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TPS 320i C
Operating instructions
EN
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
EN
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
3
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
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
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
EN
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
5
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
6
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
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
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
EN
7
Showing/hiding the filter 219
Screenshot 220
Screenshot 220
Interface 221
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
8
Safety rules
EN
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.
9
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
10
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.
EN
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.
11
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.
12
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.
EN
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.
13
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).
14
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
EN
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.
15
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.
16
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.
EN
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
17
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.
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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
EN
Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA.
Data protection The user is responsible for the safekeeping of any changes made to the factory settings.
The manufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We reserve the
right to make changes. The contents of the operating instructions shall not provide the
basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for improvement, or can point out any mistakes that you have found in the instructions, we will be most grateful for your comments.
19
20
General information
21
22
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.
EN
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.
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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.
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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
EN
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.
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*)
*) 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
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Description of the
AB
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!
EN
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.
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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.
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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
EN
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
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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
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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
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