Fronius TPS 320i C User guide

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TPS 320i C

Operating instructions

MIG/MAG power source

42,0426,0113,EN 033-14012021

Contents

Safety rules 9

Explanation of safety notices 9 General 9 Proper use 9 Mains connection 10 Environmental conditions 10 Obligations of the operator 10 Obligations of personnel 11 Residual current protective device 11 Protecting yourself and others 11 Noise emission values 11 Danger from toxic gases and vapours 12 Danger from flying sparks 12 Risks from mains current and welding current 13 Meandering welding currents 14 EMC Device Classifications 14 EMC measures 14 EMF measures 15 Specific hazards 15 Requirement for the shielding gas 16 Danger from shielding gas cylinders 16 Danger from escaping shielding gas 17 Safety measures at the installation location and during transport 17 Safety measures in normal operation 17 Commissioning, maintenance and repair 18 Safety inspection 18 Disposal 19 Safety symbols 19 Data protection 19 Copyright 19

General information 21

General 23

Device concept 23 Functional principle 23 Application areas 23 Conformities 24 Bluetooth trademarks 25 Warning notices on the device 25 Description of the warning notices on the device 27

Welding packages, welding characteristics and welding processes 29

General 29 Welding packages 29 Welding characteristics 29 Summary of MIG/MAG pulse synergic welding 32 Summary of MIG/MAG standard synergic welding 32 Summary of the PMC process 32 Summary of the LSC process 32 Summary of SynchroPulse welding 32 Summary of the CMT process 32 Short description of the CMT Cycle Step welding process 33

System components 34

General 34 Overview 34 Options 35

Controls, connections and mechanical components 37

Control panel 39

General 39 Safety 39 Control panel 40

Connections, switches and mechanical components 42

TPS 320i C power source 42

Operating concept 45

Input options 47

General 47 Turning/pressing the adjusting dial 47 Pressing buttons 48 Pressing on the display 48

Display and status line 49

Display 49 Status bar 50 Status bar – Current limit reached 51

Installation and commissioning 53

Minimum equipment needed for welding task 55

General 55 MIG/MAG gas-cooled welding 55 MIG/MAG water-cooled welding 55 Manual CMT welding 55 TIG DC welding 55 MMA welding 55

Before installation and commissioning 56

Safety 56 Proper use 56 Setup regulations 56 Mains connection 56 Generator-powered operation 57 Information on system components 57

Connecting the mains cable 58

General 58 Stipulated mains cables 58 Safety 58 Connecting the mains cable - general 58

Commissioning the TPS 320i C 61

Safety 61 General 61 Recommendation for water-cooled applications 61 Connecting the gas cylinder 61 Establishing a ground earth connection 62 Connecting the welding torch 63 Inserting/replacing feed rollers 63 Inserting the wirespool 64 Inserting the basket-type spool 65 Feeding in the wire electrode 67 Setting the contact pressure 68 Adjusting the brake 68 Design of the brake 69 Performing R/L alignment 69

Locking and unlocking the power source using the NFC key 70

General remarks 70 Locking and unlocking the power source using the NFC key 70

Welding 73

MIG/MAG modes 75

General 75 Symbols and their explanations 75 2-step mode 76

4-step mode 76 Special 4-step mode 77 Special 2-step mode 77 Spot welding 78

MIG/MAG and CMT welding 79

Safety 79 MIG/MAG and CMT welding – overview 79 Switching on the power source 79 Setting the welding process and operating mode 80 Selecting the filler metal and shielding gas 81 Setting the welding parameters 82 Setting the shielding gas flow rate 83 MIG/MAG or CMT welding 83

MIG/MAG and CMT welding parameters 84

Welding parameters for MIG/MAG pulse synergic welding, for CMT welding and PMC welding 84 Welding parameters for MIG/MAG standard synergic welding and LSC welding 85 Welding parameters for MIG/MAG standard manual welding 86 Explanation of footnotes 86

EasyJob mode 87

General 87 Activating EasyJob mode 87 Storing EasyJob operating points 88 Retrieving EasyJob operating points 88 Deleting EasyJob operating points 89

Job mode 90

General 90 Storing settings as a job 90 Job welding - retrieving a job 91 Renaming a job 92 Deleting a job 93 Loading a job 94 Optimize job 95 Setting correction limits for a job 96 Pre-settings for "Save as Job" 98

Spot welding 100

TIG welding 103

Safety 103 Preparations 103 TIG welding 104 Igniting the arc 106 Finishing welding 107

MMA welding 108

Safety 108 Preparations 108 MMA welding 109 Welding parameters for manual metal arc welding 112

Process parameters 113

Overview 115

Overview - Process parameters, Common 115 Overview – components and monitoring process parameters 115 Overview – Job process parameters 115

Process parameters, General 116

Process parameters for start of welding/end of welding 116 Process parameters for Gas-Setup 117 Process parameters for process control 118 Penetration stabilizer 118 Arc length stabilizer 120 Combination of penetration stabilizer and arc length stabilizer 122 Process parameters for SynchroPulse 123

Process parameters for Process mix 125 Process parameters for CMT Cycle Step 128 Process parameters for spot welding 129 R/L-check / alignment 129 Process parameters for TIG/MMA/SMAW setup 130

Components and monitoring process parameters 134

Process parameters for components 134 System adjust 135 Setting process parameters for arc break monitoring 137 Process parameters for wire stick contact tip 138 Process parameters for wire stick workpiece 140 Process parameter for wire end monitoring 141 Process parameters for gas monitoring 142 Motor force monitoring 144

Process parameters, Job 146

Optimising job process parameters 146 Process parameters for correction limits 148 Process parameters for pre-settings for "Save as Job" 149

Defaults 153

Defaults 155

General remarks 155 Overview 155

Defaults - view 156

Setting the language 156 Setting Units/Standards 157 Setting the time and date 158 Retrieving system data 159 Displaying characteristics 162

Defaults - System 163

Retrieving device information 163 Restoring factory settings 163 Restoring the website password 164 Mode Setup: Setting the special 4-step mode "Guntrigger", special display for JobMaster, spot welding and torch trigger job selection Setting network parameters manually 167 Setting up the WLAN 168 Bluetooth setup 169 Power source configurations 171 Wire feeder setup 172 Interface setup 173

Defaults - Documentation 176

Setting the sampling rate 176 Viewing the logbook 177 Activate/deactivate limit value monitoring 178

Defaults - Administration 180

General remarks 180 Explanation of terms used 180 Pre-defined roles and users 180 Overview 181

Administrator and creating roles 182

Recommendation for creating roles and users 182 Create administrator key 183 Creating roles 184 Copy roles 186

Creating a user 187

Creating a user 187 Copying users 188

Editing roles / users, deactivating user management 190

Editing roles 190 Deleting roles 191

165

Editing users 192 Deleting users 193 Deactivating user management 194 Lost NFC administrator key? 195

CENTRUM - Central User Management 196

Activating the CENTRUM server 196

SmartManager - The power source website 197

SmartManager - The power source website 199

General remarks 199 Opening and logging into the power source SmartManager 199 Help function, should you be unable to log in 200 Changing password / logging off 200 Settings 201 Language selection 201 Status indicator 202 Fronius 202

Current system data 203

Documentation, logbook 204

Documentation 204

Job-Data 206

Job data 206 Job overview 206 Editing a job 206 Importing a job 207 Exporting a job 207 Exporting job(s) as… 207

Power source settings 208

Process parameters 208 Name & location 208 MQTT settings 208 OPC UA settings 208

Backup & Restore 209

General remarks 209 Backup & Restore 209 Automatic backup 210

Signal visualisation 211

User management 212

General 212 Users 212 User roles 212 Export & import 213 CENTRUM 213

Overview 214

Overview 214 Expand all groups / Reduce all groups 214 Save as XML-file 214

Update 215

Update 215 Searching for an update file (performing the update) 215 Fronius WeldConnect 217

Function Packages 218

Function Packages 218 Welding Packages 218 Special characteristics 218 Options 218 Installing a function package 218

Synergic lines overview 219

Characteristics overview 219

Showing/hiding the filter 219

Screenshot 220

Interface 221

Troubleshooting and maintenance 223

Troubleshooting 225

General 225 Safety 225 MIG/MAG welding – Current limit 225 Power source - troubleshooting 226

Care, maintenance and disposal 230

General 230 Safety 230 At every start-up 230 Every 2 months 230 Every 6 months 230 Updating firmware 230 Disposal 231

Appendix 233

Average consumption values during welding 235

Average wire electrode consumption during MIG/MAG welding 235 Average shielding gas consumption during MIG/MAG welding 235 Average shielding gas consumption during TIG welding 235

Technical data 236

Explanation of the term "duty cycle" 236 Special voltages 236 Overview with critical raw materials, year of production of the device 236 TPS 320i C 238 TPS 320i C /nc 240 TPS 320i C /S/nc 242 TPS 320i C /MV/nc 244 Radio parameters 246

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.

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.

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

rent consumption.

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

Environmental conditions

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

Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage.

Ambient temperature range:

- during operation: -10 °C to + 40 °C (14 °F to 104 °F)

- during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)

Relative humidity:

- up to 50% at 40 °C (104 °F)

- up to 90% at 20 °C (68 °F)

The surrounding air must be free from dust, acids, corrosive gases or substances, etc. Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)

Obligations of the operator

The operator must only allow persons to work with the device who:

- are familiar with the fundamental instructions regarding safety at work and accident prevention and have been instructed in how to use the device

- have read and understood these operating instructions, especially the section "safety rules", and have confirmed as much with their signatures

- are trained to produce the required results.

Checks must be carried out at regular intervals to ensure that operators are working in a safety-conscious manner.

Obligations of personnel

Residual current protective device

Protecting yourself and others

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.

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

Keep all persons, especially children, out of the working area while any devices are in operation or welding is in progress. If, however, there are people in the vicinity:

- Make them aware of all the dangers (risk of dazzling by the arc, injury from flying sparks, harmful welding fumes, noise, possible risks from mains current and welding current, etc.)

- Provide suitable protective equipment

- Alternatively, erect suitable safety screens/curtains.

Noise emission values

The device generates a maximum sound power level of <80 dB(A) (ref. 1pW) when idling and in the cooling phase following operation at the maximum permissible operating point under maximum rated load conditions according to EN 60974-1.

It is not possible to provide a workplace-related emission value during welding (or cutting) as this is influenced by both the process and the environment. All manner of different welding parameters come into play, including the welding process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the power range, the type of weld metal, the resonance characteristics of the workpiece, the workplace environment, etc.

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.

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.

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).

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.

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.

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

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.

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.

General information

General

Device concept The TPS 320i C MIG/MAG power source

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

A modular design and potential for system add-ons ensure a high degree of flexibility. There is no longer an interconnecting hosepack between the power source and the wirefeeder. Its compact design makes the TPS 320i 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 workshops and industry for manual and automated applications

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.

with classical steel, galvanised sheets, chrome/nickel and aluminium.

The integral 4-roller wire drive, high performance and light weight of the TPS 320i C power source makes it the ideal choice for portable applications on building sites or in repair workshops.

Conformities FCC

This equipment complies with the limit values for an EMC device class A digital device pursuant to Part 15 of the FCC Rules. These limit values are intended to provide an adequate level of protection against harmful emissions when the device is being used in an industrial environment. This device generates and uses high-frequency energy and can cause interference to radio communications if it is not installed and used according to the Operating Instructions. The use of this device in residential areas will probably cause harmful interference, in which case the user will be obliged to correct the interference at their own expense.

FCC ID: QKWSPBMCU2

Industry Canada RSS

This device complies with the Industry Canada licence-exempt RSS standards. Its use is subject to the following conditions:

(1) The device must not cause any harmful interference. (2) The device must be able to cope with any interference, including that which could

IC: 12270A-SPBMCU2

EU Conformity with Directive 2014/53 / EU - Radio Equipment Directive (RED)

adversely affect its operation.

When installing the antennae to be used for this transmitter, it is essential to maintain a minimum distance of 20 cm from all people. They must not be set up or operated together with another antenna or another transmitter. To comply with exposure to radio frequency guidelines, the operating conditions of the transmitter must be available to OEM integrators and end users.

ANATEL / Brazil

This device is operated on a secondary basis. It has no protection against harmful interference, even from devices of the same type. This device cannot cause interference in systems operated on a primary basis. This device complies with ANATEL's specific absorption rate limit values in relation to exposure to high frequency electric, magnetic and electromagnetic fields.

IFETEL / Mexico

Operation of this device is subject to the following two conditions:

(1) The device must not cause any harmful interference. (2) This device must accept any interference received, including interference that

may cause undesired operation.

NCC / Taiwan

In accordance with NCC regulations for low-power radio frequency devices:

Article 12 A certified low-power radio frequency device must not change the frequency, increase the power or alter the characteristics and functions of the original structure without approval.

Article 14 The use of low-power radio frequency devices must not adversely affect flight safety and communications. A detected malfunction must be deactivated and corrected immediately until no malfunction is present. The notice in the preceding paragraph refers to radio communications operated in accordance with the provisions of the Telecommunications Act. Low-power radio fre-

quency devices must withstand interference from legitimate communications or radiological, electrical radio frequency devices for industrial, scientific and medical applications.

Thailand

Bluetooth trademarks

Warning notices on the device

The Bluetooth® word mark and logos are registered trademarks owned by Bluetooth SIG, Inc. and any use of such marks by Fronius International GmbH is under license. Other trademarks and trade names are those of their respective owners.

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

Safety symbols on the rating plate:

Welding is dangerous. The following basic requirements must be met:

- Welders must be sufficiently qualified

- Suitable protective equipment must be used

- All persons not involved in the welding process must be kept at a safe distance

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

- These Operating Instructions

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

Description of the

warning notices on the device

For certain device versions, warning notices are affixed to the device.

The arrangement of the symbols may vary.

! Warning! Attention!

The symbols represent possible dangers.

A Drive rollers can injure fingers.

B The welding wire and drive parts are live during operation.

Keep hands and metal objects away!

1. An electric shock can be fatal.

1.1 Wear dry, insulating gloves. Do not touch the wire electrode with bare hands. Do

not wear wet or damaged gloves.

1.2 Use a base that is insulated from the floor and work area to protect against elec-

tric shock.

1.3 Before working on the device, switch off the device and pull out the mains plug or

disconnect it from the power supply.

2. Inhalation of welding fumes can be harmful to health.

2.1 Keep your face away from any welding fumes.

2.2 Use forced-air ventilation or a local extraction system to remove welding fumes.

2.3 Remove welding fumes with a fan.

3 Welding sparks can cause an explosion or fire.

xx,xxxx,xxxx *

3.1 Keep flammable materials away from the welding process. Never weld close to

flammable materials.

3.2 Welding sparks can cause a fire. Have fire extinguishers to hand. If necessary,

have a supervisor ready who can operate the fire extinguisher.

3.3 Do not weld on drums or closed containers.

4. Arc rays can burn the eyes and injure the skin.

4.1 Wear headgear and protective goggles. Use ear protection and a shirt collar with

button. Use a welding helmet with the correct tinting. Wear suitable protective clothing over the entire body.

5. Before working on the system or welding:

undertake training on the device and read the instructions!

6. Do not remove or paint over the warning sticker.

* Manufacturer order number of the sticker

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 packages

The following welding packages are available for TPSi power sources:

- Standard Welding Package (enables MIG/MAG standard synergic welding)

- Pulse Welding Package (enables MIG/MAG pulse synergic welding)

- LSC Welding Package * (enables the LSC process)

- PMC Welding Package ** (enables the PMC process)

- CMT Welding Package *** (enables the CMT process)

* only in conjunction with the Standard Welding Package ** only in conjunction with the Pulse Welding Package *** only in conjunction with the Standard Welding Package and the Pulse Welding

Package

Welding characteristics

IMPORTANT! A TPSi power source without welding packages only offers the following

welding processes:

- MIG/MAG standard manual welding

- TIG welding

- MMA welding

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 1.0 mm M21 - arc blow *

- MIG/MAG 3450 PMC Steel 1.0 mm 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:

Marking

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)

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, specifically 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 Sprayarc - 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

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

root

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

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

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

Summary of MIG/MAG pulse synergic welding

MIG/MAG pulse synergic

MIG/MAG pulse synergic welding is a pulsed-arc process with controlled material transfer. In the base current phase, the energy supply is reduced to such an extent that the arc is only just stable and the surface of the workpiece is preheated. In the pulsing current phase, a precise current pulse ensures the targeted detachment of a droplet of welding material. This principle guarantees a low-spatter weld and precise working across the entire power range.

Summary of MIG/MAG standard synergic welding

Summary of the PMC process

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.

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

PMC = Pulse Multi Control

PMC is a pulsed arc welding process with high-speed data processing, precise recording of the process status and improved droplet detachment. Faster welding possible with a stable arc and even fusion penetration.

Summary of the LSC process

Summary of SynchroPulse welding

Summary of the CMT process

LSC = Low Spatter Control

LSC is a new, low-spatter dip transfer arc process.The current is reduced before breaking the short-circuit bridge; re-ignition takes place at significantly lower welding current values.

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.

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.

Short description of the CMT Cycle Step welding process

CMT Cycle Step is the next step in the development of the CMT welding process. A special CMT drive unit is also required for this process.

CMT Cycle Step is the welding process with the lowest heat input. The CMT Cycle Step welding process switches cyclically between CMT welding and pauses of an adjustable duration. These pauses in the welding process lower the heat input; the continuity of the weld seam is maintained. Individual CMT cycles are also possible. The size of the CMT spot welds is determined by the number of CMT cycles.

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

(1) Cooling units (2) Power sources (3) Robot accessories (4) Trolley and gas cylinder holders

also:

- Welding torch

- Grounding cable and electrode cable

- Dust filter

- Additional current sockets

Options

OPT/i gas flow rate sensor

OPT/i gas pressure sensor

OPT/i TPS 320i C CMT

OPT/i TPS 320i C TIG

OPT/i TPS 320i C wire end

OPT/i TPS 320i C PushPull

OPT/i TPS C wire feed

OPT/i TPS C polarity reverser

OPT/i TPS C QC DFS AD10

OPT/i TPS C QC DFS Powerliner

OPT/i TPS VRD

OPT/i Ext. Sensor connector

OPT/i TPS 320i C viewing window

OPT/i TPS C SpeedNet Connector

Optional second SpeedNet connection socket

Factory-installed on the rear of the power source.

OPT/i TPS dust filter

IMPORTANT! Use of the OPT/i TPS dust filter option shortens the duty cycle.

OPT/i TPS C 2nd plus socket

2nd (+) current socket on the rear of the power source (option)

OPT/i TPS C 2nd earth socket

2nd (-) current socket on the rear of the power source (option)

OPT/i Synergic Lines

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

OPT/i GUN Trigger

Option for special functions in conjunction with the torch trigger

OPT/i Jobs

Option for Job mode

OPT/i Documentation

Option for the documentation function

OPT/i Interface Designer

Option for individual interface configuration

OPT/i WebJobEdit

Option for editing jobs via the SmartManager of the power source

OPT/i Limit Monitoring

Option for specifying the limit values for the welding current, welding voltage and wire speed

OPT/i Custom NFC - ISO 14443A

Option to use a customer-specific frequency band for key cards

OPT/i CMT Cycle Step

Option for adjustable, cyclical CMT welding process

OPT/i OPC-UA

Standardised data interface protocol

OPT/i MQTT

Standardised data interface protocol

Controls, connections and mechan-

ical components

Control panel

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

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!

Control panel

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

43,0001,3547

No. Function

(1) USB port

For connecting USB flash drives (such as service dongles and licence keys). IMPORTANT! The USB port is not electrically isolated from the welding circuit. Therefore, devices that establish an electrical connection with another device must not be connected to the USB port.

(2) Adjusting dial with turn/press function

To select elements, set values and scroll through lists

(3) Display (touchscreen)

- For operating the power source directly by pressing the buttons on the display

- For displaying values

- For navigating in the menu

(4) Key card reader for NFC keys

- For locking/unlocking the power source using NFC keys

- For logging on different users (with active user management and assigned NFC keys)

NFC key = NFC card or NFC key ring

(5) Wire threading button

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

(6) Gas-test button

For setting the required gas flow rate on the gas pressure regulator. After pressing this button, gas flows for 30 seconds. Press the button again to stop the gas flow prematurely.

Connections, switches and mechanical compon-

(3)

(4)

(5)

(6)

(2)

(1)

(7)

(10)

(9)

(8)

(14)

(13)

(12)

(11)

(16)(15)

ents

TPS 320i C power source

Front

Side view

No. Function

(1) Welding torch connection

for connecting the welding torch

Rear

(2) (-) current socket with bayonet latch

used to connect the grounding cable during MIG/MAG welding

(3) Control panel cover

for protecting the control panel

(4) Control panel with display

for operating the power source

(5) (+) current socket with bayonet latch

(6) Blanking cover

reserved for the TMC connection socket of the TIG option

(7) Mains cable with strain relief device

(8) Mains switch

for switching the power source on and off

(9) Blanking cover

reserved for TIG shielding gas connection option

(10) Blanking cover

reserved for optional 2nd (-) current socket or 2nd (+) current socket

(11) Blanking cover

reserved for external sensor option

(12) MIG/MAG shielding gas connection

(13) Blanking cover

reserved for the Ethernet connection socket

(14) Blanking cover

reserved for optional 2nd SpeedNet connection

(15) Wirespool holder with brake

for holding standard wirespools weighing up to 16 kg (35.27 lbs) and with a max. diameter of 300 mm (11.81 in)

(16) 4 roller drive

Operating concept

Input options

General

NOTE!

As a result of firmware updates, you may find that there are functions available on your device that are not described in these operating instructions or vice versa.

Certain illustrations may also differ slightly from the actual controls on your device, but these controls function in exactly the same way.

WARNING!

Incorrect operation may result in serious injury or damage.

the following documents:

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

▶

stood these operating instructions Do not use the functions described here until you have thoroughly read and under-

▶

stood all the operating instructions for the system components, especially the safety rules

The following input options are available on the power source control panel:

- Turning/pressing the adjusting dial

- Pressing buttons

- Pressing on the display

Turning/pressing the adjusting dial

Turn/press the adjusting dial to select elements, change values and scroll through lists.

Turn the adjusting dial to:

Select elements from the main area of the display:

- Turning right highlights the next element in the sequence.

- Turning left highlights the preceding element in the sequence.

- In vertical lists, turn right to scroll down and turn left to scroll up.

Change values:

- Turning to the right increases the value.

- Turning to the left decreases the value.

- Slowly turning the adjusting dial changes the value in very small stages, i.e. for precision adjustments.

- Turning the adjusting dial quickly changes the value in disproportionately large stages, i.e. large value changes can be made quickly.

For certain parameters (wire speed, welding current, arc length correction, etc.), a value changed by turning the adjusting dial is applied automatically without having to press the adjusting dial.

Press the adjusting dial to:

Apply highlighted elements, e.g. to change the welding parameter value.

Apply certain welding parameter values.

Pressing buttons Pressing buttons triggers the following functions:

When the feeder inching button is pressed, the wire electrode is fed into the torch hosepack with no accompanying flow of gas or current.

When the gas test button is pressed, gas will flow out for 30 seconds. Press the button again to stop the gas test flow before the end of this period.

Pressing on the display

The display can be touched in order to

- navigate,

- trigger functions,

- select options

Pressing on (and therefore selecting) an element on the display highlights this element.

Display and status line

(1)

(2)

(4)

(5)

(6)

(3)

Display

No. Function

(1) Status bar

The status bar provides information on:

- The current welding process

- The current operating mode

- The current welding program (material, shielding gas and wire diameter)

- Active stabilizers and special processes

- Bluetooth status

- Logged-on users / power source locked state

- Active faults

- Time and date

(2) Left-hand ribbon

The left-hand ribbon contains the following buttons:

- Welding

- Welding process

- Process parameters

- Defaults

The buttons in the left-hand ribbon are actuated by touching the display.

(3) Actual value display

Welding current, welding voltage, wire speed

(4) Main area

The welding parameters, graphics, lists or navigation elements are shown in the main area. The structure of the main area and the elements shown in it vary according to the application.

The main area is operated

- using the adjusting dial,

- by touching the display.

Status bar

(1) (2) (3)

(7)(6)(5)(4)

(5) Right-hand ribbon

Depending on the button selected in the left-hand ribbon, the right-hand ribbon may be used as follows:

- as a function ribbon containing application and function buttons

- for navigating through the 2nd menu level

The buttons in the right-hand ribbon are actuated by touching the display.

(6) HOLD indicator

At the end of each welding operation, the actual values for the welding current and welding voltage are stored - HOLD lights up.

The status bar is divided into segments and contains the following information:

(1) Current welding process

(2) Current operating mode

(3) Current welding program (material, shielding gas, characteristic and wire dia-

meter)

(4) Stabilizers/CMT Cycle Step active indicator

Arc lengths

Penetration stabilizer

CMT Cycle Step (only in combination with the CMT welding process)

Symbol lights up green: Stabilizer/CMT Cycle Step is active

Symbol is grey: Stabilizer/CMT Cycle Step is available, but is not being used for welding

(5) Bluetooth status indicator (certified devices only)

(6) Current logged-on user (with active user management)

intermediate arc indicator

the key symbol when the power source is locked (e.g. when the "locked" profile/

Current limit exceeded!

role is active)

(7) Time and date

Status bar – Current limit reached

If the characteristic-dependent current limit is reached while MIG/MAG welding, a corresponding message appears in the status bar.

For detailed information, select the status bar

The information appears.

Select "Hide information" to exit

Reduce the wire speed, welding current, welding voltage or material thickness

Increase the distance between the contact tip and the workpiece

Further information on the current limit can be found in the Troubleshooting section on page 225

Installation and commissioning

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

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!

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!

(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.

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

of the power source is calculated for 3-phase

1max

devices as follows:

= I

1max

See device rating plate or technical data for I

The generator apparent power S

1max

x U1 x √3

and U1 values

1max

needed is calculated using the following rule of

GEN

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

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:

- Trolleys

- Cooling units

- Wire-feed unit holders

- Wire-feed units

- Interconnecting hosepacks

- Welding torches

- etc.

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

Connecting the mains cable

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

must be fitted before commissioning. A universal strain-relief device for cable diameters from 12 - 30 mm (0.47 - 1.18 in.) is fitted to the power source.

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

Stipulated mains cables

Safety

Power source Mains voltage: USA & Canada * | Europe

TPS 320i C /nc 3 x 380 V, 3 x 400 V, 3 x 460 V: AWG 14 | 4G 2.5 mm²

TPS 320i C /MV/nc 3 x 200 V, 3 x 230 V: AWG 10 | 4G 4.0 mm² 3 x 380 V, 3 x 400 V, 3 x 460 V: AWG 14 | 4G 2.5 mm²

TPS 320i C /S/nc ** 3 x 460 V, 3 x 575 V: AWG 14 | -

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

AWG = American wire gauge

WARNING!

Danger due to work that has been carried out incorrectly.

This can result in serious injury and damage to property.

The work described below must only be carried out by trained and qualified person-

▶

nel. Observe national standards and directives.

▶

Connecting the mains cable general

CAUTION!

Danger due to improperly prepared mains cable.

This can cause short circuits and damage.

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

▶

cable.

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

1 2

Tightening torque = 1.2 Nm (TPS 320i C, TPS 320i C /nc, TPS 320i C /S/nc)

Tightening torque = 3.5 Nm (TPS 320i C /MV/nc)

Phase conductor:

Tightening torque = 1.5 Nm, TX 15 (TPS 320i C, TPS 320i C /nc, TPS 320i C /S/nc)

Tightening torque = 1.5 Nm, TX 25 (TPS 320i C /MV/nc)

Ground conductor:

Tightening torque = 1.2 Nm

5 x TX25 Tightening torque = 3 Nm

Commissioning the TPS 320i C

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 TPS 320i C power source is described by 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.

Recommendation for water-cooled applications

Connecting the gas cylinder

- Use a PickUp 5000 trolley

- Fit the cooling unit to the PickUp 5000 trolley

- Fit the TPS 320i C power source to the cooling unit

- Use only water-cooled welding torches with an external water connection

- Connect the water connections on the welding torch directly to the cooling unit

WARNING!

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

Place gas cylinders on a solid, level surface so that they remain stable. Secure gas

▶

cylinders to prevent them from toppling over. Observe the safety rules of the gas cylinder manufacturer.

▶

Connecting the gas hose to the TPS 320i C

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

Check the seal on the pressure regu-

lator

Screw the pressure regulator onto the

gas cylinder and tighten it

Connect the pressure regulator to the

shielding gas connection on the power source using the gas hose

Establishing a ground earth connection

NOTE!

When establishing a ground earth connection, observe the following points:

Use a separate grounding cable for each power source

▶

Keep the plus cable and grounding cable together as long and as close as possible

▶

Physically separate the welding circuits of individual power sources

▶

Do not route several grounding cables in parallel;

▶

if parallel routing cannot be avoided, keep a minimum distance of 30 cm between the welding circuits Keep the grounding cable as short as possible, provide a large cable cross-section

▶

Do not cross grounding cables

▶

Avoid ferromagnetic materials between the grounding cable and the interconnecting

▶

hosepack Do not wind up long grounding cables - coil effect!

▶

Lay long grounding cables in loops Do not route grounding cables in iron pipes, metal cable conduits or on steel rails,

▶

avoid cable ducts; (routing of plus cables and grounding cables together in an iron pipe does not cause any problems) If there are several grounding cables, separating the grounding points on the com-

▶

ponent so that they are as far away from one another as possible is recommended, as well as preventing crossed current paths from occurring underneath the individual arcs. Use compensated interconnecting hosepacks (interconnecting hosepacks with

▶

integrated 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 grounding cable to the TPS 320i C

CAUTION!

A shared ground earth connection for multiple power sources will have an adverse effect on welding results!

If multiple power sources are being used to weld a component, a shared ground earth connection can have a massive impact on the welding results.

Separate the welding circuits!

▶

Provide a different ground earth connection for each welding circuit!

▶

Do not use a single, shared earth (ground) lead!

▶

Connecting the welding torch

Inserting/replacing feed rollers

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

undamaged and properly insulated.

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 match the wire electrode.

An overview of the feed rollers available and their potential application areas 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

Inserting the wirespool

3 4

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 electrode 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.

▶

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 electrode 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.

▶

1 2

Feeding in the

wire electrode

CAUTION!

Risk of injury due to springiness of spooled wire electrode.

To avoid injuries caused by the wire electrode springing back:

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

▶

electrode firmly.

CAUTION!

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

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

▶

Lay the welding torch hosepack as straight as possible.

▶

1 2

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 con-

STOP

tact pressure

NOTE!

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

Adjusting the brake

Contact pressure standard values for U-groove rollers

Steel: 4 - 5

CrNi 4 - 5

Tubular cored electrodes 2 - 3

NOTE!

After releasing the torch trigger the wirespool should stop unreeling.

Adjust brake if necessary.

STOP

Design of the brake

Performing R/L alignment

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.

IMPORTANT! For optimum welding results, the manufacturer recommends performing an R/L alignment when starting the device for the first time and when any changes are made to the welding system. More information about the R/L alignment can be found under "R/L alignment" in the "Process parameters" section of the "Welding mode" chapter (page 129).

Locking and unlocking the power source using the NFC key

General remarks NFC key = NFC card or NFC key ring

The power source can be locked using an NFC key, e.g. to prevent unauthorised access or welding parameters being changed without permission.

A contactless system on the control panel allows the power source to be locked and unlocked.

The power source must be switched on before it can be locked or unlocked.

Locking and unlocking the power source using the NFC key

Locking the power source

Hold the NFC key on the NFC key reader

The key symbol appears on the display.

The key symbol is then displayed in the status bar.

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The power source is now locked. Only the welding parameters can be viewed and adjusted using the adjusting dial.

Any attempt to call a locked function will result in a notification being displayed.

Unlocking the power source

Hold the NFC key on the NFC key reader

The crossed-out key symbol appears on the display.

The key symbol no longer appears in the status bar. All power source functions are now available again without restrictions.

NOTE!

More information about locking and unlocking the power source can be found in the "Defaults - Management / Administration" section from page 180.

Welding

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

2-step mode

GPr

GPo

GPr GPo

SL2

Slope 2: the welding current is steadily lowered until it reaches the final current

GPo

Gas post-flow

A detailed explanation of the parameters can be found in the section headed "Process parameters"

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

GPr GPo

I-E

SL1t-S

I-S

SL2

+ +

t-E

I-S

I-E

GPr GPoSL1 SL2

t-S t-E

mode

Special 2-step mode

"Special 4-step mode" is particularly suitable for welding aluminium materials. The special slope of the welding current curve takes account of the high thermal conductivity of aluminium.

"Special 2-step mode" is ideal for welding in the higher power range. In special 2-step mode, the arc starts at a lower power, which makes it easier to stabilise.

Spot welding

GPr GPoSPt

The "Spot welding" mode is suitable for welded joints on overlapped sheets.

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

- Selecting the filler metal and shielding gas

- Setting the welding and process parameters

- Setting the shielding gas flow rate

- MIG/MAG or CMT welding

Switching on the power source

NOTE!

If using a cooling unit, follow the safety rules and note the operating conditions in the cooling unit Operating Instructions.

Connect the mains cable

Move the mains switch to the "I" position

A cooling unit connected to the system will begin to operate.

Setting the weld-

4-step

ing process and operating mode

Setting the welding process

* next page: Electrode, TIG

Select "Welding process"

Select "Process"

An overview of the welding process is displayed. Various welding processes are available depending on the power source type or function package installed.

Select the desired welding process

Setting the operating mode

Select "Mode"

An overview of the operating modes is displayed:

Selecting the

filler metal and shielding gas

- 2-step mode

- 4-step mode

- Special 2-step mode

- Special 4-step mode

Select the desired operating mode

Select "Welding process"

Select "Filler metal"

Select "Change material settings"

Turn the adjusting dial and select the desired filler metal

Select "Next" / press the adjusting dial

Turn the adjusting dial and select the desired wire diameter

Select "Next" / press the adjusting dial

Turn the adjusting dial and select the desired shielding gas

Select "Next" / press the adjusting dial

NOTE!

The available characteristics per welding process are not displayed if only one characteristic is available for the selected filler metal.

In this case, the confirmation step of the filler metal wizard follows immediately; steps 10

- 14 do not apply.

Turn the adjusting dial and select the desired welding process

To select the desired characteristic, press the adjusting dial (blue background)

Turn the adjusting dial and select the desired characteristic

Press the adjusting dial and apply the selected characteristic (white background)

Select "Next"

The confirmation step of the filler metal wizard is displayed:

Setting the weld-

ing parameters

Select "Save" / press the adjusting dial

The selected filler metal and associated characteristics per welding process will be saved.

Select "Welding"

Select the desired welding parameter by turning the adjusting dial

Press the adjusting dial to change the welding parameter

The value of the welding parameter is displayed as a horizontal scale:

e.g. wire speed parameter

The value of the selected parameter can now be changed.

Turn the adjusting dial to change the welding parameter

The adjusted value of the welding parameter is applied immediately. If one of the "Wire speed", "Material thickness", "Current" or "Voltage" parameters is changed during synergic welding, the other welding parameters are immediately adjusted accordingly.

Press the adjusting dial to call up the welding parameters overview

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

tings on the welding system

Setting the

shielding gas flow rate

MIG/MAG or CMT welding

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.

Select "Welding" to display the welding parameters

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!

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.

MIG/MAG and CMT welding parameters

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

The following welding parameters for MIG/MAG pulse synergic welding, CMT welding and PMC welding can be set and displayed by pressing the "Welding" button:

Current 1) [A]

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

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

Voltage 1) [V]

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

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

Material thickness

0.1 - 30.0 mm 2) / 0.004 - 1.18 2) in.

Wire speed

0.5 - max.

2) 3)

m/min / 19.69 - max

2) 3)

ipm.

Arc length correction

for correcting the arc length;

-10 - +10

Factory setting: 0

- .... shorter arc length

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

Pulse/dynamic correction

for correcting the pulsing energy of a pulsed arc

-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

The following welding parameters for MIG/MAG standard synergic welding and LSC welding can be set and displayed by selecting the "Welding" menu button:

Current 1) [A]

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

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

Voltage 1) [V]

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

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

Material thickness

0.1 - 30.0 mm 2) / 0.004 - 1.18 2) in.

Wire speed

0.5 - max.

2) 3)

m/min / 19.69 - max

2) 3)

ipm.

Arc length correction

for correcting the arc length;

-10 - +10

Factory setting: 0

- .... shorter arc length

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

Pulse/dynamic correction

for correcting the pulsing energy of a pulsed arc

-10 - +10

Factory setting: 0

- ... lower droplet detachment force

0 ... neutral droplet detachment force + ... increased droplet detachment force

Welding parameters for MIG/MAG standard manual welding

The following welding parameters for MIG/MAG standard manual welding can be set and displayed by selecting the "Welding" menu button:

Voltage 1) [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.

Arc-force dynamic

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

0 - 10 Factory setting: 0

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

Explanation of footnotes

Wire speed

for setting a harder, more stable arc

0.5 - max. 2) m/min / 19.69 - max 2) ipm.

1) Synergic parameter

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

The real setting range depends on power source and wire feeder used and on the welding programm.

2) The real setting range depends on the welding program.

3) The maximum value depends on the wire feeder used.

EasyJob mode

General If EasyJob mode has been activated, 5 additional buttons appear on the display. These

enable up to 5 operating points to be saved at the touch of a button. The current welding settings are saved.

Activating EasyJob mode

Select "Defaults"

Select "View"

Select "EasyJobs"

The overview to activate/deactivate EasyJob mode is displayed.

Select "EasyJobs on"

Select "OK"

EasyJob mode is activated and the default settings are displayed.

Select "Welding"

Five "EasyJob" buttons are displayed for the welding parameters.

Storing EasyJob

~ 3 sec.

< 3 sec.

operating points

NOTE!

The EasyJobs are stored under job numbers 1 - 5 and can also be retrieved using "Job mode".

Storing an EasyJob overwrites any other job saved under the same number!

To store the current welding settings, touch one of the EasyJob buttons for about

three seconds

The size and colour of the button changes. After about three seconds, the button is displayed green with a frame.

The settings have now been stored. The most recently stored settings will be active. An active EasyJob is displayed with a tick on the EasyJob button. Unused EasyJob buttons are displayed in dark grey.

Retrieving EasyJob operating points

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

ton briefly (< 3 seconds)

The size and colour of the button changes briefly; it is then displayed with a tick.

If a tick is not displayed after touching an EasyJob button, this means that there is no operating point saved under this button.

Deleting EasyJob

> 5 sec.

operating points

To delete an EasyJob operating point, touch the relevant EasyJob button for approx-

imately 5 seconds

The button

- First changes its size and colour;

- Is displayed with a frame after about 3 seconds; The saved operating point is overwritten with the current settings.

- Is highlighted in red (= delete) after a total of 5 seconds.

The EasyJob operating point has been deleted.

* ... highlighted in red

Job mode

General Up to 1000 jobs can be stored and retrieved in the power source.

This eliminates the need for manual documenting of the welding parameters. "Job mode" enhances the quality of automated and manual applications.

Jobs can only be stored when in welding mode. When storing jobs, the process parameters and certain machine defaults are taken into account in addition to the present welding settings.

Storing settings as a job

Set the parameters that are to be stored as a job:

- Welding parameters

- Welding process

- Process parameters

- Machine defaults (if necessary)

Select "Save as Job"

The job list is displayed.

To overwrite an existing job, select it by turning and pressing the adjusting dial (or selecting "Next"). The selected job can be overwritten after acknowledging the confirmation prompt.

Select "Create a new Job" to create a new job

Press the adjusting dial / select "Next"

The next free job number is displayed.

Turn the adjusting dial and select the desired storage location

Press the adjusting dial / select "Next"

The keyboard is displayed.

Enter a job name

Select "OK" and confirm the job name / press the adjusting dial

The name is saved and a confirmation that the job has been stored is displayed.

To exit, select "Finish" / press the adjusting dial

Job welding retrieving a job

NOTE!

Before retrieving a job, make sure that the welding system has been installed and set up for the job.

Select "Welding process"

Select "Process"

Select "Job mode"

Job mode is activated. "Job welding" and the data from the most recently retrieved job are displayed.

Select "Job welding"

Turn the adjusting dial and select "Job number" (white background)

To select the desired job, press the adjusting dial (blue background)

Turn the adjusting dial to select the desired job number (blue background)

The name of the selected job is displayed above the actual value display.

Press the adjusting dial and accept the selected job number (white background)

Start welding

IMPORTANT! "Job number" is the only parameter that can be altered in Job mode; all

the others are read-only.

Renaming a job

universal

Select "Save as Job"

(also works in Job mode)

The job list is displayed.

Turn the adjusting dial and select the job to be renamed

Select "Rename Job"

The keyboard is displayed.

Change the job name using the keyboard

Select "OK" and confirm the amended job name / press the adjusting dial

The job name is changed and the job list is displayed.

To exit, select "Cancel"

Deleting a job

universal

Select "Save as Job"

(also works in Job mode)

The job list is displayed.

Turn the adjusting dial and select the job to be deleted

Select "Delete Job"

A confirmation prompt asking whether you really want to delete the job is displayed.

Select "Yes" to delete the selected job

The job is deleted, the job list is displayed.

To exit, select "Cancel"

Loading a job The load job function can be used to load the data for a saved job or an EasyJob to the

universal

welding screen. The relevant data from the job is displayed in the welding parameters and can be changed, saved as a new job or EasyJob, or used to start welding.

Select "Save as Job"

(also works in Job mode)

The job list is displayed.

Turn the adjusting dial and select the job to be loaded

Select "load Job"

The load job information is shown.

Select "Yes"

The data for the selected job is loaded onto the welding screen.

The data for the loaded job can now be used for welding (no job mode), changed, or be saved as a new job or an EasyJob.

Optimize job

* Only displayed if the OPT/i CMT Cycle Step option is present on the power source. In TWIN mode, the TWIN

process control button is displayed after the "Process mix" button.

Select "Process parameters"

Select "JOB"

An overview of the job functions is displayed.

Select "Optimize Job"

The overview of the most recently optimised job is displayed.

Turn the adjusting dial and select either the job or the job welding parameters to be

modified

The choice between the job and the job welding parameters can also be made by touching the "Job number / Job parameter" button.

Select job:

- Press the adjusting dial

The job number is highlighted in blue and can now be changed.

- Turn the adjusting dial to select the job to be altered

- Press the adjusting dial to change the job

Select job welding parameters:

- Turn the adjusting dial and select the parameter to be changed

- Press the adjusting dial

The value of the parameter is highlighted in blue and can now be changed.

Setting correction limits for a job

- Turn the adjusting dial; the amended value is applied immediately

- Press the adjusting dial to select other parameters

Select "Finish"

Individual correction limits for welding power and arc length can be defined for each job. If correction limits are defined for a job, the welding power and arc length for the job in question can be corrected within the defined limits while welding.

* Only displayed if the OPT/i CMT Cycle Step option is present on the power source. In TWIN mode, the TWIN

process control button is displayed after the "Process mix" button.

Select "Process parameters"

Select "JOB"

An overview of the job functions is displayed.

Select "Correction limits"

A list of the job correction limits for the last job opened is displayed.

Turn the adjusting dial and select either the job or the job limits to be modified

The choice between the job and the job limits can also be made by touching the "Job number / Job parameter" button.

Select job:

- Press the adjusting dial

The job number is highlighted in blue and can now be changed.

- Turn the adjusting dial to select the job to be altered

- Press the adjusting dial to change the job

Select job limits:

- Turn the adjusting dial and select the desired limit group

- Press the adjusting dial

The selected limit group opens.

- Turn the adjusting dial and select the top or bottom limit

- Press the adjusting dial

The value of the limit parameter is highlighted in blue and can now be changed.

- Turn the adjusting dial; the amended value is applied immediately

- Press the adjusting dial to select other limit parameters

Select "Finish"

Pre-settings for "Save as Job"

Pre-settings for "Save as Job" are used to set the default values that are assumed for every newly created job.

* Only displayed if the OPT/i CMT Cycle Step option is present on the power source. In TWIN mode, the TWIN

process control button is displayed after the "Process mix" button.

Select "Process parameters"

Select "JOB"

An overview of the job functions is displayed.

Select "Pre-settings for "Save as Job""

Confirm the displayed information

The default settings for saving new jobs are displayed.

Turn the adjusting dial and select the desired parameter

Press the adjusting dial

Turn the adjusting dial and change the value

Press the adjusting dial

Select "Finish"

Spot welding

4-step

Spot welding

Select "Welding process"

Select "Process"

Select the desired welding process

100

Select "Mode"

Select "Spot welding"

Select "Process parameters"

Fronius TPS 320i C User guide

Specifications and Main Features

Frequently Asked Questions

User Manual