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TPS 320i, TPS 400i, TPS 500i, TPS 600i, TPS 400i LSC ADV

Fronius TPS 320i, TPS 400i, TPS 500i, TPS 600i, TPS 400i LSC ADV Operating Instruction [EN]

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Operating instructions
TPS 320i / 400i / 500i / 600i TPS 400i LSC ADV
Operating instructions
EN
42,0426,0114,EN 040-08062022
Contents
Explanation of safety notices 10 General 10 Proper use 11 Mains connection 11 Environmental conditions 11 Obligations of the operator 12 Obligations of personnel 12 Residual current protective device 12 Protecting yourself and others 12 Noise emission values 13 Danger from toxic gases and vapours 13 Danger from flying sparks 14 Risks from mains current and welding current 14 Meandering welding currents 15 EMC Device Classifications 15 EMC measures 16 EMF measures 16 Specific hazards 16 Requirement for the shielding gas 17 Danger from shielding gas cylinders 18 Danger from escaping shielding gas 18 Safety measures at the installation location and during transport 18 Safety measures in normal operation 19 Commissioning, maintenance and repair 20 Safety inspection 20 Disposal 20 Safety symbols 20 Data protection 21 Copyright 21
EN
General information 23
Device concept 25 Functional principle 25 Application areas 25 Conformities 26 Bluetooth trademarks 27 Warning notices on the device 27
General 29 Welding packages 29 Welding characteristics 29 Summary of MIG/MAG pulse synergic welding 34 Summary of MIG/MAG standard synergic welding 34 Summary of the PMC process 34 Summary of the LSC / LSC Advanced process 34 Summary of SynchroPulse welding 35 Summary of the CMT process 35 Short description of the CMT Cycle Step welding process 35 Short description of WireSense 36 Brief description of ConstantWire 36 Short description of arc air gouging 36
System components 37
General 37 Overview 37 Options 38 OPT/i Safety Stop PL d option 40
3
Controls, connections and mechanical components 41
Control panel 43
General 43 Safety 43 Control panel 44
Connections, switches and mechanical components 46
TPS 320i / 400i / 500i / 600i, TPS 400i LSC ADV power source 46
Operating concept 49
General 51 Turning/pressing the adjusting dial 51 Pressing buttons 52 Pressing on the display 52
Display 53 Status bar 54 Status bar – Current limit reached 55
Installation and commissioning 57
Minimum equipment needed for welding task 59
General 59 MIG/MAG gas-cooled welding 59 MIG/MAG water-cooled welding 59 MIG/MAG automated welding 59 Manual CMT welding 59 Automated CMT welding 60 TIG DC welding 60 MMA welding 60 Arc air gouging 60
Before installation and commissioning 61
Safety 61 Proper use 61 Setup regulations 61 Mains connection 61 Generator-powered operation 62 Information on system components 62
Connecting the mains cable 63
General 63 Stipulated mains cables 63 Safety 64 Connecting the mains cable - general 64
Commissioning the TPS 320i / 400i / 500i / 600i, TPS 400i LSC ADV 66
Safety 66 General 66 TPS 320i / 400i / 500i / 600i: Assembling the system components (overview) 67 TPS 400i LSC ADV: Assembling the system components (overview) 68 Fixing the strain-relief device for the interconnecting hosepack 69 Connecting the interconnecting hosepack 69 Correct arrangement of the interconnecting hosepack 70 Connecting the gas cylinder 71 Establishing a ground earth connection 72 Connecting MIG/MAG welding torches to the wirefeeder 73 Other tasks 75
Locking and unlocking the power source using the NFC key 76
General 76 Locking and unlocking the power source using the NFC key 76
Welding 79
4
General 81 Symbols and their explanations 81 2-step mode 82 4-step mode 82 Special 4-step mode 83 Special 2-step mode 83 Spot welding 84
Safety 85 MIG/MAG and CMT welding – overview 85 Switch on the power source 85 Setting the welding process and operating mode 86 Selecting the filler metal and shielding gas 87 Setting the welding parameters 88 Setting the shielding gas flow rate 89 MIG/MAG or CMT welding 89
MIG/MAG and CMT welding parameters 91
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 92 Welding parameters for MIG/MAG standard manual welding 93 Explanation of footnotes 93
General 94 Activating EasyJob mode 94 Storing EasyJob operating points 95 Retrieving EasyJob operating points 95 Deleting EasyJob operating points 96
Job mode 97
General 97 Storing settings as a job 97 Job welding - retrieving a job 98 Renaming a job 99 Deleting a job 100 Loading a job 101 Optimize job 102 Setting correction limits for a job 103 Pre-settings for "Save as Job" 105
Spot welding 107
Safety 110 Preparations 110 TIG welding 111 Igniting the arc 113 Finishing welding 114
Safety 115 Preparatory work 115 MMA welding 116 Welding parameters for manual metal arc welding 119
Safety 120 Preparation 120 Arc air gouging 121
91
EN
Process parameters 123
Overview 125
Process parameters, General 126
5
Common process parameters 126 Process parameters for CEL 126 Process parameters for start of welding/end of welding 127 Process parameters for Gas-Setup 129 Process parameters for process control 130 Penetration stabilizer 130 Arc length stabilizer 132 Combination of penetration stabilizer and arc length stabilizer 134 Process parameters for SynchroPulse 135 Process parameters for Process mix 137 Process parameters for TWIN process regulation 140 Process parameters for CMT Cycle Step 142 Process parameters for ConstantWire 143 Process parameters for spot welding 144 R/L-check / alignment 144 Process parameters for TIG / electrode setup 145
Process parameters - Components and monitoring 149 Process parameters for components 149 Process parameters for emptying / filling torch hosepack 151 System adjust 152 Arc break watchdog settings 152 Wire stick contact tip 153 Wire stick work piece 153 Welding circuit coupling 154 Wire end monitoring 155 Gas monitoring 156 Motor force monitoring 157 Wire buffer monitoring 157
Process parameters, Job 158
Overview – Process parameters, Job 158 Optimising job process parameters 158 Process parameters for correction limits 161 Process parameters for "Save as Job" pre-settings 161
Defaults 165
General remarks 167 Overview 167
Defaults view 168 Setting the language 168 Setting units / standards 168 Setting the time and date 169 Retrieving system data 169 Displaying characteristics 172
Defaults - System 173
Defaults - System 173 Retrieving device information 173 Restore factory settings 173 Restoring the website password 174 Mode Setup: Setting the special 4-step "Guntrigger", special display for JobMaster, spot welding and torch trigger job selection Service Connect 176 Setting network parameters manually 177 Setting up the WLAN 178 Bluetooth setup 179 Power source configurations 181 Wire feeder setup 181 Interface setup 181 TWIN setup 182
175
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Defaults - Documentation 183 Setting the sampling rate 183 Viewing the logbook 183 Activating/deactivating limit value monitoring 184
Defaults - Administration 185
Defaults - Administration 185 General remarks 185 Explanation of terms 185 Pre-defined roles and users 186 User management overview 186
Administrator and creating roles 187
Recommendation for creating roles and users 187 Creating an administrator key 188 Creating roles 188 Copy roles 189
Creating a user 190 Copying users 190
Editing roles / users, deactivating user management 192
Editing roles 192 Deleting roles 192 Editing users 192 Deleting users 193 Deactivating user management 193 Lost NFC administrator key? 194
CENTRUM - Central User Management 195
Activating the CENTRUM server 195
EN
SmartManager - The power source website 197
SmartManager - The power source website 199
General 199 Opening and logging into the power source SmartManager 199 Help function, should you be unable to log in 200 Changing password / logging off 200 Settings 201 Language selection 201 Status indicator 202 Fronius 202
Current system data 203
Documentation 204
Job data 206 Job overview 206 Editing a job 206 Importing a job 207 Exporting a job 207 Exporting job(s) as… 207
Power source settings 209
Process parameters 209 Name & location 209 MQTT settings 209 OPC UA settings 209
General remarks 210 Backup & Restore 210 Automatic backup 211
Signal visualisation 212
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General 213 Users 213 User roles 213 Export & import 214 CENTRUM 214
Overview 215 Expand all groups / Reduce all groups 215 Save as XML-file 215
Update 216
Update 216 Searching for an update file (performing the update) 216 Fronius WeldConnect 218
Function Packages 219 Welding Packages 219 Special characteristics 219 Options 219 Installing a function package 219
Synergic lines overview 220
Characteristics overview 220 Showing/hiding the filter 220
Screenshot 221
Interface 222
Troubleshooting and maintenance 223
General 225 Safety 225 MIG/MAG welding – Current limit 225 Power source - troubleshooting 226
Care, maintenance and disposal 230
General 230 Safety 230 At every start-up 230 Every 2 months 230 Every 6 months 230 Updating firmware 231 Disposal 231
Appendix 233
Average wire electrode consumption during MIG/MAG welding 235 Average shielding gas consumption during MIG/MAG welding 235 Average shielding gas consumption during TIG welding 235
Technical data 236
Explanation of the term "duty cycle" 236 Special voltages 236 Overview with critical raw materials, year of production of the device 237 TPS 320i 238 TPS 320i /nc 240 TPS 320i /600V/nc 242 TPS 320i /MV/nc 243 TPS 400i 245 TPS 400i /nc 247 TPS 400i /600V/nc 249 TPS 400i /MV/nc 250 TPS 400i LSC ADV 252
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TPS 400i LSC ADV /nc 254 TPS 400i LSC ADV /600V/nc 256 TPS 400i LSC ADV /MV/nc 257 TPS 500i 259 TPS 500i /nc 261 TPS 500i /600V/nc 263 TPS 500i /MV/nc 264 TPS 600i 266 TPS 600i /nc 268 TPS 600i /600V/nc 270 Radio parameters 271
EN
9
Safety rules
Explanation of safety notices
DANGER!
Indicates immediate danger.
If not avoided, death or serious injury will result.
▶
WARNING!
Indicates a potentially hazardous situation.
If not avoided, death or serious injury may result.
▶
CAUTION!
Indicates a situation where damage or injury could occur.
If not avoided, minor injury and/or damage to property may result.
▶
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
General The device is manufactured using state-of-the-art technology and according to
recognised safety standards. If used incorrectly or misused, however, it can cause:
injury or death to the operator or a third party,
-
damage to the device and other material assets belonging to the operating
-
company, inefficient operation of the device.
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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,
-
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.
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This is for your personal safety!
Proper use The device is to be used exclusively for its intended purpose.
The device is intended solely for the welding processes specified on the rating plate. Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage.
Proper use includes:
carefully reading and following all the instructions given in the operating in-
-
structions studying and obeying all safety and danger notices carefully
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performing all stipulated inspection and maintenance work.
-
Never use the device for the following purposes:
Thawing out pipes
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Charging batteries
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Starting engines
-
The device is designed for use in industry and the workshop. The manufacturer accepts no responsibility for any damage caused through use in a domestic set­ting.
The manufacturer likewise accepts no liability for inadequate or incorrect results.
EN
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
-
-
Criteria with regard to the maximum permissible mains impedance
-
Criteria with regard to the minimum short-circuit power requirement
*)
at the interface with the public grid
*)
*)
see "Technical data"
In this case, the plant operator or the person using the device should check whether the device may be connected, where appropriate by discussing the mat­ter with the power supply company.
IMPORTANT! Ensure that the mains connection is earthed properly
Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage.
Ambient temperature range:
during operation: -10 °C to + 40 °C (14 °F to 104 °F)
-
during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
-
Relative humidity:
up to 50% at 40 °C (104 °F)
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up to 90% at 20 °C (68 °F)
-
The surrounding air must be free from dust, acids, corrosive gases or substances, etc. Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)
11
Obligations of the operator
The operator must only allow persons to work with the device who:
are familiar with the fundamental instructions regarding safety at work and
-
accident prevention and have been instructed in how to use the device have read and understood these operating instructions, especially the sec-
-
tion "safety rules", and have confirmed as much with their signatures are trained to produce the required results.
-
Checks must be carried out at regular intervals to ensure that operators are working in a safety-conscious manner.
Obligations of personnel
Residual current protective device
Protecting your­self and others
Before using the device, all persons instructed to do so undertake:
to observe the basic instructions regarding safety at work and accident pre-
-
vention to read these operating instructions, especially the "Safety rules" section and
-
sign to confirm that they have understood them and will follow them.
Before leaving the workplace, ensure that people or property cannot come to any harm in your absence.
Local regulations and national guidelines may require a residual current protect­ive device when connecting equipment to the public grid. The type of residual current protective device recommended by the manufac­turer for the equipment is indicated in the technical data.
Anyone working with the device exposes themselves to numerous risks, e.g.
flying sparks and hot pieces of metal
-
Arc radiation, which can damage eyes and skin
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Hazardous electromagnetic fields, which can endanger the lives of those us-
-
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
-
12
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
Keep all persons, especially children, out of the working area while any devices are in operation or welding is in progress. If, however, there are people in the vi­cinity:
Make them aware of all the dangers (risk of dazzling by the arc, injury from
-
flying sparks, harmful welding fumes, noise, possible risks from mains cur­rent and welding current, etc.) Provide suitable protective equipment
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Alternatively, erect suitable safety screens/curtains.
-
EN
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
-
must be extracted from the working area using appropriate methods.
-
Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least 20 m³ per hour at all times.
Otherwise, a welding helmet with an air supply must be worn.
If there is any doubt about whether the extraction capacity is sufficient, the measured toxic emission values should be compared with the permissible limit values.
The following components are responsible, amongst other things, for the degree of toxicity of welding fumes:
Metals used for the workpiece
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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).
13
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.
Danger from fly­ing 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
-
Never touch the electrode when the power source is switched on.
-
Double the open circuit voltage of a power source can occur between the welding electrodes of two power sources. Touching the potentials of both electrodes at the same time may be fatal under certain circumstances.
14
Arrange for the mains cable to be checked regularly by a qualified electrician to ensure the ground conductor is functioning properly.
Protection class I devices require a mains supply with ground conductor and a connector system with ground conductor contact for proper operation.
Operation of the device on a mains supply without ground conductor and on a socket without ground conductor contact is only permitted if all national regula­tions for protective separation are observed. Otherwise, this is considered gross negligence. The manufacturer shall not be held liable for any damage arising from such usage.
If necessary, provide adequate earthing for the workpiece.
Switch off unused devices.
Wear a safety harness if working at height.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to prevent anyone from plugging the mains plug back in and switching it on again.
After opening the device:
Discharge all live components
-
Ensure that all components in the device are de-energised.
-
If work on live parts is required, appoint a second person to switch off the main switch at the right moment.
EN
Meandering welding currents
If the following instructions are ignored, meandering welding currents can devel­op with the following consequences:
Fire hazard
-
Overheating of parts connected to the workpiece
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Damage to ground conductors
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Damage to device and other electrical equipment
-
Ensure that the workpiece is held securely by the workpiece clamp.
Attach the workpiece clamp as close as possible to the area that is to be welded.
Position the device with sufficient insulation against electrically conductive envir­onments, 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
Devices in emission class A:
Are only designed for use in industrial settings
-
Can cause line-bound and radiated interference in other areas
-
Devices in emission class B:
Satisfy the emissions criteria for residential and industrial areas. This is also
-
true for residential areas in which the energy is supplied from the public low­voltage mains.
15
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
-
Network, signal and data transfer lines
-
IT and telecommunications devices
-
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
-
must be laid close together (to avoid EMF problems)
-
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.
-
Shield, if necessary
5. Shield other devices nearby
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Shield the entire welding installation
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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
-
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
-
them around any part of the body
Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example:
Fans
-
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.
16
During operation
Ensure that all covers are closed and all side panels are fitted properly.
-
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.
EN
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
Especially with ring lines, contaminated shielding gas can cause damage to equipment and reduce welding quality. Meet the following requirements regarding shielding gas quality:
Solid particle size < 40 µm
-
Pressure condensation point < -20 °C
-
Max. oil content < 25 mg/m³
-
17
Use filters if necessary.
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
-
the main gas supply. Close the shielding gas cylinder valve or main gas supply if no welding is tak-
-
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°.
-
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.
Only set up and operate the device in accordance with the degree of protection shown on the rating plate.
When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft.
7.69 in.) to ensure that cooling air can flow in and out freely.
When transporting the device, observe the relevant national and local guidelines and accident prevention regulations. This applies especially to guidelines regard­ing the risks arising during transport.
Do not lift or transport operational devices. Switch off devices before transport or lifting.
Before transporting the device, allow coolant to drain completely and detach the following components:
Wirefeeder
-
Wirespool
-
Shielding gas cylinder
-
After transporting the device, the device must be visually inspected for damage before commissioning. Any damage must be repaired by trained service techni­cians before commissioning the device.
EN
Safety measures in normal opera­tion
Only operate the device when all safety devices are fully functional. If the safety devices are not fully functional, there is a risk of
injury or death to the operator or a third party
-
damage to the device and other material assets belonging to the operator
-
inefficient operation of the device
-
Any safety devices that are not functioning properly must be repaired before switching on the device.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper function­ing of safety devices.
Always fasten the shielding gas cylinder securely and remove it beforehand if the device is to be transported by crane.
Only the manufacturer's original coolant is suitable for use with our devices due to its properties (electrical conductibility, anti-freeze agent, material compatibil­ity, flammability, etc.).
Only use suitable original coolant from the manufacturer.
Do not mix the manufacturer's original coolant with other coolants.
Only connect the manufacturer's system components to the cooling circuit.
The manufacturer accepts no liability for damage resulting from use of other sys­tem components or a different coolant. In addition, all warranty claims will be forfeited.
Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under certain conditions. Transport the coolant only in its original, sealed con­tainers and keep well away from any sources of ignition.
Used coolant must be disposed of properly in accordance with the relevant na­tional and international regulations. The coolant safety data sheet may be ob­tained from your service centre or downloaded from the manufacturer's website.
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Check the coolant level before starting to weld, while the system is still cool.
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).
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Do not carry out any modifications, alterations, etc. to the device without the
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manufacturer's consent. Components that are not in perfect condition must be replaced immediately.
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When ordering, please give the exact designation and part number as shown
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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
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after any additional parts are installed, or after any conversions
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after repair, care and maintenance has been carried out
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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.
EN
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General information
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General
Device concept The MIG/MAG power sources TPS
320i, TPS 400i, TPS 500i and TPS 600i are completely digitised, micro­processor-controlled inverter power sources.
The modular design and potential for system add-ons ensure a high degree of flexibility. The devices can be adap- ted 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
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exact reproducibility of all results
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excellent weld properties.
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The devices are used in workshops and industry for manual and automated ap­plications with classical steel, galvanised sheets, chrome/nickel and aluminium.
The power sources are designed for:
Automobile and component supply industry
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Machine manufacturing and rail vehicle construction
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Chemical plant construction
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Equipment construction
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Shipyards, etc.
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Conformities FCC
This equipment complies with the limit values for an EMC device class A digital device pursuant to Part 15 of the FCC Rules. These limit values are intended to provide an adequate level of protection against harmful emissions when the device is being used in an industrial environment. This device generates and uses high-frequency energy and can cause interference to radio communications if it is not installed and used according to the Operating Instructions. The use of this device in residential areas will probably cause harmful interfer­ence, in which case the user will be obliged to correct the interference at their own expense.
FCC ID: QKWSPBMCU2
Industry Canada RSS
This device complies with the Industry Canada licence-exempt RSS standards. Its use is subject to the following conditions:
(1) The device must not cause any harmful interference. (2) The device must be able to cope with any interference, including that
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.
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Article 14 The use of low-power radio frequency devices must not adversely affect flight safety and communications. A detected malfunction must be deactivated and corrected immediately until no malfunction is present. The notice in the preceding paragraph refers to radio communications operated in accordance with the provisions of the Telecommunications Act. Low-power 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.
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Safety symbols on the rating plate:
Welding is dangerous. The following basic requirements must be met:
Welders must be sufficiently qualified
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Suitable protective equipment must be used
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All persons not involved in the welding process must be kept at a safe dis-
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tance
Do not use the functions described here until you have fully read and understood the following documents:
These Operating Instructions
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All the Operating Instructions for the system components, especially the
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safety rules
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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
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TIG welding
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MMA welding
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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 *
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MIG/MAG 3450 PMC Steel 1,0mm M21 - dynamic *
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MIG/MAG 3044 Pulse AlMg5 1.2 mm I1 - universal *
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MIG/MAG 2684 Standard Steel 0.9 mm M22 - root *
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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
ADV ***
CMT
Also required: Inverter module for an alternating current process
Negatively poled process phase with low heat input and high deposition rate
ADV ***
LSC
Also required: Electronic switch for interrupting power
Maximum reduction in current caused by opening the circuit in each required process phase
Only in conjunction with TPS 400i LSC ADV
arc blow
PMC Characteristics with improved arc break properties through deflection when ex­posed to 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)
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cladding
CMT, LSC, PMC Characteristics 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
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