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TPS 320i C
Operating Instruction [EN]
240 pgs11.32 Mb0
Operating Instruction [CS]
240 pgs11.37 Mb0
Operating Instruction [DE]
244 pgs11.36 Mb0
Operating Instruction [ES]
244 pgs11.34 Mb0
Operating Instruction [ET]
236 pgs11.32 Mb0
Operating Instruction [FR]
248 pgs11.37 Mb0
Operating Instruction [HR]
240 pgs11.35 Mb0
Operating Instruction [HU]
240 pgs11.38 Mb0
Operating Instruction [IT]
244 pgs11.34 Mb0
Operating Instruction [JP]
232 pgs11.59 Mb0
Operating Instruction [NO]
236 pgs11.34 Mb0
Operating Instruction [PL]
244 pgs11.37 Mb0
Operating Instruction [PT]
244 pgs11.34 Mb0
Operating Instruction [RO]
240 pgs11.41 Mb0
Operating Instruction [RU]
248 pgs11.42 Mb0
Operating Instruction [SK]
240 pgs11.37 Mb0
Operating Instruction [SV]
236 pgs11.32 Mb0
Operating Instruction [TR]
236 pgs11.47 Mb0
Operating Instruction [ZH]
228 pgs11.58 Mb0
User guide
248 pgs7.25 Mb0

Fronius TPS 320i C Operating Instruction [EN]

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Operating instructions
TPS 320i C
Operating instructions
EN
42,0426,0113,EN 040-28062022
Contents
Safety rules 9
EN
General information 21
General 23
Welding packages, welding characteristics and welding processes 29
System components 35
Controls, connections and mechanical components 39
Control panel 41
3
Connections, switches and mechanical components 44
Operating concept 47
Input options 49
Display and status line 51
Installation and commissioning 55
Minimum equipment needed for welding task 57
Before installation and commissioning 58
Safety 58 Proper use 58 Setup regulations 58 Mains connection 58 Generator-powered operation 59 Information on system components 59
Connecting the mains cable 60
Commissioning the TPS 320i C 63
Locking and unlocking the power source using the NFC key 74
Welding 77
MIG/MAG modes 79
4
MIG/MAG and CMT welding 83
MIG/MAG and CMT welding parameters 89
Welding parameters for MIG/MAG pulse synergic welding, for CMT welding and PMC welding Welding parameters for MIG/MAG standard synergic welding and LSC welding 90 Welding parameters for MIG/MAG standard manual welding 91 Explanation of footnotes 91
EasyJob mode 92
General 92 Activating EasyJob mode 92 Storing EasyJob operating points 93 Retrieving EasyJob operating points 93 Deleting EasyJob operating points 94
Job mode 95
Spot welding 105
TIG welding 108
MMA welding 113
89
EN
Process parameters 119
Overview 121
Process parameters, General 122
Common process parameters 122 Process parameters for CEL 122 Process parameters for start of welding/end of welding 123 Process parameters for Gas-Setup 125 Process parameters for process control 126 Penetration stabilizer 126 Arc length stabilizer 128 Combination of penetration stabilizer and arc length stabilizer 130
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Process parameters for SynchroPulse 131 Process parameters for Process mix 133 Process parameters for CMT Cycle Step 136 Process parameters for spot welding 137 R/L-check / alignment 137 Process parameters for TIG / electrode setup 138
Components and monitoring process parameters 142
Process parameters, Job 150
Overview – Process parameters, Job 150 Optimising job process parameters 150 Process parameters for correction limits 152 Process parameters for "Save as Job" pre-settings 153
Defaults 157
Defaults 159
General remarks 159 Overview 159
Defaults - view 160
Defaults - System 165
Defaults - System 165 Retrieving device information 165 Restore factory settings 165 Restoring the website password 166 Mode Setup: Setting the special 4-step "Guntrigger", special display for JobMaster, spot welding and torch trigger job selection Service Connect 168 Setting network parameters manually 169 Setting up the WLAN 170 Bluetooth setup 171 Power source configurations 173 Wire feeder setup 173 Interface setup 173
Defaults - Documentation 174
Defaults - Documentation 174 Setting the sampling rate 174 Viewing the logbook 174 Activating/deactivating limit value monitoring 175
Defaults - Administration 176
Defaults - Administration 176 General remarks 176 Explanation of terms 176 Pre-defined roles and users 177 User management overview 177
167
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Administrator and creating roles 178
Recommendation for creating roles and users 178 Creating an administrator key 179 Creating roles 179 Copy roles 180
Creating a user 181
Editing roles / users, deactivating user management 183
CENTRUM - Central User Management 186
Activating the CENTRUM server 186
SmartManager - The power source website 187
SmartManager - The power source website 189
Current system data 193
Current system data 193
Documentation, logbook 194
Documentation 194
Job-Data 196
Job data 196 Job overview 196 Editing a job 196 Importing a job 197 Exporting a job 197 Exporting job(s) as… 197
Power source settings 199
Process parameters 199 Name & location 199 MQTT settings 199 OPC UA settings 199
Backup & Restore 200
General remarks 200 Backup & Restore 200 Automatic backup 201
Signal visualisation 202
User management 203
Overview 205
Update 206
EN
7
Function Packages 209
Synergic lines overview 210
Screenshot 211
Interface 212
Interface 212
Troubleshooting and maintenance 213
Troubleshooting 215
Care, maintenance and disposal 220
Appendix 223
Average consumption values during welding 225
Technical data 226
Explanation of the term "duty cycle" 226 Special voltages 226 Overview with critical raw materials, year of production of the device 227 TPS 320i C 228 TPS 320i C /nc 230 TPS 320i C /S/nc 232 TPS 320i C /MV/nc 234 Radio parameters 236
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
recognised safety standards. If used incorrectly or misused, however, it can cause:
injury or death to the operator or a third party,
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damage to the device and other material assets belonging to the operating
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company, inefficient operation of the device.
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All persons involved in commissioning, operating, maintaining and servicing the device must:
be suitably qualified,
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have sufficient knowledge of welding and
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read and follow these operating instructions carefully.
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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,
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must not be damaged,
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must not be removed,
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must not be covered, pasted or painted over.
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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!
9
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 in-
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structions studying and obeying all safety and danger notices carefully
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performing all stipulated inspection and maintenance work.
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Never use the device for the following purposes:
Thawing out pipes
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Charging batteries
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Starting engines
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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
Environmental conditions
Devices with a higher rating may affect the energy quality of the mains due to their current consumption.
This may affect a number device types in terms of:
Connection restrictions
-
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Criteria with regard to the maximum permissible mains impedance
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Criteria with regard to the minimum short-circuit power requirement
*)
at the interface with the public grid
*)
*)
see "Technical data"
In this case, the plant operator or the person using the device should check whether the device may be connected, where appropriate by discussing the mat­ter with the power supply company.
IMPORTANT! Ensure that the mains connection is earthed properly
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)
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during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
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10
Relative humidity:
up to 50% at 40 °C (104 °F)
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up to 90% at 20 °C (68 °F)
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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
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accident prevention and have been instructed in how to use the device have read and understood these operating instructions, especially the sec-
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tion "safety rules", and have confirmed as much with their signatures are trained to produce the required results.
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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 pre-
-
vention to read these operating instructions, especially the "Safety rules" section and
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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
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Arc radiation, which can damage eyes and skin
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Hazardous electromagnetic fields, which can endanger the lives of those us-
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ing cardiac pacemakers Risk of electrocution from mains current and welding current
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Greater noise pollution
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Harmful welding fumes and gases
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Suitable protective clothing must be worn when working with the device. The protective clothing must have the following properties:
Flame-resistant
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Insulating and dry
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Covers the whole body, is undamaged and in good condition
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Safety helmet
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Trousers with no turn-ups
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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
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and regulation filter Wear regulation protective goggles with side protection behind the protect-
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ive visor Wear stout footwear that provides insulation even in wet conditions
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Protect the hands with suitable gloves (electrically insulated and providing
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protection against heat) Wear ear protection to reduce the harmful effects of noise and to prevent in-
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jury
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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
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flying sparks, harmful welding fumes, noise, possible risks from mains cur­rent and welding current, etc.) Provide suitable protective equipment
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Alternatively, erect suitable safety screens/curtains.
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Noise emission values
Danger from tox­ic gases and va­pours
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.
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
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must be extracted from the working area using appropriate methods.
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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
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Electrodes
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Coatings
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Cleaners, degreasers, etc.
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Welding process used
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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).
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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.
EN
Danger from fly- ing sparks
Risks from mains current and welding current
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.
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
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Never touch the electrode when the power source is switched on.
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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.
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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
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Ensure that all components in the device are de-energised.
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If work on live parts is required, appoint a second person to switch off the main switch at the right moment.
Meandering welding currents
If the following instructions are ignored, meandering welding currents can devel­op with the following consequences:
Fire hazard
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Overheating of parts connected to the workpiece
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Damage to ground conductors
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Damage to device and other electrical equipment
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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, such as insulation against conductive floor or insulation to conductive racks.
If power 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.
EMC Device Classifications
14
Devices in emission class A:
Are only designed for use in industrial settings
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Can cause line-bound and radiated interference in other areas
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Devices in emission class B:
Satisfy the emissions criteria for residential and industrial areas. This is also
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true for residential areas in which the energy is supplied from the public low­voltage 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
emissions, 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
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Network, signal and data transfer lines
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IT and telecommunications devices
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Measuring and calibrating devices
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Supporting measures for avoidance of EMC problems:
Mains supply
1. If electromagnetic interference arises despite the correct mains connec-
-
tion, additional measures are necessary (e.g. use of a suitable line filter)
Welding power-leads
2. must be kept as short as possible
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must be laid close together (to avoid EMF problems)
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must be kept well apart from other leads
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Equipotential bonding
3.
Earthing of the workpiece
4. If necessary, establish an earth connection using suitable capacitors.
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Shield, if necessary
5. Shield other devices nearby
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Shield the entire welding installation
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EN
EMF measures Electromagnetic fields may pose as yet unknown risks to health:
Effects on the health of persons in the vicinity, e.g. those with pacemakers
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and hearing aids Individuals with pacemakers must seek advice from their doctor before ap-
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proaching the device or any welding that is in progress For safety reasons, maintain as large a distance as possible between the
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welding power-leads and the head/torso of the welder Do not carry welding power-leads and hosepacks over the shoulders or wind
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them around any part of the body
Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example:
Fans
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Cogs
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Rollers
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Shafts
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Wirespools and welding wires
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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.
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During operation
Ensure that all covers are closed and all side panels are fitted properly.
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Keep all covers and side panels closed.
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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 wirefeeder) 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 or ropes onto all suspension points provided on the load-carry-
-
ing equipment. Chains and ropes must be at the smallest angle possible to the vertical.
-
Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).
-
If the wirefeeder 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 tackle (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
16
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
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Max. oil content < 25 mg/m³
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Use filters if necessary.
EN
Danger from shielding gas cyl­inders
Shielding gas cylinders contain gas under pressure and can explode if damaged. As the shielding gas cylinders are part of the welding equipment, they must be handled with the greatest of care.
Protect shielding gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instructions to prevent them falling over.
Keep the shielding gas cylinders well away from any welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.
Only use shielding gas cylinders suitable for the application in hand, along with the correct and appropriate accessories (regulator, hoses and fittings). Only use shielding gas cylinders and accessories that are in good condition.
Turn your face to one side when opening the valve of a shielding gas cylinder.
Close the shielding gas cylinder valve if no welding is taking place.
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
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the main gas supply. Close the shielding gas cylinder valve or main gas supply if no welding is tak-
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ing place. Check the shielding gas cylinder or main gas supply for uncontrolled gas
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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°.
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Special regulations apply in rooms at risk of fire or explosion
Observe relevant national and international regulations.
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Use internal directives and checks to ensure that the workplace environment is always clean and clearly laid out.
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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
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Wirespool
-
Shielding gas cylinder
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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
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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.
18
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.
EN
Commissioning, maintenance and repair
Safety inspec­tion
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.
The manufacturer recommends that a safety inspection of the device is per­formed at least once every 12 months.
The manufacturer recommends that the power source be calibrated during the same 12-month period.
A safety inspection should be carried out by a qualified electrician
after any changes are made
-
after any additional parts are installed, or after any conversions
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after repair, care and maintenance has been carried out
-
at least every twelve months.
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For safety inspections, follow the appropriate national and international stand­ards and directives.
Further details on safety inspection and calibration can be obtained from your service centre. They will provide you on request with any documents you may re­quire.
Disposal Waste electrical and electronic equipment must be collected separately and re-
cycled in an environmentally-friendly way, in accordance with the European Dir­ective and national legislation. Used equipment must be returned to the distrib­utor or disposed of via an approved local collection and disposal facility. Correct disposal of used equipment promotes the sustainable recycling of material re­sources. Failing to dispose of used equipment correctly can lead to adverse health and/or environmental impacts.
Packaging materials
Separate collection according to material. Check your local authority regulations. Crush containers to reduce size.
Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage
and electromagnetic compatibility directives (e.g. relevant product standards of the EN 60 974 series).
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Fronius International GmbH hereby declares that the device is compliant with Directive 2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following address: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA.
Data protection The user is responsible for the safekeeping of any changes made to the factory
settings. The manufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We reserve the right to make changes. The contents of the operating instructions shall not provide the basis for any claims whatsoever on the part of the pur­chaser. If you have any suggestions for improvement, or can point out any mis­takes that you have found in the instructions, we will be most grateful for your comments.
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General information
21
22
General
Device concept The TPS 320i C MIG/MAG power
source is a completely digitised, micro­processor-controlled 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 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.
-
The devices are used in workshops and industry for manual and automated ap­plications 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.
23
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
IC: 12270A-SPBMCU2
EU Conformity with Directive 2014/53 / EU - Radio Equipment Directive (RED)
which could 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.
24
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 ra-
dio frequency 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.
25
*)
*) 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 dis-
-
tance
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
26
Description of
A B
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!
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 electric 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.
27
2.2 Use forced-air ventilation or a local extraction system to remove welding
xx,xxxx,xxxx *
fumes.
2.3 Remove welding fumes with a fan.
3 Welding sparks can cause an explosion or fire.
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 neces-
sary, 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 col-
lar 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
28
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 4,066,012 (enables MIG/MAG standard synergic welding)
Pulse Welding Package 4,066,013 (enables MIG/MAG pulse synergic welding)
LSC Welding Package * 4,066,014 (enables the LSC process)
PMC Welding Package ** 4,066,015 (enables the PMC process)
EN
Welding charac­teristics
CMT Welding Package *** 4,066,016 (enables the CMT process)
ConstantWire Welding Package 4,066,019 (enables constant current or constant voltage operation during brazing)
* 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
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 1,0mm M21 - arc blow *
-
MIG/MAG 3450 PMC Steel 1,0mm M21 - dynamic *
-
MIG/MAG 3044 Pulse AlMg5 1.2 mm I1 - universal *
-
MIG/MAG 2684 Standard Steel 0.9 mm M22 - root *
-
29
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
additive
CMT Characteristics with reduced heat input and greater stability at a higher depos­ition rate for welding bead onto bead in adaptive structures
arc blow
PMC Characteristic with improved arc break properties by deflecting the external magnetic fields
arcing
Standard Characteristics for a special type of hardfacing on a wet or dry surface (e.g. grinding rollers in the sugar and ethanol industries)
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
30
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
LH
Characteristics for LaserHybrid applications (laser + MIG/MAG process)
marking
Characteristics for marking conductive surfaces
Marking is performed by spark erosion without significant power, triggered by a reversing wire electrode.
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
EN
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
pin
Characteristics for welding pins to a surface A withdrawal movement of the wire electrode in conjunction with the current path define the appearance of the pin.
pipe
PMC Characteristic for pipe applications and positional welding on narrow gap applic­ations
retro
CMT, Pulse, PMC, Standard
31
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
seam track
PMC, Pulse Characteristics with increased seam tracking signal, especially for use with sever­al welding torches on one component.
TIME
PMC Characteristics for welding with long stick out and TIME shielding gases (T.I.M.E. = Transferred Ionized Molten Energy)
universal
CMT, PMC, Pulse, Standard Characteristics for conventional welding tasks in renowned Fronius quality
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
32
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.
EN
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
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.
33
Summary of SynchroPulse welding
SynchroPulse is available for all processes (standard/pulsed/LSC/PMC). Due to the cyclical change of welding power between two operating points, Syn­chroPulse achieves a flaking seam appearance and non-continuous heat input.
Summary of the CMT process
CMT = Cold Metal Transfer
A special CMT drive unit is required for the CMT process.
The reversing wire movement in the CMT process results in a droplet detachment with improved dip transfer arc properties. The advantages of the CMT process are as follows
Low heat input
-
Less spattering
-
Reduced emissions
-
High process stability
-
The CMT process is suitable for:
Joint welding, cladding and brazing – particularly in the case of high require-
-
ments 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.
34
System components
(1)
(2)
(3)
(4)
General The power sources can be operated with various system components and op-
tions. 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
EN
(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
-
35
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
36
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
OPT/i SynchroPulse 10 Hz
To increase the SynchroPulse frequency from 3 Hz to 10 Hz
EN
37
38
Controls, connections and mechan-
ical components
39
40
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.
EN
Safety
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried
▶
out by technically trained and qualified personnel. Read and understand this document in full.
▶
Read and understand all safety rules and user documentation for this device
▶
and all system components.
41
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 as-
-
signed NFC keys)
NFC key = NFC card or NFC key ring
42
(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.
EN
43
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
(2) (-) current socket with bayonet latch
used to connect the grounding cable during MIG/MAG welding
Rear
44
(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
EN
45
46
Operating concept
47
48
Input options
EN
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
▶
understood these operating instructions Do not use the functions described here until you have thoroughly read and
▶
understood 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.
49
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.
50
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 diamet-
-
er) Active stabilizers and special processes
-
Bluetooth status
-
Logged-on users / power source locked state
-
Active faults
-
Time and date
-
EN
(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.
-
51
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
diameter)
(4) Stabilizers/CMT Cycle Step active indicator
Arc lengths
Penetration stabilizer
CMT Cycle Step (only in combination with the CMT welding pro-
cess)
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)
52
or
intermediate arc indicator
or
Current limit exceeded!
1
Status bar – Current limit reached
the key symbol when the power source is locked (e.g. when the "locked" profile/role is active)
(7) Time and date
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
1
EN
The information appears.
Select "Hide information" to exit
2
Reduce the wire speed, welding current, welding voltage or material thick-
3
ness
or
Increase the distance between the contact tip and the workpiece
Further information on the current limit can be found in the Troubleshooting section on page 215
53
54
Installation and commissioning
55
56
Minimum equipment needed for welding task
General Depending on which welding process you intend to use, a certain minimum equip-
ment 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.
EN
MIG/MAG gas­cooled welding
MIG/MAG wa­ter-cooled 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!
TIG DC welding
MMA welding
OPT/i PushPull
-
CMT interconnecting hosepack
-
Wire electrode
-
Gas connection (shielding gas supply)
-
Power source
-
Grounding (earthing) cable
-
TIG gas-valve torch
-
Gas connection (shielding gas supply)
-
Filler metal (depending on the application)
-
Power source
-
Grounding (earthing) cable
-
Electrode holder with welding cable
-
Rod electrodes
-
57
Before installation and commissioning
Safety
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal 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:
-
-
Setup regula­tions
The device is tested to IP 23 protection, meaning:
-
-
WARNING!
All the work and functions described in this document must only be carried out by technically trained and qualified personnel. Read and understand this document in full.
Read and understand all safety rules and user documentation for this device and all system components.
following all the information in the operating instructions carrying out all the specified inspection and servicing work
protection against penetration by solid foreign bodies with diameters > 12.5 mm (0.49 in.) protection against direct sprays of water at any angle up to 60° from the ver­tical
Mains connec­tion
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.
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.
-
58
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
1max
to select the correct generator output. The maximum apparent power S
of the power source is calculated for 3-
1max
phase devices as follows:
S
= 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
GEN
of thumb:
S
GEN
= S
1max
x 1.35
EN
Information on system compon­ents
A smaller generator may be used when not welding at full power.
IMPORTANT! The generator apparent power S the maximum apparent power S
of the power source.
1max
must always be higher than
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.
59
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
▶
personnel. Observe national standards and directives.
▶
60
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.
Connecting the mains cable ­general
IMPORTANT! The ground conductor should be approx. 20 - 25 mm (0.8 - 1 in.)
longer than the phase conductors.
1 2
3
EN
4
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)
61
5
2
1
3
4
5
6
1
2
3
5
4
6
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
6
5 x TX25 Tightening torque = 3 Nm
7
62
Commissioning the TPS 320i C
EN
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 water­cooled 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. Se-
▶
cure gas cylinders to prevent them from toppling over. Observe the safety rules of the gas cylinder manufacturer.
▶
63
Connecting the gas hose to the TPS 320i C
Place the gas cylinder on a solid,
1
level surface in such a way that it remains stable
Secure the gas cylinder to prevent
2
it from toppling over (but not around the neck of the cylinder)
Take the protective cap off the gas
3
cylinder
Briefly open the gas cylinder valve
4
to remove any dust or dirt
Check the seal on the pressure
5
regulator
Screw the pressure regulator onto
6
the gas cylinder and tighten it
Connect the pressure regulator to
7
the shielding gas connection on the power source using the gas hose
64
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 inter-
▶
connecting hosepack Do not wind up long grounding cables - coil effect!
▶
Lay long grounding cables in loops
EN
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
▶
component 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)
65
Plug the grounding cable into the
1
(-) current socket
Lock the grounding cable in place
2
Use the other end of the grounding
3
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
Before connecting the welding torch, check that all cables, lines and hosep-
1
acks are undamaged and properly insulated.
2
66
Inserting/repla­cing feed rollers
In order to achieve optimum wire electrode feed, the feed rollers must be suit­able for the diameter and alloy of the wire being welded.
NOTE!
Only use feed rollers that 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
EN
3 4
67
Inserting the wirespool
CAUTION!
Risk of injury due to springiness of spooled wire electrode.
While inserting the wirespool, hold the end of the wire electrode firmly to
▶
avoid injuries 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.
▶
1
68
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 fit-
▶
ted 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.
EN
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.
▶
69
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
70
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
▶
(grounded) parts (e.g. the housing, etc.) when pressing the torch trigger
1
2
4
5
3
3
1
1
2
3
4
EN
Setting the con­tact pressure
NOTE!
Set the contact pressure in such a way that the wire electrode is not deformed but nevertheless ensures proper wirefeeding.
1
Contact pressure standard values for U-groove rollers
Steel: 4 - 5
CrNi 4 - 5
Tubular cored electrodes 2 - 3
71
Adjusting the
4
3
STOP
6
7
5
1
2
2
1
2
1
4
STOP
OK
3
brake
NOTE!
After releasing the torch trigger the wirespool should stop unreeling.
Adjust brake if necessary.
1
3
2
Design of the brake
72
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 of the brake is for in­formation purposes only.
Performing R/L alignment
IMPORTANT! For optimum welding results, the manufacturer recommends per-
forming 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 137).
EN
73
Locking and unlocking the power source using the NFC key
General 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
74
Hold the NFC key on the NFC key reader
1
The key symbol appears on the display.
The key symbol is then displayed in the status bar.
The power source is now locked. Only the welding parameters can be viewed and adjusted using the adjusting dial.
Any attempt to call a locked function will result in a notification being displayed.
Unlocking the power source
Hold the NFC key on the NFC key reader
1
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 - Administration" section from page 176.
EN
75
76
Welding
77
78
MIG/MAG modes
S
EN
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
▶
understood these Operating Instructions. Do not use the functions described here until you have fully read and under-
▶
stood 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
I
Welding-current phase: uniform thermal input into the base material, whose tem­perature is raised by the advancing heat
I-E
Final current phase: to prevent any local overheating of the base material due to heat build-up towards the end of welding. This eliminates any risk of weld seam drop-through.
t-E
Final current time
79
E
2-step mode
t
I
+
I
GPr
GPo
t
I
+
I
GPr GPo
+
End arc length correction
SL2
Slope 2: the welding current is steadily lowered until it reaches the final current
GPo
Gas post-flow
A detailed explanation of the parameters can be found in the section headed "Process parameters"
"2-step mode" is suitable for
Tacking work
-
Short weld seams
-
Automated and robot welding
-
4-step mode
"4-step mode" is suitable for longer weld seams.
80
Special 4-step
I
t
I
GPr GPo
I-E
SL1t-S
I-S
SL2
+ +
S
E
t-E
I
I-S
I-E
+
I
S
E
GPr GPoSL1 SL2
t
t-S t-E
mode
Special 2-step mode
EN
"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 2­step mode, the arc starts at a lower power, which makes it easier to stabilise.
81
Spot welding
I
+
I
GPr GPoSPt
t
The "Spot welding" mode is suitable for welded joints on overlapped sheets.
82
MIG/MAG and CMT welding
EN
Safety
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried
▶
out by technically trained and qualified personnel. Read and understand this document in full.
▶
Read and understand all safety rules and user documentation for this device
▶
and all system components.
WARNING!
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved and dis-
▶
connect them from the grid. Secure all devices and components involved so they cannot be switched back
▶
on. After opening the device, use a suitable measuring instrument to check that
▶
electrically charged components (such as capacitors) have been discharged.
MIG/MAG and CMT welding – overview
Switch on the power source
The "MIG/MAG and CMT welding" section comprises the following steps:
Switching on the power source
-
Selecting the welding process and operating mode
-
Selecting the filler metal and shielding gas
-
Setting the welding and process parameters
-
Setting the shielding gas flow rate
-
MIG/MAG or CMT welding
-
NOTE!
If using a cooling unit, follow the safety rules and note the operating conditions in the cooling unit Operating Instructions.
Connect the mains cable
1
Move the mains switch to the "I" position
2
A cooling unit connected to the welding system will begin to operate.
IMPORTANT! For optimum welding results, the manufacturer recommends per­forming an R/L alignment when starting the device for the first time and when any changes are made to the welding system. More information on R/L alignment can be found under "R/L alignment" in the MIG/MAG process parameters section (page 137).
83
Setting the
2
3
1
*
5
4
4-step
welding process and operating mode
Setting the welding process
* next page: Electrode, TIG
Select "Welding process"
1
Select "Process"
2
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
3
Setting the operating mode
84
Select "Mode"
4
An overview of the operating modes is displayed:
Selecting the
1
2
3
filler metal and shielding gas
2-step mode
-
4-step mode
-
Special 2-step mode
-
Special 4-step mode
-
Select the desired operating mode
5
EN
Select "Welding process"
1
Select "Filler metal"
2
Select "Change material settings"
3
Turn the adjusting dial and select the desired filler metal
4
Select "Next" / press the adjusting dial
5
Turn the adjusting dial and select the desired wire diameter
6
Select "Next" / press the adjusting dial
7
Turn the adjusting dial and select the desired shielding gas
8
Select "Next" / press the adjusting dial
9
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
10
To select the desired characteristic, press the adjusting dial (blue back-
11
ground)
Turn the adjusting dial and select the desired characteristic
12
Press the adjusting dial and apply the selected characteristic (white back-
13
ground)
Select "Next"
14
85
Setting the
1
2
3
4
welding para­meters
The confirmation step of the filler metal wizard is displayed:
Select "Save" / press the adjusting dial
15
The selected filler metal and associated characteristics per welding process will be saved.
Select "Welding"
1
Select the desired welding parameter by turning the adjusting dial
2
Press the adjusting dial to change the welding parameter
3
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
4
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.
86
Press the adjusting dial to call up the welding parameters overview
5
Adjust the process parameters accordingly to make user- or application-spe-
1
6
cific settings on the welding system
EN
Setting the shielding gas flow rate
MIG/MAG or CMT welding
Open the gas cylinder valve
1
Press the gas test button
2
Shielding gas flows out
Turn the adjusting screw on the underside of the pressure regulator until the
3
pressure gauge shows the required shielding gas flow rate
Press the gas test button
4
The flow of gas stops.
Select "Welding" to display the welding parameters
1
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
2
Whenever welding ends, the actual values for the welding current, welding voltage and wire speed are stored, and HOLD appears on the display.
87
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.
88
MIG/MAG and CMT welding parameters
EN
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.
1)
Wire speed
0.5 - max.
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
1)
2) 3)
m/min / 19.69 - max
2) 3)
ipm.
89
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
1)
0.1 - 30.0 mm 2) / 0.004 - 1.18 2) in.
Wire speed
0.5 - max.
1)
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
90
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
EN
Explanation of footnotes
Wire speed
1)
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.
91
EasyJob mode
3
1
2
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 / View / EasyJobs
1
The overview to activate/deactivate EasyJob mode is displayed.
Select "EasyJobs on"
4
Select "OK"
5
EasyJob mode is activated and the default settings are displayed.
Select "Welding"
6
Five EasyJob buttons are displayed for the welding parameters.
92
Storing EasyJob
1
~ 3 sec.
1
< 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
1
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.
EN
Retrieving Easy­Job operating points
To retrieve a saved EasyJob operating point, touch the corresponding Easy-
1
Job button briefly (< 3 seconds)
The size and colour of the button changes briefly; it is then displayed with a tick.
If a tick is not displayed after touching an EasyJob button, this means that there is no operating point saved under this button.
93
Deleting Easy-
1
> 5 sec.
*
Job operating points
To delete an EasyJob operating point, touch the relevant EasyJob button for
1
approximately 5 seconds
The button
First changes its size and colour;
-
Is displayed with a frame after about 3 seconds;
-
The saved operating point is overwritten with the current settings. Is highlighted in red (= delete) after a total of 5 seconds.
-
The EasyJob operating point has been deleted.
* ... highlighted in red
94
Job mode
2
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.
EN
Storing settings as a job
Set the parameters that are to be stored as a job:
1
Welding parameters
-
Welding process
-
Process parameters
-
Machine defaults (if necessary)
-
Select "Save as Job"
2
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"
3
The next free job number is displayed.
Turn the adjusting dial and select the desired storage location
4
Press the adjusting dial / select "Next"
5
The keyboard is displayed.
95
Enter a job name
3
1
2
6
Select "OK" and confirm the job name / press the adjusting dial
7
The name is saved and a confirmation that the job has been stored is displayed.
To exit, select "Finish" / press the adjusting dial
8
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"
1
Select "Process"
2
Select "Job mode"
3
Job mode is activated. "Job welding" and the data from the most recently retrieved job are displayed.
Select "Job welding"
4
Turn the adjusting dial and select "Job number" (white background)
5
To select the desired job, press the adjusting dial (blue background)
6
Turn the adjusting dial to select the desired job number (blue background)
7
The name of the selected job is displayed above the actual value display.
Press the adjusting dial and accept the selected job number (white back-
8
ground)
Start welding
9
IMPORTANT! "Job number" is the only parameter that can be altered in Job
mode; all the others are read-only.
96
Renaming a job
1
2
3
universal
Select "Save as Job"
1
(also works in Job mode)
The job list is displayed.
EN
Turn the adjusting dial and select the job to be renamed
2
Select "Rename Job"
3
The keyboard is displayed.
Change the job name using the keyboard
4
Select "OK" and confirm the amended job name / press the adjusting dial
5
The job name is changed and the job list is displayed.
To exit, select "Cancel"
6
97
Deleting a job
1
2
3
universal
Select "Save as Job"
1
(also works in Job mode)
The job list is displayed.
98
Turn the adjusting dial and select the job to be deleted
2
Select "Delete Job"
3
A confirmation prompt asking whether you really want to delete the job is dis­played.
Select "Yes" to delete the selected job
4
The job is deleted, the job list is displayed.
To exit, select "Cancel"
5
Loading a job The load job function can be used to load the data for a saved job or an EasyJob
1
universal
to the welding screen. The relevant data from the job is displayed in the welding parameters and can be changed, saved as a new job or EasyJob, or used to start welding.
EN
Select "Save as Job"
1
(also works in Job mode)
The job list is displayed.
Turn the adjusting dial and select the job to be loaded
2
Select "load Job"
3
The load job information is shown.
Select "Yes"
4
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.
99
Optimize job
2
1
*
3
* 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"
1
Select "JOB"
2
An overview of the job functions is displayed.
Select "Optimize Job"
3
100
The overview of the most recently optimised job is displayed.
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