic welding, for CMT welding and PMC welding 74 Welding parameters for MIG/MAG standard synergic welding and LSC welding 75

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Welding parameters for MIG/MAG standard manual welding 77 Explanation of footnotes 78

EasyJob mode 79

General 79 EasyJob mode 79

Spot welding 80

TIG welding 82

Safety 82 Preparations 82 TIG welding 82 Igniting the arc 84 Finishing welding 84

MMA welding 85

Safety 85 Preparations 85 MMA welding 85 Welding parameters for manual metal arc welding 87

Setup settings 89

Setup menu - overview 91

Entering/exiting the Setup menu 91 Setup menu - overview 92

Process parameters 93

Process parameters for start of welding/end of welding 93 Process parameters for Gas-Setup 94 Process parameters for process control 95 Penetration stabilizer 95 Arc length stabilizer 97 Combination of penetration stabilizer and arc length stabilizer 99 Process parameters for spot welding 100 Process parameters for monitoring and components 100 Process parameters for electrode setup 101 Process parameters for TIG setup 104 Process parameters for SynchroPulse 105 Process parameters for Process Mix 107 R/L alignment 109

Settings 111

General remarks 111 Overview 111 Setting the units 111 Setting the standards 112 Setting the display brightness 112 Displaying replaced characteristics 112 Setting F1 and F2 special function parameters via the Setup menu 112 Setting the Favourites button via the Setup menu 113 Retrieving system data 113 Setting the interior lighting 114 Restoring the factory settings 115 Resetting the password for the power source website 115 Retrieving device information 115 Setting the special display for JobMaster 115 Setting the mode for spot welding 116

Setting the language 117

Keylock 118

SmartManager - The power source website 119

SmartManager - The power source website 121

General remarks 121

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Calling up the power source website 121 Changing password / logging off 121 Settings 122 Language selection 122 Fronius 122

Overview 123

Overview 123 Expand all groups / Reduce all groups 123 Save as XML-file 123

Update 124

Update 124 Searching for an update file (performing the update) 124 Fronius WeldConnect 126

Screenshot 127

Backup & Restore 128

General remarks 128 Backup & Restore 128 Automatic backup 129

Function Packages 130

Function Packages 130 Welding Packages 130 Special characteristics 130 Options 130 Installing a function package 130

Synergic lines overview 131

Characteristics overview 131 Show /hide filter 131

Troubleshooting and maintenance 133

The Error menu 135

Troubleshooting 136

General 136 Safety 136 Power source - troubleshooting 136

Care, maintenance and disposal 140

General 140 Safety 140 At every start-up 140 If necessary 140 Every 2 months 140 Every 6 months 140 Updating firmware 140 Disposal 141

Technical data 143

Average consumption values during welding 145

Average wire electrode consumption during MIG/MAG welding 145 Average shielding gas consumption during MIG/MAG welding 145 Average shielding gas consumption during TIG welding 145

Technical data 146

Explanation of the term "duty cycle" 146 Special voltages 146 TPS 270i C 147 TPS 270i C /nc 148 TPS 270i C /MV/nc 149 TPS 270i C /S/nc 151 Overview with critical raw materials, year of production of the device 152

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Safety rules

Explanation of safety notices

DANGER!

Indicates immediate danger.

If not avoided, death or serious injury will result.

▶

WARNING!

Indicates a potentially hazardous situation.

If not avoided, death or serious injury may result.

▶

CAUTION!

Indicates a situation where damage or injury could occur.

If not avoided, minor injury and/or damage to property may result.

▶

NOTE!

Indicates a risk of flawed results and possible damage to the equipment.

General The device is manufactured using state-of-the-art technology and according to recog-

nised 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.

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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.

Proper use includes:

- 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.

Environmental conditions

Obligations of the operator

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.)

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.

Obligations of personnel

Mains connection Devices with a higher rating may affect the energy quality of the mains due to their cur-

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.

rent consumption.

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This may affect a number device types 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.

IMPORTANT! Ensure that the mains connection is earthed properly

Residual current protective device

Protecting yourself and others

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.

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

Noise emission values

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.

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.

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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.

Danger from toxic gases and vapours

The fumes produced during welding contain harmful gases and vapours.

Welding fumes contain substances that cause cancer, as stated in Monograph 118 of the International Agency for Research on Cancer.

Use at-source extraction and a room extraction system. If necessary, use a welding torch with an integrated extraction device.

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. Ensure that there is a ventilation rate of at least 20 m³ per hour at all times.

Otherwise, a welding helmet with an air supply must be worn.

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.

The following components are responsible, amongst other things, for the degree of toxicity of welding fumes:

- Metals used for the workpiece

- Electrodes

- Coatings

- Cleaners, degreasers, etc.

- Welding process used

Danger from flying sparks

The relevant material safety data sheets and manufacturer's specifications for the listed components should therefore be studied carefully.

Recommendations for trade fair scenarios, risk management measures and for identifying working conditions can be found on the European Welding Association website under Health & Safety (https://european-welding.org).

Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation area.

Close the shielding gas cylinder valve or main gas supply if no welding is taking place.

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 alternatively 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.

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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 welding 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 base or cover for the earth or ground potential. This base 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. Use the handle to ensure the power connections are tight before every use. In the case of power cables with a bayonet connector, rotate the power cable around the longitudinal axis by at least 180° and pretension.

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.

Protection class I devices require a mains supply with ground conductor and a connector system with ground conductor contact for proper operation.

Operation of the device on a mains supply without ground conductor and on a socket without ground conductor contact is only permitted if all national regulations for protective separation are observed. Otherwise, this is considered gross negligence. The manufacturer shall not be held liable for any damage arising from such usage.

If necessary, provide adequate earthing 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 anyone 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.

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If work on live parts is required, appoint a second person to switch off the main switch at the right moment.

Meandering welding currents

EMC Device Classifications

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.

Position the device with sufficient insulation against electrically conductive environments, e.g. Insulation against conductive floor or insulation to conductive racks.

If distribution boards, twin-head mounts, etc., are being used, note the following: The electrode 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 wirefeeder.

Devices in emission class A:

- Are only designed for use in industrial settings

- Can cause line-bound and radiated interference in other areas

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, addi-

tional measures are necessary (e.g. use a suitable line filter).

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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.

During operation

- 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.

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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.

Requirement for the shielding gas

Danger from shielding gas cylinders

Especially with ring lines, contaminated shielding gas can cause damage to equipment and reduce welding quality. Meet the following requirements regarding shielding gas quality:

- Solid particle size < 40 µm

- Pressure condensation point < -20 °C

- Max. oil content < 25 mg/m³

Use filters if necessary.

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.

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Close the shielding gas cylinder valve if no welding is taking place.

Danger from escaping shielding gas

Safety measures at the installation location and during transport

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 international regulations for shielding gas cylinders and accessories.

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 oxygen 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.

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.

Before transporting the device, allow coolant to drain completely and detach the following 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

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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 properties (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 components 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 certain 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

Safety inspection The manufacturer recommends that a safety inspection of the device is performed at

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.

least once every 12 months.

The manufacturer recommends that the power source be calibrated during the same 12month 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.

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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.

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.

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General information

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General

Device concept The TPS 270i C MIG/MAG power source

is a completely digitised, microprocessorcontrolled inverter power source with integrated 4-roller wire drive.

The modular design and potential for system add-ons ensure a high degree of flexibility. Its compact design makes the TPS 270i C particularly suitable for mobile applications.

The power source can be adapted to any specific situation.

Functional principle

Application areas The devices are used in trade and industry for manual applications with classical steel,

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.

galvanised sheets, chrome/nickel and aluminium.

The integrated 4-roller wire drive, high performance and low weight of the power source makes it the ideal choice for portable applications on building sites or in repair workshops.

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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 warning notices and safety symbols must not be removed or painted over. They warn against incorrect operation, as this may result in serious injury and damage.

*) on the inside of the device

Welding is dangerous. The following basic requirements must be met to ensure the equipment is used properly:

- Anyone performing automated welding must be sufficiently qualified

- Suitable protective equipment must be used

- All persons not involved must be kept at a safe distance from the wirefeeder and the welding process

Do not use the functions described here until you have fully read and understood the following documents:

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- These Operating Instructions

- All the Operating Instructions for the system components, especially the safety rules

Do not dispose of used devices with domestic waste. Dispose of them according to the safety rules.

Keep hands, hair, clothing and tools away from moving parts. For example:

- Cogs

- Feed rollers

- 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.

Page 24

Description of

Warning Notices on the Device

On certain device versions, warning notices are attached to the device.

The arrangement of the symbols may vary.

. Warning! Watch Out!

There are possible hazards as shown by the symbols.

A Drive rolls can injure fingers.

B Welding wire and drive parts are at welding voltage during operation

Keep hands and metal objects away.

1. Electric shock can kill.

1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear

wet or damaged gloves.

1.2 Protect yourself from electric shock by insulating yourself from work and ground.

1.3 Disconnect input plug or power before working on machine

2. Breathing welding fumes can be hazardous to your health.

2.1 Keep your head out of the fumes.

2.2 Use forced ventilation or local exhaust to remove the fumes.

2.3 Use ventilating fan to remove fumes.

Page 25

3 Welding sparks can cause explosion or fire.

xx,xxxx,xxxx *

3.1 Keep flammables away from welding. Don’t weld near flammables.

3.2 Welding sparks can cause fires.Have a fire extinguisher nearby and have a

watchperson ready to use it.

3.3 Do not weld on drums or any closed containers.

4. Arc rays can burn eyes and injure skin.

4.1 Wear hat and safety glasses. Use ear protection and button shirt collar. Use

welding helmet with correct shade of filter. Wear complete body protection.

5. Become trained and read the instructions before working on the machine or

welding.

6. Do not remove or paint over (cover) the label.

* identifying number to order label from manufacturer

Page 26

Welding packages, welding characteristics and welding processes

General Various welding packages, welding characteristics and welding processes are available

with TPSi power sources that enable a wide range of materials to be effectively welded.

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 *

- MIG/MAG 3044 Pulse AlMg5 1.2 mm I1 - universal *

- MIG/MAG 2684 Standard Steel 0.9 mm M22 - root *

The additional designation (*) next to the welding process provides information about the special properties and use of the welding characteristic. The description of the characteristics is set out as follows:

Designation

Welding process Properties

arc blow

PMC Characteristic with improved arc break properties by deflecting the external magnetic fields

braze

CMT, LSC, PMC Characteristics for brazing processes (high brazing speed, reliable wetting and good flow of braze material)

braze+

CMT Optimised characteristics for brazing processes with special "Braze+" gas nozzle (narrow gas nozzle opening, high shielding gas flow rate)

cladding

CMT, LSC, PMC Characteristic for cladding with low penetration, low dilution and wide weld seam flow for improved wetting

dynamic

CMT, PMC, Pulse, Standard Characteristics for high welding speeds with concentrated arc

flanged edge

CMT Characteristics for flange welds with frequency and energy yield adjustments; the edge is fully covered with the weld seam but not melted down

galvanized

CMT, LSC, PMC, Pulse, Standard Characteristics for galvanised sheet surfaces (low zinc pore risk, reduced zinc melting loss)

Page 27

galvannealed

PMC Characteristics for iron/zinc-coated sheet surfaces

gap-bridging

CMT, PMC Characteristics with very low heat input for optimum gap-bridging ability

Hot spot

CMT Characteristics with hot start sequence, specially for plug welds and MIG/MAG spot weld joints

mix ** PMC

Also required: Pulse and PMC welding packages

Characteristics with process switch between pulsed and dip transfer arc Specially for welding vertical-up seams with cyclic change between a hot and cold supporting process phase.

mix ** / *** CMT

Also required: CMT drive unit WF 60i Robacta Drive CMT, Pulse, Standard and CMT welding packages

Characteristics with process switch between pulsed and CMT, where the CMT process is initiated by wire movement reversal.

mix drive *** PMC

Also required: PushPull drive unit WF 25i Robacta Drive or WF 60i Robacta Drive CMT, Pulse and PMC welding packages

Characteristics with process switch between pulsed and dip transfer arc, where the dip transfer arc is initiated by wire movement reversal.

multi arc

PMC Characteristics for components being welded by several arcs each influencing the other

PCS ** PMC 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

pipe

PMC Characteristic for pipe applications and positional welding on narrow gap applications

retro

CMT, Pulse, PMC, Standard Characteristics with the properties of the TransPuls Synergic (TPS) predecessor series

ripple drive *** PMC

Also required: CMT drive unit WF 60i Robacta Drive CMT

Page 28

Characteristics that behave like interval mode for clear weld rippling, especially with aluminium

root

CMT, LSC, Standard Characteristics for root passes with powerful arc

seam track

PMC, Pulse Characteristics with increased seam-tracking signal, especially for use with several welding torches on one component.

TIME

PMC Characteristics for welding with long stick out and TIME shielding gases (T.I.M.E. = Transferred Ionized Molten Energy)

universal

CMT, PMC, Pulse, Standard Characteristics for conventional welding tasks in renowned Fronius quality

WAAM

CMT Characteristics with reduced heat input and greater stability at a higher deposition rate for welding bead onto bead in adaptive structures

Summary of MIG/MAG pulse synergic welding

weld+

CMT Characteristics for welding with short stick out and Braze+ gas nozzle (gas nozzle with small opening and high flow velocity)

** Mixed process characteristics *** Welding characteristics with special properties provided by additional hardware

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.

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 mid-power range during the short circuit.

Page 29

Spray arc A short circuit-free transfer of material in the high power range.

Summary of the PMC process

Summary of the LSC process

Summary of SynchroPulse welding

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.

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.

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.

Page 30

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 improved 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.

Page 31

System components

(1)

(2)

(3)

(4)

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

Options

(1) Power source (2) Cooling unit (3) Gas cylinder holder (4) Trolley

also:

- Welding torch

- Grounding cable and electrode cable

- Dust filter

- Additional current sockets

OPT/i TPS C wire feed

OPT/i TPS C polarity reverser

OPT/i TPS C SpeedNet Connector

Optional second SpeedNet connection socket

Installed on the rear of the power source.

OPT/i TPS 270i C ext. Sensor

OPT/i TPS 270i C PushPull

OPT/i TPS C TIG TMC

OPT/i TPS 270i C Ethernet

OPT/i Synergic Lines

Option for enabling all special characteristics available on TPSi power sources; this also automatically enables special characteristics created in future.

Page 32

OPT/i GUN Trigger

Option for special functions in conjunction with the torch trigger

Page 33

Controls, connections and mechan-

ical components

Page 34

Page 35

Control panel

(1) (2) (3) (4) (5) (6)

(7)

(10)

(8)

(9)

(17)

(16)

(15) (14)

(13)

(12)

(11)

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

Danger from incorrect operation.

Possible serious injury and damage to property.

▶ ▶

Control panel

WARNING!

Do not use the functions described here until you have read and completely understood these Operating Instructions. Do not use the functions described here until you have fully read and understood all of the Operating Instructions for the system components, in particular the safety rules!

Page 36

No. Function

(1) Process control parameter indicator

For the LSC and PMC welding processes

Penetration stabilizer indicator

Lights up if the penetration stabilizer is active

Arc length stabilizer indicator

Lights up when the arc length stabilizer is active

(2) Left parameter selection

The corresponding indicator lights up when a parameter is selected. The following parameters can be selected by pressing the button:

Material thickness *

In mm or inches

Welding current *

In A Before the start of welding, the machine automatically displays a standard value based on the programmed parameters. The actual value is displayed during welding.

Wire speed *

In m/min or ipm

Special function

Any parameter can be assigned to this The function can be selected if a parameter has been saved.

Penetration stabilizer

Page 37

Arc length stabilizer

The "Penetration stabilizer" and "Arc length stabilizer" process control parameters can only be selected when the LSC/PMC welding process is used. The currently adjustable parameter is marked with an arrow. * Synergic parameter When a synergic parameter is changed, the synergic function automatically changes all other synergic parameters to match.

(3) Display

For displaying values

(4) Hold/Intermediate arc indicator

Hold indicator

The indicator lights up at the end of each welding operation and the actual values for the welding current, welding voltage and wire speed, etc. are automatically shown on the display.

Intermediate arc indicator

The indicator lights up when a spatter-prone intermediate arc occurs between the dip transfer arc and the spray arc.

(5) Right parameter selection

The corresponding indicator lights up when a parameter is selected. The following parameters can be selected by pressing the button:

Arc length correction

For correcting the arc length

Welding voltage *

In V Before the start of welding, the machine automatically displays a standard value based on the programmed parameters. The actual value is displayed during welding.

Pulse/dynamic correction

Page 38

The function varies according to the welding process being used. A description of the various functions can be found in the Welding chapter under the corresponding welding process.

Special function

Any parameter can be assigned to this The function can be selected if a parameter has been saved. * Synergic parameter When a synergic parameter is changed, the synergic function automatically changes all other synergic parameters to match.

(6) Indicators

SFI indicator

Lights up when SFI (Spatter Free Ignition) is active

SynchroPulse indicator

Lights up when SynchroPulse is active

VRD indicator

Lights up when the voltage reduction device (VRD) is active

(7) EasyJob buttons

For saving, retrieving and deleting EasyJobs The LED on the corresponding button lights up when an EasyJob is selected.

(8) Right adjusting dial with turn/press function

For setting the arc length correction, welding voltage, pulse/dynamic correction and F2 parameters Turn the adjusting dial to: change values, select parameters (in the Setup menu and when selecting the filler metal) Press the adjusting dial to: confirm a menu selection, apply values

(9) Welding process selection

The corresponding LED lights up when a welding process is selected. The following welding processes can be selected by pressing the button:

Page 39

- PULS SYNERGIC (MIG/MAG pulse synergic welding)

- SYNERGIC (MIG/MAG standard synergic welding)

- LSC/PMC (LSC = Low Spatter Control, PMC = Pulse Multi Control)

- STICK/TIG (MMA welding/TIG welding)

- CMT / SP (CMT welding / special programs)

(10) USB port

For updating the software using a USB Ethernet adapter

(11) Mode selection

The corresponding LED lights up when a mode is selected. The following modes can be selected by pressing the button:

- MODE (Special modes depending on the function package)

(12) 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.

MANUAL (MIG/MAG standard manual welding)

Depending on which function package is enabled

2T (2-step mode)

4T (4-step mode)

S4T (Special 4-step mode)

S2T (Special 2-step mode)

(13) Wire threading button

To thread the wire electrode into the torch hosepack with no accompanying flow of gas or current

(14) Left adjusting dial with turn/press function

- For setting the sheet thickness, welding current, wire speed, F1, penetration stabilizer and arc length stabilizer parameters

- For displaying help texts

Turn the adjusting dial to: select parameters, change values, display long help texts Press the adjusting dial to: confirm a menu selection, apply values, call up help texts for parameters

(15) Favourites button

Individual parameters or parent folders can be assigned to it

(16) Filler metal info button

For showing the currently set filler metal

(17) Filler metal selection button

For selecting the filler metal

Page 40

Displaying plain

text for parameters

The left adjusting dial can be used to display the corresponding plain text for each parameter abbreviation shown on the display.

Example:

Parameter or entry from the Setup menu has been selected using the right

adjusting dial; the LED on the right adjusting dial lights up.

Press the left adjusting dial

The plain text for the parameter is displayed; the LED on the left adjusting dial lights up.

To display extended plain texts, turn the left adjusting dial

The plain text is moved across the display.

To make another selection, turn the right adjusting dial

Page 41

F1/F2 special function parameters, Favourites but-

I-S [%] 150

~ 3 sec.

I-S [%] 0.0

~ 3 sec.

ton

F1 and F2 special function parameters

Setting F1 and F2 special function parameters

Example: the selected parameter I-S is assigned to F1

Select the desired parameter in the Setup menu

Further information on the Setup menu can be found from page 89

To assign the selected parameter to F1 or F2, press the parameter selection button

for approx. 3 seconds: F1 ... left parameter selection F2 ... right parameter selection

F1/F2 flashes while the parameter selection button is pressed.

As soon as the parameter is saved, the indicator for the corresponding special function parameter lights up. F1 (for example) and a tick is shown next to the parameter:

The selected parameter is now stored under F1.

If a parameter cannot be assigned to the F1 or F2 special function parameters, after approx. 5 seconds F1 (for example) and X is displayed:

This deletes an existing stored parameter.

Retrieving F1 and F2 special function parameters

Page 42

Press the parameter selection button until F1 or F2 lights up:

150 0.0

2 2

> 5 sec.

~ 3 sec.

F1 ... left parameter selection F2 ... right parameter selection

The stored parameter is shown first, then the currently set value of the parameter.

Change the value of the parameter by turning the adjusting dial:

F1 ... left adjusting dial F2 ... right adjusting dial

Deleting F1 and F2 special function parameters

The Favourites button

Press the parameter selection button for at least 5 seconds:

F1 ... left parameter selection F2 ... right parameter selection

The stored parameter is deleted, F1 (for example) and X is shown on the display:

The F1 and F2 special function parameters can also be set in the Setup menu (page

112).

Assigning the Favourites button

Individual parameters or parent folders from the Setup menu can be assigned to the Favourites button. These parameters or parent folders can then be called up directly using the control panel.

Example: The selected SynchroPulse folder is assigned to the Favourites button

Page 43

Select the desired parameter or the desired parent folder in the Setup menu

< 3 sec.

> 5 sec.

Further information on the Setup menu can be found from page 89

To assign the selected parameter or folder to the Favourites button, press the

Favourites button for approx. 3 seconds

Next to the parameter or folder and a tick are shown:

The selected parameter or folder is now assigned to the Favourites button.

Retrieving favourites

Parameters or folders stored under the Favourites button can be retrieved in any setting, except for when the Setup menu is active. Ongoing selection processes or called up jobs are cancelled when favourites are retrieved.

Briefly press the "Favourites" button (< 3 seconds)

The LED on the Favourites button lights up and the stored parameter or folder is shown on the display.

To end retrieval of the favourite, briefly press the Favourites button again (< 3

seconds)

The LED on the Favourites button goes out and the display switches to the welding parameters.

Deleting favourites

Press the Favourites button for at least 5 seconds:

The stored parameter or folder is deleted and and X are shown on the display:

Page 44

The Favourites button can also be assigned in the Setup menu (page 113).

Page 45

Connections, switches and mechanical compon-

(1)

(2)

(3)

(4)

(5)

(11)

(6)

(7)

(10)

(8)

(9)

ents

Connections, switches and mechanical components

Front

No. Function

(1) Control panel with display

for operating the power source

(2) (+) current socket with bayonet

latch

(3) Blanking cover

reserved for the TMC connection socket of the TIG option

(4) Welding torch connection

for connecting the welding torch

(5) (-) current socket with bayonet

latch

used to connect the grounding cable during MIG/MAG welding

Rear

No. Function

(6) MIG/MAG shielding gas connec-

tion socket

(7) Blanking cover/TIG shielding

gas connection socket (option)

(8) Blanking cover/Ethernet con-

nection socket (option)

(9) Blanking cover/SpeedNet Con-

nector connection socket (option)/external sensor (option)

(10) Mains cable with strain relief

device

(11) Mains switch

for switching the power source on and off

Page 46

(13)

(12)

Side view

No. Function

(12) Wirespool holder with brake

for holding standard wirespools weighing up to 19 kg (41.89 lb.) and with a max. diameter of 300 mm (11.81 in)

(13) 4 roller drive

Page 47

Installation and commissioning

Page 48

Page 49

Minimum equipment needed for welding task

General Depending on which welding process you intend to use, a certain minimum equipment

level 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

Manual CMT welding

- Power source

- Grounding (earthing) cable

- MIG/MAG welding torch, gas-cooled

- Shielding gas supply

- Wire electrode

- Power source

- Cooling unit

- Grounding (earthing) cable

- MIG/MAG welding torch, water-cooled

- Shielding gas supply

- 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

- CMT interconnecting hosepack

- Wire electrode

- Gas connection (shielding gas supply)

TIG DC welding - Power source

- Grounding (earthing) cable

- TIG gas-valve torch

- Gas connection (shielding gas supply)

- Filler metal (depending on the application)

MMA welding - Power source

- Grounding (earthing) cable

- Electrode holder with welding cable

- Rod electrodes

Page 50

Before installation and commissioning

Safety

Danger from incorrect operation.

Possible serious injury and damage to property.

▶ ▶

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

- protection against direct sprays of water at any angle up to 60° from the vertical

WARNING!

(0.49 in.)

The device can be set up and operated outdoors in accordance with IP23. Avoid direct wetting (e.g. from rain).

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 surface in such a way

▶

that they remain stable.

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 lead is indicated in the technical data.

Page 51

CAUTION!

Generatorpowered operation

An inadequately dimensioned electrical installation can cause serious damage.

The mains lead and its fuse protection must be dimensioned to suit the local power

▶

supply. The technical data shown on the rating plate applies.

The power source is generator-compatible.

The maximum apparent power S

of the power source must be known in order to

1max

select the correct generator output. The maximum apparent power S

3-phase devices: S

Single-phase devices: S

1max

= I

1max

= I

See device rating plate or technical data for I

The generator apparent power S

of the power source is calculated as follows:

1max

x U1 x √3

x U

1max

GEN

and U1 values

1max

needed is calculated using the following rule of

thumb:

GEN

= S

1max

x 1.35

Information on system components

A smaller generator may be used when not welding at full power.

IMPORTANT! The generator apparent power S imum apparent power S

of the power source.

1max

must always be higher than the max-

GEN

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.

The steps and activities described below include references to various system components, including:

- Trolley

- Welding torch

- etc.

For more detailed information about installing and connecting the system components, please refer to the appropriate operating instructions.

Page 52

Connecting the mains cable

Safety

Danger due to work that has been carried out incorrectly.

This can result in serious injury and damage to property.

▶ ▶

Danger due to improperly prepared mains cable.

This can cause short circuits and damage.

▶

General If no mains cable is connected, a mains cable that is suitable for the connection voltage

must be fitted before commissioning. Strain-relief devices for the following cable cross-sections are fitted to TPS 270i C power sources:

WARNING!

The work described below must only be carried out by trained and qualified personnel. Observe national standards and directives.

CAUTION!

Fit ferrules to all phase conductors and the ground conductor of the stripped mains cable.

Stipulated mains cables

Power source External diameter of cable

TPS 270i C /nc 14 - 16 mm TPS 270 i C / S/nc 14 - 16 mm TPS 270i C /MV/nc 14 - 18.5 mm

Strain-relief devices for other cable cross-sections must be designed accordingly.

Power source Mains voltage Cable cross-section

USA / Canada * Europe

3 x 380 V

TPS 270i C /nc

TPS 270i C /MV/nc

TPS 270i C /S/nc**3 x 460 V

3 x 400 V 3 x 460 V

3 x 200 V 3 x 230 V

3 x 380 V 3 x 400 V 3 x 460 V

3 x 575 V

AWG 14 4G 2.5 mm²

AWG 12 4G 2.5 mm²

AWG 14 4G 2.5 mm²

AWG 14 -

* Cable type for USA / Canada: Extra-hard usage ** Power source without CE mark; not available in Europe

AWG = American wire gauge

Page 53

Connecting the mains cable general

CAUTION!

Risk of injury and damage from short circuits.

Short circuits can occur between the phase conductors or between the phase conductors and the ground conductor unless ferrules are used.

Strip the insulation of the mains cable and fit ferrules to all phase conductors, as well

▶

as the ground conductor.

NOTE!

Mains cables must be connected to devices in compliance with national standards and guidelines and the work must be carried out by suitably qualified personnel!

IMPORTANT! The ground conductor should be approx. 20 - 25 mm (0.8 - 1 in.) longer

than the phase conductors.

6 x TX25

5 x TX25

Tightening torque = 1.2 Nm

IMPORTANT! When connecting the cable to the switch, ensure:

- To route the conductors near to the switch

- Not to make the conductors unnecessarily long

- To fit the protective hose supplied over the cable and insert the covered cable into the strain-relief device if cable diameters are small

Page 54

Tightening torque = 1.2 Nm

5 x TX25, tightening torque = 3 Nm

Tightening torque = 1.2 Nm

6 x TX25, tightening torque = 3 Nm

Page 55

Start-up

Safety

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.

▶ ▶

Danger from electrical current due to electrically conductive dust in the device.

This can result in serious injury and damage to property.

▶

General Commissioning the power source is described with reference to a manual gas-cooled

MIG/MAG application.

WARNING!

Before carrying out any work on the device make sure that the power source mains switch is in the "O" position Before carrying out any work on the device make sure that the power source is unplugged from the mains

WARNING!

Only operate the device with an air filter fitted. The air filter is a very important safety device for adhering to the IP 23 protection class.

Connecting the gas cylinder

WARNING!

There is a high risk of very serious injury and damage if a gas cylinder falls over.

Place them on a solid, level surface in such a way that they remain stable

▶

Secure the gas cylinders to prevent them from falling over

▶

Observe the safety rules of the gas cylinder manufacturer

▶

Place the gas cylinder on a solid, level

surface in such a way that it remains stable

Secure the gas cylinder to prevent it

from toppling over (but not around the neck of the cylinder)

Take the protective cap off the gas cyl-

inder Briefly open the gas cylinder valve to

remove any dust or dirt Inspect the seal on the gas pressure

regulator Screw the pressure regulator onto the

gas cylinder and tighten it Connect the pressure regulator to the

Connecting the gas hose

shielding gas connection on the power source using the gas hose

Page 56

Establishing a

ground earth connection

Connecting the grounding cable

Plug the grounding cable into the (-)

current socket Lock the grounding cable in place

Use the other end of the grounding

cable to establish a connection to the workpiece

Connecting the welding torch

Before connecting the welding torch, check that all cables, lines and hosepacks are

undamaged and properly insulated.

Open the wire-feed unit cover

Page 57

Inserting/replacing feed rollers

In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the diameter and alloy of the wire being welded.

NOTE!

Only use feed rollers that are suitable for the wire electrode.

An overview of the feed rollers available and their possible areas of use can be found in the spare parts lists.

CAUTION!

Risk of injury if the feed roller holders fly upwards.

When unlocking the lever, keep fingers away from the area to the left and right of the

▶

lever.

1 2

3 4

Page 58

Inserting the wirespool

CAUTION!

Risk of injury due to springiness of spooled wire electrode.

While inserting the wirespool, hold the end of the wire electrode firmly to avoid injur-

▶

ies caused by the wire springing back.

CAUTION!

Risk of injury from falling wirespool.

Make sure that the wirespool is fitted securely to the wirespool holder.

▶

CAUTION!

Risk of injury and impaired performance if the wirespool topples over because the locking ring has been placed the wrong way round.

Always position the locking ring as shown in the diagram on the left.

▶

Page 59

Inserting the basket-type spool

CAUTION!

Risk of injury due to springiness of spooled wire electrode.

While inserting the basket-type spool, hold the end of the wire electrode firmly to

▶

avoid injuries caused by the wire springing back.

CAUTION!

Risk of injury from falling basket-type spool.

Make sure that the basket-type spool and basket-type spool adapter are fitted

▶

securely to the wirespool holder.

NOTE!

When working with basket-type spools, only use the basket-type spool adapter included in the scope of supply.

CAUTION!

Risk of injury from falling basket-type spool.

Place the basket-type spool on the adapter provided in such a way that the bars on

▶

the spool are inside the adapter guideways.

CAUTION!

Risk of injury and impaired performance if the basket-type spool topples over because the locking ring has been placed the wrong way round.

Always position the locking ring as shown in the diagram on the left.

▶

Page 60

1 2

Feeding in the wire electrode

CAUTION!

Risk of injury from springiness of spooled wire electrode.

When inserting the wire electrode into the 4-roller drive, hold the end of the wire

▶

electrode firmly to avoid injuries caused by the wire springing back.

CAUTION!

Risk of damage to the welding torch from sharp end of wire electrode.

Deburr the end of the wire electrode well before feeding in.

▶

Arrange the welding torch hosepack in as straight a line as possible.

Page 61

CAUTION!

Risk of injury and damage from electric shock and from the wire electrode emerging from the torch.

Keep the welding torch away from the face and body when pressing the torch trigger

▶

or feeder inching button. Do not point the welding torch at people

▶

Make sure that the wire electrode does not touch any conductive or earthed (groun-

▶

ded) parts (e.g. the housing, etc.) when pressing the torch trigger

Setting the contact pressure

NOTE!

Set the contact pressure in such a way that the wire electrode is not deformed but nevertheless ensures proper wirefeeding.

Page 62

Contact pressure standard values for U-groove rollers

Steel: 4 - 5

CrNi 4 - 5

Tubular cored electrodes 2 - 3

Page 63

Adjusting the

STOP

brake

NOTE!

After releasing the torch trigger the wirespool should stop unreeling.

Adjust brake if necessary.

Design of the brake

WARNING!

Danger from incorrect installation.

This can result in severe personal injury and damage to property.

Do not dismantle the brake.

▶

Maintenance and servicing of brakes

▶

is to be carried out by trained, qualified personnel only.

The brake is only available as a complete unit. This illustration is for information purposes only.

Page 64

Performing R/L alignment

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.

Page 65

Welding

Page 66

Page 67

MIG/MAG modes

General

Symbols and their explanations

WARNING!

Danger from incorrect operation.

Possible serious injury and damage to property.

Do not use the functions described here until you have read and completely under-

▶

stood these Operating Instructions. Do not use the functions described here until you have fully read and understood all

▶

of the Operating Instructions for the system components, in particular the safety rules!

See the Setup menu for information on settings, setting range and units of measurement for the available parameters.

Press the torch trigger | Hold the torch trigger | Release the torch trigger

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

Start arc length correction

SL1

Slope 1: the starting current is steadily lowered until it reaches the welding current

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

End arc length correction

Page 68

SL2

GPr GPo

I-E

SL1t-S

I-S

SL2

+ +

t-E

I-S

I-E

GPr GPoSL1 SL2

t-S t-E

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"

2-step mode

4-step mode

Special 4-step mode

"2-step mode" is suitable for

- Tacking work

- Short weld seams

- Automated and robot welding

"4-step mode" is suitable for longer weld seams.

"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 2step mode, the arc starts at a low power, which makes it easier to stabilise.

Page 69

MIG/MAG and CMT welding

Safety

MIG/MAG and CMT welding – overview

WARNING!

Danger from incorrect operation.

Possible serious injury and damage to property.

Do not use the functions described here until you have read and completely under-

▶

stood these Operating Instructions. Do not use the functions described here until you have fully read and understood all

▶

of the Operating Instructions for the system components, in particular the safety rules!

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 Before carrying out any work on the device make sure that the power source is

▶

unplugged from the mains

The "MIG/MAG and CMT welding" section comprises the following steps:

- Switching on the power source

- Selecting the welding process and operating mode

- Retrieving the currently set filler metal

- Selecting the filler metal

- Setting the welding parameters

- Setting the shielding gas flow rate

- MIG/MAG or CMT welding

Switching on the power source

Setting the welding process and operating mode

Connect the mains cable

Move the mains switch to the "I" position

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.

Press the "Welding process" button until the LED for the desired welding process

lights up

Page 70

Retrieving the

...

currently set filler metal

Press the "Mode" button until the LED for the desired operating mode lights up

Press the "Filler metal info" button

The LED on the button lights up and the currently set filler metal is shown on the display:

Turn the right adjusting dial

The currently set wire diameter is shown on the display:

Selecting the filler metal

Turn the right adjusting dial

The currently set shielding gas is shown on the display:

Turn the right adjusting dial

The currently set characteristic is shown on the display:

Press the "Filler metal info" button

The currently set welding parameter values are shown on the display.

Press the "Filler metal selection" button

The LED on the button lights up and "filler metal?" is shown on the display:

Page 71

Press the right adjusting dial

The first available filler metal is displayed:

Select the desired filler metal by turning the right adjusting dial

Press the right adjusting dial

"diameter?" is shown on the display: *

Press the right adjusting dial

The first available wire diameter is displayed:

Select the desired wire diameter by turning the right adjusting dial

Press the right adjusting dial

"gas?" is shown on the display: *

Press the right adjusting dial

The first available shielding gas is displayed:

Select the desired shielding gas by turning the right adjusting dial

Press the right adjusting dial

If available, the first available characteristic is displayed: *

Select the desired characteristic by turning the right adjusting dial

Press the right adjusting dial

A prompt to apply the new filler metal is displayed: *

Press the right adjusting dial

The set filler metal is saved.

Page 72

Setting the weld-

22.8 5O.O

ing parameters

* The previous item can be called up by turning the right adjusting wheel and

selecting "back".

Press the button until the desired welding parameter lights up

Material thickness

Welding current

Setting the shielding gas flow rate

Wire speed

Special function

Turn the left adjusting dial to change the value of the welding parameter

Turn the right adjusting dial to change the value of the welding parameter

The amended parameter values are applied immediately. If one of the wire speed, material thickness, welding current or welding voltage parameters are changed during synergic welding, the remaining parameters are immediately altered accordingly.

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 pres-

sure gauge shows the required shielding gas flow rate Press the gas test button

The flow of gas stops.

Page 73

MIG/MAG or CMT welding

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.

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!

It is not always possible to change parameters that have been set on a system component control panel (e.g. remote control) on the power source control panel.

Page 74

MIG/MAG and CMT welding parameters

Welding parameters for MIG/MAG pulse synergic welding, for CMT welding and PMC welding

The following welding parameters can be set and displayed for MIG/MAG pulse synergic welding, CMT welding and PMC welding:

using the left adjusting dial:

Material thickness

Setting range: 0.1 - 30.0 mm 2) / 0.004 - 1.18 in.

Welding current

in 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.

Wire speed

Setting range: 0.5 - 25 m/min 2) / 20 - 980 ipm.

Special function

any parameter can be assigned to this (see page 41)

The function can be selected if a parameter has been saved.

Penetration stabilizer4) (see page 95)

Setting range: 0 - 10 m/min / 0 - 393.7 ipm Factory setting: 0

Arc length stabilizer4) (see page 97)

Setting range: 0 - 5 Factory setting: 0

Page 75

using the right adjusting dial:

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

Welding voltage

in 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.

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 + ... increased droplet detachment force

Welding parameters for MIG/MAG standard synergic welding and LSC welding

Special function

any parameter can be assigned to this (see page 41)

The function can be selected if a parameter has been saved.

The following welding parameters can be set and displayed for MIG/MAG standard synergic welding and LSC welding:

using the left adjusting dial:

Material thickness

Page 76

Setting range: 0.1 - 30.0 mm 2) / 0.004 - 1.18 in.

Welding current

in 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.

Wire speed

for setting a harder, more stable arc

Setting range: 0.5 - 25 m/min 2) / 20 - 980 ipm.

Special function

any parameter can be assigned to this (see page 41)

The function can be selected if a parameter has been saved.

Penetration stabilizer4) (see page 95)

Setting range: 0 - 10 m/min / 0 - 393.7 ipm Factory setting: 0

using the right adjusting dial:

Arc length stabilizer4) (see page 97)

Setting range: 0 - 2 Factory setting: 0

Arc length correction

for correcting the arc length, which is pre-set by the characteristic or the synergic program

Setting range: -10 - +10 Factory setting: 0

Page 77

- .... shorter arc length

0 ... neutral arc length + ... longer arc length

Welding voltage

in 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.

Pulse/dynamic correction

for influencing the short-circuiting dynamic at the instant of droplet transfer

Setting range: -10 - +10 Factory setting: 0

- ... harder and more stable arc

0 ... neutral arc + ... soft and low-spatter arc

Welding parameters for MIG/MAG standard manual welding

Special function

any parameter can be assigned to this (see page 41)

The function can be selected if a parameter has been saved.

The following welding parameters can be set and displayed for MIG/MAG standard manual welding:

using the left adjusting dial:

Wire speed

for setting a harder, more stable arc

Setting range: 0.5 - 25 m/min 2) / 20 - 980 ipm.

Special function

any parameter can be assigned to this (see page 41)

The function can be selected if a parameter has been saved.

Page 78

using the right adjusting dial:

Welding voltage

in V

Setting range: depends on the welding process and welding program selected

Pulse/dynamic correction

for influencing the short-circuiting dynamic at the instant of droplet transfer

Setting range: 0 - 10 Factory setting: 0

0 ... harder and more stable arc 10 ... soft and low-spatter arc

Special function

any parameter can be assigned to this (see page 41)

The function can be selected if a parameter has been saved.

Explanation of footnotes

1) Synergic parameter

When a synergic parameter is changed, the synergic function automatically changes all other synergic parameters to match.

The actual setting range depends on the power source and wirefeeder used and on the welding program selected.

2) The actual setting range depends on the welding program selected.

3) The maximum value depends on the wirefeeder used.

4) Only in the LSC and PMC welding processes

Page 79

EasyJob mode

~ 3 sec.

< 3 sec.

> 5 sec.

General The 5 EasyJob buttons enable up to 5 operating points to be saved quickly.

The current welding settings are saved.

EasyJob mode

Storing EasyJob operating points

To store the current welding settings, press one of the EasyJob buttons for approx. 3

seconds.

"Job", the button number and a tick are shown on the display and the EasyJob button LED lights up, e.g.:

The settings have now been stored.

IMPORTANT! If an operating point has already been saved under an EasyJob button it will be overwritten without any prior warning.

Retrieving EasyJob operating points

To retrieve a saved EasyJob operating point, press the corresponding EasyJob but-

ton briefly (< 3 seconds).

The EasyJob button LED lights up and the saved values are shown on the display.

If no values are displayed after pressing an EasyJob button, an operating point is not stored under this EasyJob button.

Deleting EasyJob operating points

To delete an EasyJob operating point, press the relevant EasyJob button for approx.

5 seconds.

After approx. 3 seconds the saved operating point will be overwritten with the current settings and "Job", the button number and a tick are shown on the display. After a total of approx. 5 seconds the EasyJob button LED goes out and "Job", the

button number and an X are shown on the display, e.g.: The EasyJob operating point has been deleted.

Page 80

Spot welding

Spot welding Spot welding can be carried out in the following welding processes:

PULSE SYNERGIC | SYNERGIC | MANUAL | LSC/PMC | SP (CMT)

Select the desired welding process by pressing the "Welding process" button

Select the MODE by pressing the "Mode" button

"Spot" appears briefly on the display.

Setup menu / Process parameters / Spot welding

Press the right adjusting dial

The SPt (spot welding time) parameter is shown.

Enter the desired value for the spot welding time: press and turn the right adjusting

dial

Setting range: 0.1 - 10.0 s Factory setting: 1.0 s

Confirm the value by pressing the right adjusting dial

NOTE!

4-step mode is assigned as standard for spot welding.

Press the torch trigger - Spot welding process runs until the end of the spot welding time

- Press again to stop the spot welding time prematurely The spot welding setting can be changed to 2-step in the Setup menu under Set-

▶

tings / System / SPm (more information on 2-step and 4-step mode for spot welding starts on page 116)

Select the filler metal, wire diameter and shielding gas

Open the gas cylinder valve

Set the shielding gas flow rate

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 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, etc.)

Spot welding

Procedure for producing a welding spot:

Hold the welding torch vertical

Press and release the torch trigger

Keep the torch in the same position

Page 81

Wait for the gas post-flow time

Lift the torch off the workpiece

NOTE!

Pre-set start of welding and end of welding parameters are also active for spot welding.

A start of welding / end of welding action for spot welding can be stored in the Setup

▶

menu under Process parameters / Start/End. If the final current time is active, the end of welding is not after the pre-set spot weld-

▶

ing time, but only once the pre-set slope and final current times have ended.

Page 82

TIG welding

Safety

Preparations

WARNING!

Danger from incorrect operation.

Possible serious injury and damage to property.

Do not use the functions described here until you have read and completely under-

▶

stood these Operating Instructions. Do not use the functions described here until you have fully read and understood all

▶

of the Operating Instructions for the system components, in particular the safety rules!

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 Before carrying out any work on the device make sure that the power source is

▶

unplugged from the mains

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

TIG welding

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.)

Move the mains switch to the "I" position

Page 83

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.

Press the "Welding process" button until the LED for the STICK/TIG welding process

lights up and "TIG" is shown on the display.

After a short time, the currently set welding current is shown on the display. The welding current indicator lights up.

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.

To change the welding current, turn the left adjusting dial

The altered welding current is applied immediately.

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)

Page 84

Igniting the arc The welding arc is ignited by touching the workpiece with the tungsten electrode.

1 2 3 4

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 Gradually tilt the welding torch up until the tungsten electrode touches the workpiece

Raise the torch and tilt it into the normal position - the arc now ignites

Carry out welding

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

Page 85

MMA welding

Safety

Preparations

WARNING!

Danger from incorrect operation.

Possible serious injury and damage to property.

Do not use the functions described here until you have read and completely under-

▶

stood these Operating Instructions. Do not use the functions described here until you have fully read and understood all

▶

of the Operating Instructions for the system components, in particular the safety rules!

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 Before carrying out any work on the device make sure that the power source is

▶

unplugged from the mains

Move the mains switch to the "O" position

Disconnect the mains plug

Remove the MIG/MAG welding torch

MMA welding

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

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 conduct-

▶

ive or earthed parts (e.g. housing, etc.)

Move the mains switch to the "I" position

Page 86

IMPORTANT! For optimum welding results, the manufacturer recommends performing

STICK

175 20

an R/L alignment when starting the device for the first time and when any changes are made to the welding system.

Press the "Welding process" button until the LED for the STICK/TIG welding process

lights up and "STICK" is shown on the display.

After a short time, the currently set welding current and the currently set dynamic are shown on the display. The welding current and dynamic indicators light up.

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.

To change the welding current, turn the left adjusting dial

If required, turn the right adjusting dial to change the dynamic

The amended values are applied immediately.

Adjust the process parameters accordingly to make user- or application-specific set-

tings on the welding system Start welding

Page 87

Welding parameters for manual metal arc welding

The following welding parameters can be set and displayed for manual metal arc welding:

using the left adjusting dial:

Main current

in A

Setting range: depends on the power source available

Before the start of welding, the machine automatically displays a standard value based on the programmed parameters. The actual value is displayed during welding.

using the right adjusting dial:

Arc-force dynamic

to influence the short-circuiting dynamic at the instant of droplet transfer

Setting range: 0 - 100 Factory setting: 20

0 ... soft and low-spatter arc 100 ... harder and more stable arc

Page 88

Page 89

Setup settings

Page 90

Page 91

Setup menu - overview

Entering/exiting the Setup menu

To enter the Setup menu, press the "Welding process" and "Mode" buttons at the

same time

"Process parameters" is shown on the display.

To exit the Setup menu, press the "Welding process" and "Mode" buttons at the

same time

Page 92

Setup menu overview

Process param.

Start/End

Display System back

Settings

Gas-setup

Process c.

Spot welding

Components

STICK

TIG

SynchroPulse

Process Mix

R/L-check / align-

ment

Unit 9) xx

Standard

UIBS

DRSL.

F1/F2 Param

Favourite

11)

13)

14)

10)

12)

15)

< back System data < back

< back

FAC

16)

17)

CLS [s]

Web-PWreset

Information

SPm

19)

20)

iJob xx

18)

Language xx

... Turn the right adjusting dial

... Press the right adjusting dial

Press the left adjusting dial:

...

The parameter is shown in plain text

Turn the left adjusting dial: To read long plain texts for parameters; the plain text for the parameter is moved to the

...

left on the display

1) Process parameters

2) Language abbreviation

3) Start/end of welding

4) Process control

5) Component monitoring

6) Electrode setup

7) TIG setup

8) Process Mix

9) Units

10) metric/imperial

11) Standards

12) CEN/AWS

13) Display brightness

14) Display replaced characteristics

15) Activate F1/F2 parameter

16) Duration of interior lighting

17) Restore factory settings

18) Reset password for the website

19) Mode Setup – Special display for JobMaster

20) 2-step/4-step spot welding

Page 93

Process parameters

Process parameters for start of welding/end of welding

The following process parameters can be set and displayed for the start and end of welding:

I-S Starting current

For setting the starting current for MIG/MAG welding (e.g. aluminium welding start-up)

Setting range: 0 - 200% (of welding current) Factory setting: 135%

AlS Start arc length correction

For correcting the arc length at the start of welding

Setting range: -10 - +10% (of welding voltage) Factory setting: 0

- .... shorter arc length

0 ... neutral arc length + ... longer arc length

t-S Starting current time

For setting the length of time the starting current is to be active

Setting range: off / 0.1 - 10.0 s Factory setting: off

SL1 Slope 1

For setting the time during which the starting current is decreased or increased to the welding current

Setting range: 0 - 9.9 s Factory setting: 1 s

SL2 Slope 2

For setting the time during which the welding current is decreased or increased to the final current.

Setting range: 0 - 9.9 s Factory setting: 1 s

I-E Final current

For setting the final current so that a) heat build-up towards the end of welding is prevented and b) the end-crater can be filled when welding aluminium

Setting range: 0 - 200% (of welding current) Factory setting: 50

AlE End arc length correction

For correcting the arc length at the end of welding

Page 94

Setting range: -10 - +10% (of welding voltage) Factory setting: 0

- .... shorter arc length

0 ... neutral arc length + ... longer arc length

t-E Final current time

For setting the length of time for which the final current is to be active

Setting range: off / 0.1 - 10.0 s Factory setting: off

SFI

to activate/deactivate the SFI function (Spatter Free Ignition of the arc)

Setting range: off / on Factory setting: off

SFI-HS SFI HotStart

For setting a HotStart time in conjunction with SFI ignition

During SFI ignition, a spray arc phase occurs within the set HotStart time. This increases the heat input irrespective of the mode, thus ensuring deeper penetration right from the very start of welding.

Setting range: off / 0.01 - 2.00 s Factory setting: off

W-r Wire retract

For setting the wire withdrawal value (= composite value based on backward movement of wire and a time). The wire withdrawal depends on the features of the welding torch.

Setting range: 0.0 - 10.0 Factory setting: 0.0

IgC Ignition current (manual mode)

For setting the ignition current for MIG/MAG standard manual welding

Setting range: 100 - 450 A Factory setting: 450

W-r (man.) Wire retract (manual mode)

For setting the wire withdrawal value (= composite value based on backward movement of wire and a time) for MIG/MAG standard manual welding. The wire withdrawal depends on the features of the welding torch.

Process parameters for Gas-Setup

Setting range: 0.0 - 10.0 Factory setting: 0.0

The following process parameters can be set and displayed for Gas-Setup:

Page 95

GPr Gas pre-flow

For setting the gas flow time before the arc is ignited

Setting range: 0 - 9.9 s Factory setting: 0.1 s

GPo Gas post-flow

For setting the gas flow time after the arc has gone out

Setting range: 0 - 9.9 s Factory setting: 0.5 s

GCV Gas set value

For specifying the gas set value in l/min

GCF Gas factor

For setting the gas correction factor

Setting range: aut, 0.90 - 20.0 Factory setting: aut

Process parameters for process control

Penetration stabilizer

The following process parameters can be set and displayed for the process control:

- PSt - penetration stabilizer

- AlSt - arc length stabilizer

Penetration stabilizer and arc length stabilizer can also be set in combination with one another.

The penetration stabilizer is used to set the max. permitted change in the wire speed to ensure that the welding current and hence the penetration is kept stable or constant with variable stick out.

The penetration stabilizer parameter is only available when the WP PMC (Welding Process Pulse Multi Control) or WP LSC (Welding Process Low Spatter Control) option has been enabled on the power source.

0 - 10.0 m/min (ipm) Factory setting: 0 m/min

0 The penetration stabilizer is not activated. The wire speed remains constant.

0.1 - 10.0 The penetration stabilizer is activated. The welding current remains constant.

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Application examples

I [A]

[m/min]

t [s]

< s

2 x1

> x

I [A]

[m/min]

t [s]

< s

2 x1

= x

Penetration stabilizer = 0 m/min (not activated)

Changing the contact tube distance (h) alters the resistance in the welding circuit due to the longer stick out (s2).

The constant voltage control for constant arc length causes a reduction in the mean current value and hence a smaller penetration (x2).

Penetration stabilizer = n m/min (activated)

Specifying a value for the penetration stabilizer ensures a constant arc length without large current variations if the stick out is changed (s1 ==> s2).

The penetration (x1, x2) remains virtually unchanged and stable.

Penetration stabilizer = 0.5 m/min (activated)

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I [A]

[m/min]

1 2

t [s]

< s

3 x1

> x

0,5 m/min

Penetration stabilizer = 0.5 m/min (activated)

To minimise the change in welding current if the stick out is changed (s1 ==> s3), the wire speed is increased or reduced by 0.5 m/min.

In the example shown, the stabilising effect is obtained without a change in current up to the set value of 0.5 m/min (Position 2).

I ... Welding current vD ... Wire speed

Arc length stabilizer

The arc length stabilizer forces short arcs, advantageous for welding, via a short-circuit current control and keeps them stable even with a variable stick out or external interference.

The arc length stabilizer welding parameter is only available if the WP PMC (Welding Process Pulse Multi Control) option has been enabled on the power source.

0.0 - 5.0 (effect of stabilizer) Factory setting: 0.0

0.0 The arc length stabilizer is deactivated.

0.1 - 5.0 The arc length stabilizer is activated. The arc length is decreased until short circuits start to occur.

Application examples

Arc length stabilizer = 0 / 0.5 / 2.0

Arc length stabilizer = 0

Arc length stabilizer = 0.5

Arc length stabilizer = 2

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I [A]

[m/min]

U [V]

t [s]

> L2 > L

Arc length stabilizer = 0 / 0.5 / 2.0

L1 = L

Activating the arc length stabilizer reduces the arc length until short circuits start to occur. The frequency of the short circuits is controlled and kept stable.

Increasing the arc length stabilizer causes a further shortening of the arc length (L1 ==> L2 ==> L3). The advantages of a short, stable and controlled arc can be used more effectively.

Arc length stabilizer with change of weld seam profile and position

Arc length stabilizer not activated

A change of weld seam profile or welding position can negatively affect the welding result

Arc length stabilizer activated

Since the number and duration of the short circuits is controlled, the properties of the arc stay the same if the weld seam profile or welding position is changed.

I ... Welding current vD ... Wire speed U ... Welding voltage * ... Number of short circuits

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Combination of

Δs

I [A]

[m/min]

U [V]

t [s]

Δs

I [A]

[m/min]

U [V]

t [s]

penetration stabilizer and arc length stabilizer

Example: Stick out change

Arc length stabilizer without penetration stabilizer

The advantages of a short arc are maintained even if the stick out is changed, since the short-circuit properties stay the same.

Arc length stabiliser with penetration stabilizer

If the stick out is changed with the penetration stabilizer activated, the penetration also stays the same. The short circuit behaviour is controlled by the arc length stabilizer.

I ... Welding current vD ... Wire speed U ... Welding voltage * ... Number of short circuits Δs ... Stick out change

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Process parameters for spot welding

SPt Spot welding time

0.1 - 10.0 s Factory setting: 1.0 s

Process parameters for monitoring and components

The following process parameters can be set and displayed for the system components of a welding system:

C-C Cooling unit mode

To determine whether a cooling unit is to be switched on or off, or operated automatically

Setting range: eco / auto / on / off (depending on the cooling unit) Factory setting: auto

C-t Delay time flow sensor

For setting the time from when the flow sensor responds until a warning message is output

Setting range: 5 - 25 s Factory setting: 10 s

CFU Cooler flow warning limit

Setting range: off, 0.75 - 0.95 l/min Factory setting: off

Fdi Feeder inching speed

in m/min (ipm) For setting the wire speed at which the wire electrode is threaded into the torch hosepack

100

Setting range: min. - max. (depending on the wirefeeder) Factory setting: 10.0 m/min

ito Ignition time-out

Length of wire that is fed before the safety cut-out trips

Setting range: off / 5 - 100 mm (0.2 - 3.94 in.) Factory setting: off

The ignition time-out process parameter is a safety function. The length of wire that is fed before the safety cut-out trips may differ from the pre-set wire length, particularly when the wire is being fed at fast wire speeds.

How it works: Once the torch trigger is pressed, gas pre-flow begins immediately. Wirefeeding then begins, followed by ignition. If no current starts flowing before the specified length of wire has been fed, the power source cuts out automatically. To try again, press the torch trigger again.

Fronius TPS 270i C Operating Instruction [EN]

Specifications and Main Features

Frequently Asked Questions

User Manual