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

Download

Operating instructions

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

Operating instructions

42,0426,0114,EN 040-08062022

Contents

Safety rules 10

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

General information 23

General 25

Device concept 25 Functional principle 25 Application areas 25 Conformities 26 Bluetooth trademarks 27 Warning notices on the device 27

Welding packages, welding characteristics and welding processes 29

General 29 Welding packages 29 Welding characteristics 29 Summary of MIG/MAG pulse synergic welding 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

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

Input options 51

General 51 Turning/pressing the adjusting dial 51 Pressing buttons 52 Pressing on the display 52

Display and status line 53

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

MIG/MAG modes 81

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

MIG/MAG and CMT welding 85

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

EasyJob mode 94

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

TIG welding 110

Safety 110 Preparations 110 TIG welding 111 Igniting the arc 113 Finishing welding 114

MMA welding 115

Safety 115 Preparatory work 115 MMA welding 116 Welding parameters for manual metal arc welding 119

Arc Air Gauging 120

Safety 120 Preparation 120 Arc air gouging 121

Process parameters 123

Overview 125

Process parameters, General 126

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

Components and monitoring process parameters 149

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

Defaults 167

General remarks 167 Overview 167

Defaults - view 168

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

Defaults - Documentation 183

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

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

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, logbook 204

Documentation 204

Job-Data 206

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

Power source settings 209

Process parameters 209 Name & location 209 MQTT settings 209 OPC UA settings 209

Backup & Restore 210

General remarks 210 Backup & Restore 210 Automatic backup 211

Signal visualisation 212

User management 213

General 213 Users 213 User roles 213 Export & import 214 CENTRUM 214

Overview 215

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

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

Troubleshooting 225

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

Care, maintenance and disposal 230

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

Appendix 233

Average consumption values during welding 235

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

Technical data 236

Explanation of the term "duty cycle" 236 Special voltages 236 Overview with critical raw materials, year of production of the device 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

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

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.

All persons involved in commissioning, operating, maintaining and servicing the device must:

be suitably qualified,

have sufficient knowledge of welding and

read and follow these operating instructions carefully.

The operating instructions must always be at hand wherever the device is being used. In addition to the operating instructions, attention must also be paid to any generally applicable and local regulations regarding accident prevention and environmental protection.

All safety and danger notices on the device

must be in a legible state,

must not be damaged,

must not be removed,

must not be covered, pasted or painted over.

For the location of the safety and danger notices on the device, refer to the section headed "General" in the operating instructions for the device. Before switching on the device, rectify any faults that could compromise safety.

This is for your personal safety!

Proper use The device is to be used exclusively for its intended purpose.

The device is intended solely for the welding processes specified on the rating plate. Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage.

Proper use includes:

carefully reading and following all the instructions given in the operating in-

structions studying and obeying all safety and danger notices carefully

performing all stipulated inspection and maintenance work.

Never use the device for the following purposes:

Thawing out pipes

Charging batteries

Starting engines

The device is designed for use in industry and the workshop. The manufacturer accepts no responsibility for any damage caused through use in a domestic setting.

The manufacturer likewise accepts no liability for inadequate or incorrect results.

Mains connection

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)

up to 90% at 20 °C (68 °F)

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

Obligations of the operator

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

are familiar with the fundamental instructions regarding safety at work and

accident prevention and have been instructed in how to use the device have read and understood these operating instructions, especially the 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

Hazardous electromagnetic fields, which can endanger the lives of those us-

ing cardiac pacemakers Risk of electrocution from mains current and welding current

Greater noise pollution

Harmful welding fumes and gases

Suitable protective clothing must be worn when working with the device. The protective clothing must have the following properties:

Flame-resistant

Insulating and dry

Covers the whole body, is undamaged and in good condition

Safety helmet

Trousers with no turn-ups

Protective clothing refers to a variety of different items. Operators should:

Protect eyes and face from UV rays, heat and sparks using a protective visor

and regulation filter Wear regulation protective goggles with side protection behind the protect-

ive visor Wear stout footwear that provides insulation even in wet conditions

Protect the hands with suitable gloves (electrically insulated and providing

protection against heat) Wear ear protection to reduce the harmful effects of noise and to prevent in-

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

Alternatively, erect suitable safety screens/curtains.

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

Electrodes

Coatings

Cleaners, degreasers, etc.

Welding process used

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

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

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

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

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.

Arrange for the mains cable to be checked regularly by a qualified electrician to ensure the ground conductor is functioning properly.

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

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

If necessary, provide adequate earthing for the workpiece.

Switch off unused devices.

Wear a safety harness if working at height.

Before working on the device, switch it off and pull out the mains plug.

Attach a clearly legible and easy-to-understand warning sign to the device to prevent anyone from plugging the mains plug back in and switching it on again.

After opening the device:

Discharge all live components

Ensure that all components in the device are de-energised.

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

Meandering welding currents

If the following instructions are ignored, meandering welding currents can develop with the following consequences:

Fire hazard

Overheating of parts connected to the workpiece

Damage to ground conductors

Damage to device and other electrical equipment

Ensure that the workpiece is held securely by the workpiece clamp.

Attach the workpiece clamp as close as possible to the area that is to be welded.

Position the device with sufficient insulation against electrically conductive environments, 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.

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

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

Equipotential bonding

Earthing of the workpiece

4. If necessary, establish an earth connection using suitable capacitors.

Shield, if necessary

5. Shield other devices nearby

Shield the entire welding installation

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-

proaching the device or any welding that is in progress For safety reasons, maintain as large a distance as possible between the

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

Rollers

Shafts

Wirespools and welding wires

Do not reach into the rotating cogs of the wire drive or into rotating drive components.

Covers and side panels may only be opened/removed while maintenance or repair work is being carried out.

During operation

Ensure that all covers are closed and all side panels are fitted properly.

Keep all covers and side panels closed.

The welding wire emerging from the welding torch poses a high risk of injury (piercing of the hand, injuries to the face and eyes, etc.).

Therefore, always keep the welding torch away from the body (devices with 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

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

Solid particle size < 40 µm

Pressure condensation point < -20 °C

Max. oil content < 25 mg/m³

Use filters if necessary.

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

leakage before every start-up.

A device toppling over could easily kill someone. Place the device on a solid, level surface such that it remains stable

The maximum permissible tilt angle is 10°.

Special regulations apply in rooms at risk of fire or explosion

Observe relevant national and international regulations.

Use internal directives and checks to ensure that the workplace environment is always clean and clearly laid out.

Only set up and operate the device in accordance with the degree of protection shown on the rating plate.

When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft.

7.69 in.) to ensure that cooling air can ﬂow in and out freely.

When transporting the device, observe the relevant national and local guidelines and accident prevention regulations. This applies especially to guidelines regarding the risks arising during transport.

Do not lift or transport operational devices. Switch off devices before transport or lifting.

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

Wirefeeder

Wirespool

Shielding gas cylinder

After transporting the device, the device must be visually inspected for damage before commissioning. Any damage must be repaired by trained service technicians before commissioning the device.

Safety measures in normal operation

Only operate the device when all safety devices are fully functional. If the safety devices are not fully functional, there is a risk of

injury or death to the operator or a third party

damage to the device and other material assets belonging to the operator

inefficient operation of the device

Any safety devices that are not functioning properly must be repaired before switching on the device.

Never bypass or disable safety devices.

Before switching on the device, ensure that no one is likely to be endangered.

Check the device at least once a week for obvious damage and proper functioning of safety devices.

Always fasten the shielding gas cylinder securely and remove it beforehand if the device is to be transported by crane.

Only the manufacturer's original coolant is suitable for use with our devices due to its properties (electrical conductibility, anti-freeze agent, material compatibility, ﬂammability, etc.).

Only use suitable original coolant from the manufacturer.

Do not mix the manufacturer's original coolant with other coolants.

Only connect the manufacturer's system components to the cooling circuit.

The manufacturer accepts no liability for damage resulting from use of other system components or a different coolant. In addition, all warranty claims will be forfeited.

Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under certain conditions. Transport the coolant only in its original, sealed containers and keep well away from any sources of ignition.

Used coolant must be disposed of properly in accordance with the relevant national and international regulations. The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer's website.

Check the coolant level before starting to weld, while the system is still cool.

Commissioning, maintenance and repair

Safety inspection

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

after repair, care and maintenance has been carried out

at least every twelve months.

For safety inspections, follow the appropriate national and international standards and directives.

Further details on safety inspection and calibration can be obtained from your service centre. They will provide you on request with any documents you may require.

Disposal 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).

Fronius International GmbH hereby declares that the device is compliant with Directive 2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following address: http://www.fronius.com

Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA.

Data protection The user is responsible for the safekeeping of any changes made to the factory

settings. The manufacturer accepts no liability for any deleted personal settings.

The text and illustrations are all technically correct at the time of printing. We reserve the right to make changes. The contents of the operating instructions shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for improvement, or can point out any mistakes that you have found in the instructions, we will be most grateful for your comments.

General information

General

Device concept The 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.

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 power sources are designed for:

Automobile and component supply industry

Machine manufacturing and rail vehicle construction

Chemical plant construction

Equipment construction

Shipyards, etc.

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.

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

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.

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

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)

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 *

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)

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

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

galvanized

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

galvannealed

PMC Characteristics for iron-zinc coated sheet surfaces

gap bridging

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

hotspot

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

mix ** / ***

PMC

Also required: Pulse and PMC welding packages

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

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 ** / ***

CMT

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

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

mix drive ***

PMC

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

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

multi arc

PMC

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

open root

Characteristics for root pass with air gap and optimised root penetration without root reversion.

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.

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 Characteristics for pipe applications and positional welding on narrow gap applications

retro

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

ripple drive ***

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

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

root

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

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)

TWIN

PMC Synchronised characteristics for two wire electrodes in a single weld pool (tandem welding process)

universal

CMT, PMC, Pulse, Standard Characteristics for conventional welding tasks

weld+

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

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

hardware

Summary of MIG/MAG pulse synergic welding

MIG/MAG pulse synergic

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

Summary of MIG/MAG standard synergic welding

Summary of the PMC process

MIG/MAG standard synergic

The MIG/MAG standard synergic welding process is a MIG/MAG welding process across the entire power range of the power source with the following arc types:

Short circuit arc Droplet transfer takes place during a short circuit in the lower power range.

Intermediate arc The droplet increases in size on the end of the wire electrode and is transferred in the mid-power range during the short circuit.

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

PMC = Pulse Multi Control

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

Summary of the LSC / LSC Advanced 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.

LSC Advanced The TPS 400i LSC ADV is required for the LSC Advanced process. The TPS 400i LSC ADV accelerates the reduction in current and improves the LSC properties. The LSC Advanced process is predominantly used when the welding circuit inductivity is higher.

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.

Short description of WireSense

WireSense is an assistance procedure for automated applications where the wire electrode functions as a sensor. The wire electrode can be used to check the component position before each welding operation, and real sheet edge heights and their position are reliably detected.

Benefits:

React to real component deviations

No re-training - time and cost savings

No need to calibrate TCP and sensor

WireSense requires CMT hardware: WF 60i Robacta Drive CMT, SB 500i R with wire buffer or SB 60i R, WFI REEL

The CMT Welding Package is not required for WireSense.

Brief description of ConstantWire

Short description of arc air gouging

ConstantWire is used in laser brazing and other laser welding applications. The welding wire is fed to the solder or weld pool, and the ignition of an arc is prevented by controlling the wire speed. Constant current (CC) and constant voltage (CV) applications are possible. The welding wire can be fed either under current for hot wire applications or currentless for cold wire applications.

During arc air gouging, an arc is ignited between a carbon electrode and the workpiece, and the base material is melted and cleaned with compressed air. The operating parameters for arc air gouging are defined in a special characteristic.

Applications:

Removing shrink holes, pores, or slag inclusions from workpieces

Detaching sprue or finishing entire workpiece surfaces in casting operations

Edge preparation for heavy plates

Preparation and repair of weld seams

Working out root passes or defects

Production of air gaps

System components

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(2a)

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

(1) Cooling units (2) Power sources (2a) TPS 400i LSC ADV power source (3) Robot accessories (4) Interconnecting hosepacks (max. 50 m)* (5) Wirefeeders (6) Wirefeeder holder (7) Trolley and gas cylinder holders

* Interconnecting hosepacks > 50 m only in combination with optional

OPT/i SpeedNet Repeater

also:

Welding torch

Grounding cable and electrode cable

Dust filter

Additional current sockets

Options

OPT/i TPS 2.SpeedNet Connector

Optional second SpeedNet connection socket

Factory-installed on the rear of the power source (but can also be installed on the front of the power source).

OPT/i TPS 4x Switch SpeedNet

Option if more than one additional SpeedNet connection socket is required.

IMPORTANT! The OPT/i TPS 4x Switch SpeedNet option cannot be operated in conjunction with the OPT/i TPS 2. SpeedNet Connector option. If the OPT/i TPS

2.SpeedNet Connector option is installed in the power source, it must be re-

moved.

The OPT/i TPS 4x Switch SpeedNet option is installed in TPS 600i power sources as standard.

OPT/i TPS SpeedNet Connector

Expansion of the OPT/i TPS 4x Switch SpeedNet option

Can only be used in conjunction with the OPT/i TPS 4x Switch SpeedNet option, maximum of 2 per power source

OPT/i TPS 2nd NT241 CU 1400i

Where a CU 1400 cooling unit is being used, the OPT/i TPS 2nd NT241 CU1400i option must be installed in TPS 320i - 600i power sources. .

The OPT/i TPS 2nd NT241 CU1400 option is installed in TPS 600i power sources as standard.

OPT/i TPS motor supply +

If 3 or more drive motors are to be operated in the welding system, the OPT/i TPS motor supply + option must be installed in the TPS320i - 600i power sources.

OPT/i TPS dust filter

IMPORTANT! Use of the OPT/i TPS dust filter option on TPS 320i - 600i power

sources shortens the duty cycle.

OPT/i TPS 2nd plus socket PC 2nd (+) current socket (Power Connector) on the front of the power source (option)

OPT/i TPS 2nd earth socket

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

OPT/i TPS 2nd DINSE plus socket

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

OPT/i TPS 2nd earth socket PC

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

OPT/i SpeedNet Repeater

Signal amplifier if interconnecting hosepacks or connections from the power source to the wirefeeder are more than 50 m in length

Arc air gouging torch KRIS 13

Electrode holder with compressed air connection for arc air gouging

OPT/i Synergic Lines

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

OPT/i GUN Trigger

Option for special functions in conjunction with the torch trigger

OPT/i Jobs

Option for Job mode

OPT/i Documentation

Option for the documentation function

OPT/i Interface Designer

Option for individual interface configuration

OPT/i WebJobEdit

Option for editing jobs via the SmartManager of the power source

OPT/i Limit Monitoring

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

OPT/i Custom NFC - ISO 14443A

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

OPT/i CMT Cycle Step

Option for adjustable, cyclical CMT welding process

OPT/i OPC-UA

Standardised data interface protocol

OPT/i MQTT

Standardised data interface protocol

Opt/i Wire Sense

Seam tracking / edge detection by means of wire electrode in automated applications Only in conjunction with CMT hardware

OPT/i Touch Sense Adv.

For applications with 2 welding systems on one component: while one welding system is in welding operation, the welding position can be determined on the other welding system

OPT/i SenseLead

Option to prevent inductance problems

OPT/i CU Interface

Interface for CU 4700 and CU 1800 cooling units

OPT/i SynchroPulse 10 Hz

To increase the SynchroPulse frequency from 3 Hz to 10 Hz

OPT/i Safety Stop PL d option

IMPORTANT! The safety function OPT/i Safety Stop PL d has been designed ac-

cording to EN ISO 13849-1:2008 + AC:2009 as category 3. This requires two-channel feel of the input signal. Bridging of two-channel operation (e.g. with a shorting bar) is not permitted and will result in loss of PL d.

Functional description

The OPT/i Safety Stop PL d option guarantees a safety stop of the power source according to PL d with controlled end of welding in less than one second. Every time the power source is switched on, the safety function Safety Stop PL d performs a self-test.

IMPORTANT! This self-test must be performed at least once a year to check the operation of the safety shutdown.

If the voltage drops on at least one of 2 inputs, Safety Stop PL d halts the current welding operation; the wirefeeder motor and the welding voltage are switched off. The power source outputs an error code. Communication via the robot interface or the bus system remains unaffected. To re-start the welding system, the power must be re-connected. An error must be acknowledged via the torch trigger, display or interface and Weld-Start must be carried out again.

A non-simultaneous shutdown of both inputs (> 750 ms) is output by the system as a critical, non-resettable error. The power source is permanently switched off. A reset is carried out by switching the power source off and on again.

Controls, connections and mechan-

ical components

Control panel

General Welding parameters can be easily changed and selected using the adjusting dial.

The parameters are shown on the display while welding is in progress.

The synergic function ensures that other welding parameters are also adjusted whenever an individual parameter is changed.

NOTE!

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

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

Safety

WARNING!

Danger from incorrect operation 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.

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

(5) Wire threading button

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

(6) Gas-test button

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

Connections, switches and mechanical compon-

(1)

(2)

(3)

(4)

(6)

(5)

(7)

(8)

(12) (13)

(9)

(10)

(11)

ents

TPS 320i / 400i / 500i / 600i, TPS 400i LSC ADV power source

Front

No. Function

(1) Mains switch

for switching the power source on and off

(2) Control panel cover

for protecting the control panel

(3) Control panel with display

for operating the power source

(4) (-) current socket with bayonet latch

for connecting the grounding cable during MIG/MAG welding

(5) Blanking cover

reserved for the second (+) current socket option with bayonet latch

(6) Blanking cover

reserved for the second SpeedNet connection option

(7) Blanking cover

reserved for the second SpeedNet connection option

(8) (+) current socket with fine-pitch thread (Power Connector)

for connecting the power cable from the interconnecting hosepack during MIG/MAG welding

Rear

(9) SpeedNet connection

for connecting the interconnecting hosepack

(10) Ethernet connection socket

(11) Mains cable with strain relief device

(12) Blanking cover

reserved for the second (-) current socket option with bayonet latch

The second (-) current socket is used to connect the interconnecting

hosepack during MIG/MAG welding for polarity reversal (e.g. for ﬂux- cored wire welding)

(13) Blanking cover

reserved for the second SpeedNet connection option or robot interface RI FB Inside/i

Fitted on the TPS 600i is another cover plate, containing the system bus connection for the OPT/i TPS 4x Switch SpeedNet option.

Operating concept

Input options

General

NOTE!

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

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

WARNING!

Incorrect operation may result in serious injury or damage.

the following documents:

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

▶

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.

Press the adjusting dial to:

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

Apply certain welding parameter values.

Pressing buttons Pressing buttons triggers the following functions:

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

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

Pressing on the display

The display can be touched in order to

navigate,

trigger functions,

select options

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

Display and status line

(1)

(2)

(4)

(5)

(6)

(3)

Display

No. Function

(1) Status bar

The status bar provides information on:

The current welding process

The current operating mode

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

er) Active stabilizers and special processes

Bluetooth status

Logged-on users / power source locked state

Active faults

Time and date

(2) Left-hand ribbon

The left-hand ribbon contains the following buttons:

Welding

Welding process

Process parameters

Defaults

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

(3) Actual value display

Welding current, welding voltage, wire speed

(4) Main area

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

The main area is operated

using the adjusting dial,

by touching the display.

Status bar

(1) (2) (3)

(6) (8)(7)(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 length stabilizer

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)

Symbol lights up blue: active connection to a Bluetooth device

Symbol is grey: Bluetooth device detected, no active connection

intermediate arc indicator

(6) TWIN mode only:

Current limit exceeded!

power source number, LEAD / TRAIL / SINGLE

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

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

(8) Time and date

Status bar – Current limit reached

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

For detailed information, select the status bar

The information appears.

Select "Hide information" to exit

Reduce the wire speed, welding current, welding voltage or material thick-

ness

Increase the distance between the contact tip and the workpiece

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

Installation and commissioning

Minimum equipment needed for welding task

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

MIG/MAG gascooled welding

MIG/MAG water-cooled welding

MIG/MAG automated welding

Power source

Grounding (earthing) cable

MIG/MAG welding torch, gas-cooled

Shielding gas supply

Wire-feed unit

Interconnecting hosepack

Wire electrode

Power source

Cooling unit

Grounding (earthing) cable

MIG/MAG welding torch, water-cooled

Shielding gas supply

Wire-feed unit

Interconnecting hosepack

Wire electrode

Power source

Robot interface or field bus connection

Grounding cable

MIG/MAG robot welding torch or automatic MIG/MAG welding torch

Manual CMT welding

A cooling unit is also required with water-cooled robot or machine welding torches.

Gas connection (shielding gas supply)

Wirefeeder

Interconnecting hosepack

Wire electrode

Power source

Standard, Pulse and CMT welding packages enabled on the power source

Grounding cable

PullMig CMT welding torch incl. CMT drive unit and CMT wire buffer

IMPORTANT! For water-cooled CMT applications, a cooling unit is also required!

OPT/i PushPull

Wirefeeder

CMT interconnecting hosepack

Wire electrode

Gas connection (shielding gas supply)

Automated CMT welding

Power source

Standard, Pulse and CMT welding packages enabled on the power source

Robot interface or field bus connection

Grounding cable

CMT welding torch incl. CMT drive unit

Cooling unit

Unreeling wirefeeder (WFi REEL)

Interconnecting hosepack

Torch hosepack

Wirefeeding hose

Media splitter (e.g. SB 500i R, SB 60i R)

CMT wire buffer (included with SB 60i R)

Wire electrode

Gas connection (shielding gas supply)

TIG DC welding

MMA welding

Arc air gouging

Power source with built-in OPT/i TPS 2nd plus socket option

Grounding (earthing) cable

TIG gas-valve torch

Gas connection (shielding gas supply)

Filler metal (depending on the application)

Power source with built-in OPT/i TPS 2nd plus socket option

Grounding (earthing) cable

Electrode holder with welding cable

Rod electrodes

Power source with OPT/i TPS 2nd plus socket option installed

Grounding cable 120i PC

PowerConnector adapter- Dinse

Arc air gouging torch KRIS 13

Compressed air supply

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.

CAUTION!

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.

Generatorpowered operation

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:

= 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:

GEN

= S

1max

x 1.35

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.

Information on system components

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

Trolleys

Cooling units

Wire-feed unit holders

Wire-feed units

Interconnecting hosepacks

Welding torches

etc.

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

Connecting the mains cable

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

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

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

Stipulated mains cables

Power source Mains voltage: USA & Canada * | Europe

TPS 320i /nc 3 x 400 V: AWG 12 | 4 G 2.5 3 X 460 V: AWG 14 | 4 G 2,5

TPS 320i /MV/nc 3 x 230 V: AWG 10 | 4 G 4 3 X 460 V: AWG 14 | 4 G 2,5

TPS 320i /600V/nc ** 3 x 575 V: AWG 14 | -

TPS 400i /nc 3 x 400 V: AWG 10 | 4 G 4 3 X 460 V: AWG 12 | 4 G 4

TPS 400i /MV/nc 3 x 230 V: AWG 6 | 4 G 6 3 x 460 V: AWG 10 | 4 G 4

TPS 400i /600V/nc ** 3 x 575 V: AWG 12 | -

TPS 500i /nc 3 x 400 V: AWG 8 | 4 G 4 3 x 460 V: AWG 10 | 4 G 4

TPS 500i /MV/nc 3 x 230 V: AWG 6 | 4 G 10 3 x 460 V: AWG 10 | 4 G 4

TPS 500i /600V/nc ** 3 x 575 V: AWG 10 | -

TPS 600i /nc 3 x 400 V: AWG 6 | 4 G 10 3 X 460 V: AWG 6 | 4 G 10

TPS 600i /600V/nc ** 3 x 575 V: AWG 6 | -

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

AWG = American wire gauge

Safety

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.

▶

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. 30 mm (1.18 in.) longer

than the phase conductors.

1 2

3 4

5 6

Commissioning the TPS 320i / 400i / 500i / 600i, TPS 400i LSC ADV

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 A manual water-cooled MIG/MAG application is used to describe how to com-

mission the TPS 320i / 400i / 500i / 600i and TPS 400i LSC ADV power sources.

The following illustrations provide an overview of the structure of the individual system components. Refer to the respective system component operating instructions for detailed information about the various work steps involved.

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.

TPS 320i / 400i /

500i / 600i: Assembling the system components (overview)

TPS 400i LSC ADV: Assembling the system components (overview)

Fixing the strain-

relief device for the interconnecting hosepack

Connecting the interconnecting hosepack

Fixing the strain-relief device to the trolley

Fixing the strain-relief device to the wirefeeder

NOTE!

There is no cooling unit present in the case of gas-cooled systems.

There is no need to attach the coolant connections in the case of gas-cooled systems.

Connecting the interconnecting hosepack to the power source and cooling unit

Connecting the interconnecting hosepack to the wirefeeder

* only if coolant connections are installed in the wirefeeder and a water-cooled interconnecting hosepack is being used

Correct arrangement of the interconnecting hosepack

CAUTION!

Risk of damage to the welding system components due to overheating caused by laying the interconnecting hosepack incorrectly.

Lay the interconnecting hosepack without loops

▶

Do not put anything on top of the interconnecting hosepack

▶

Do not wind up the interconnecting hosepack next to gas cylinders and do

▶

not wind it around gas cylinders

Correct arrangement of the interconnecting hosepack

IMPORTANT!

The duty cycle value (D.C.) for the interconnecting hosepack can only be at-

tained when the interconnecting hosepacks are laid correctly. Carry out R/L alignment if the arrangement of an interconnecting hosepack

changes (see page 144). Magnetically compensated interconnecting hosepacks make it possible to

change the arrangement without affecting the welding circuit inductivity. Magnetically compensated interconnecting hosepacks are available from Fronius with a minimum length of 10 m.

Connecting the

gas cylinder

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 falling over. Observe the safety rules of the gas cylinder manufacturer.

▶

Place the gas cylinder on the base

of the trolley

Secure the gas cylinder by fixing

the cylinder strap around the upper part of the cylinder (but not around the neck) to prevent it from toppling over

Take the protective cap off the gas

cylinder

Brieﬂy open the gas cylinder valve

to remove any dust or dirt

Inspect the seal on the gas pres-

sure regulator

Screw the pressure regulator onto

Fixing the gas cylinder on the trolley

the gas cylinder and tighten it

Connect the shielding gas hose of

the interconnecting hosepack to the pressure regulator using the gas hose

Establishing a

- -

ground earth connection

NOTE!

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

Use a separate grounding cable for each power source

▶

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

▶

possible Physically separate the welding circuits of individual power sources

▶

Do not route several grounding cables in parallel;

▶

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

▶

section Do not cross grounding cables

▶

Avoid ferromagnetic materials between the grounding cable and the inter-

▶

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

▶

Lay long grounding cables in loops

▶

Do not route grounding cables in iron pipes, metal cable conduits or on steel rails, avoid cable ducts; (routing of plus cables and grounding cables together in an iron pipe does not cause any problems) If there are several grounding cables, separating the grounding points on the 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)

Plug the grounding cable into the

(-) current socket and twist to fasten it

Use the other end of the grounding

cable to establish a connection to the workpiece

IMPORTANT! For optimum weld properties, route the grounding cable as close as possible to the interconnecting hosepack.

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 MIG/MAG welding torches to the wirefeeder

Check that all cables, leads and

hosepacks are undamaged and correctly insulated

Open the wire drive cover

Open the clamping lever on the

wire drive

Check that the welding torch is

properly equipped. Insert it marking at the top first - into the welding torch connection on the wirefeeder.

Close the clamping lever on the

wire drive

* On water-cooled welding

torches:

Connect the coolant ﬂow hose to

the coolant ﬂow connection (blue)

Connect the coolant return hose to

the coolant return connection (red)

Close the wire drive cover

Check that all connections are

connected properly

Other tasks Carry out the following steps in accordance with the wirefeeder operating in-

structions:

Insert the feed rollers into the wirefeeder

Insert the wirespool or basket-type spool with adapter into the wirefeeder

Feed in the wire electrode

Set the contact pressure

Adjust the brake

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 144).

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

Hold the NFC key on the NFC key reader

The key symbol appears on the display.

The key symbol is then displayed in the status bar.

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

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

Unlocking the power source

Hold the NFC key on the NFC key reader

The crossed-out key symbol appears on the display.

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

NOTE!

More information about locking and unlocking the power source can be found in the "Defaults - Administration" section from page 185.

Welding

MIG/MAG modes

General

Symbols and their explanations

WARNING!

Danger from incorrect operation.

Possible serious injury and damage to property.

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

▶

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

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

2-step mode

GPr

GPo

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.

Special 4-step

GPr GPo

I-E

SL1t-S

I-S

SL2

+ +

t-E

I-S

I-E

GPr GPoSL1 SL2

t-S t-E

mode

Special 2-step mode

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

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

Spot welding

GPr GPoSPt

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

MIG/MAG and CMT welding

Safety

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

Move the mains switch to the "I" position

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 144).

Setting the

4-step

welding process and operating mode

Setting the welding process

* next page: Electrode, TIG

Select "Welding process"

Select "Process"

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

Select the desired welding process

Setting the operating mode

Select "Mode"

An overview of the operating modes is displayed:

Selecting the

filler metal and shielding gas

2-step mode

4-step mode

Special 2-step mode

Special 4-step mode

Select the desired operating mode

Select "Welding process"

Select "Filler metal"

Select "Change material settings"

Turn the adjusting dial and select the desired filler metal

Select "Next" / press the adjusting dial

Turn the adjusting dial and select the desired wire diameter

Select "Next" / press the adjusting dial

Turn the adjusting dial and select the desired shielding gas

Select "Next" / press the adjusting dial

NOTE!

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

In this case, the confirmation step of the filler metal wizard follows immediately; steps 10 - 14 do not apply.

Turn the adjusting dial and select the desired welding process

To select the desired characteristic, press the adjusting dial (blue back-

ground)

Turn the adjusting dial and select the desired characteristic

Press the adjusting dial and apply the selected characteristic (white back-

ground)

Select "Next"

Setting the

welding parameters

The confirmation step of the filler metal wizard is displayed:

Select "Save" / press the adjusting dial

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

Select "Welding"

Select the desired welding parameter by turning the adjusting dial

Press the adjusting dial to change the welding parameter

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

e.g. wire speed parameter

The value of the selected parameter can now be changed.

Turn the adjusting dial to change the welding parameter

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

Press the adjusting dial to call up the welding parameters overview

Adjust the process parameters accordingly to make user- or application-spe-

cific settings on the welding system

Setting the shielding gas ﬂow rate

MIG/MAG or CMT welding

Open the gas cylinder valve

Press the gas test button

Shielding gas ﬂows out

Turn the adjusting screw on the underside of the pressure regulator until the

pressure gauge shows the required shielding gas ﬂow rate

Press the gas test button

The ﬂow of gas stops.

Select "Welding" to display the welding parameters

CAUTION!

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

When pressing the torch trigger:

keep the torch away from your face and body

▶

do not point the welding torch at people

▶

make sure that the wire electrode does not touch any electrically conducting

▶

or earthed (grounded) parts, such as the housing, etc.

Press the torch trigger and start welding

Whenever welding ends, the actual values for the welding current, welding voltage and wire speed are stored, and HOLD appears on the display.

NOTE!

Parameters that have been set on a system component control panel (e.g. wire feed unit or remote control) might not be able to be changed on the power source control panel.

MIG/MAG and CMT welding parameters

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

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

Current 1) [A]

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

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

Voltage 1) [V]

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

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

Material thickness

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

Wire speed

0.5 - max.

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

2) 3)

m/min / 19.69 - max

2) 3)

ipm.

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

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

Current 1) [A]

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

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

Voltage 1) [V]

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

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

Material thickness

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

Wire speed

0.5 - max.

2) 3)

m/min / 19.69 - max

2) 3)

ipm.

Arc length correction

for correcting the arc length;

-10 - +10

Factory setting: 0

- .... shorter arc length

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

Pulse/dynamic correction

for correcting the pulsing energy of a pulsed arc

-10 - +10

Factory setting: 0

- ... lower droplet detachment force

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

Welding parameters for MIG/MAG standard manual welding

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

Voltage 1) [V]

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

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

Arc-force dynamic

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

0 - 10 Factory setting: 0

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

Explanation of footnotes

Wire speed

for setting a harder, more stable arc

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

1) Synergic parameter

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

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

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

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

EasyJob mode

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

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

Activating EasyJob mode

Select Defaults / View / EasyJobs

The overview to activate/deactivate EasyJob mode is displayed.

Select "EasyJobs on"

Select "OK"

EasyJob mode is activated and the default settings are displayed.

Select "Welding"

Five EasyJob buttons are displayed for the welding parameters.

Storing EasyJob

~ 3 sec.

< 3 sec.

operating points

NOTE!

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

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

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

about three seconds

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

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

Retrieving EasyJob operating points

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

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.

Deleting Easy-

> 5 sec.

Job operating points

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

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

Job mode

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

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

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

Storing settings as a job

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

Welding parameters

Welding process

Process parameters

Machine defaults (if necessary)

Select "Save as Job"

The job list is displayed.

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

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

Press the adjusting dial / select "Next"

The next free job number is displayed.

Turn the adjusting dial and select the desired storage location

Press the adjusting dial / select "Next"

The keyboard is displayed.

Enter a job name

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

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

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

Job welding - retrieving a job

NOTE!

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

Select "Welding process"

Select "Process"

Select "Job mode"

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

Select "Job welding"

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

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

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

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

Press the adjusting dial and accept the selected job number (white back-

ground)

Start welding

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

mode; all the others are read-only.

Renaming a job

universal

Select "Save as Job"

(also works in Job mode)

The job list is displayed.

Turn the adjusting dial and select the job to be renamed

Select "Rename Job"

The keyboard is displayed.

Change the job name using the keyboard

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

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

To exit, select "Cancel"

Deleting a job

universal

Select "Save as Job"

(also works in Job mode)

The job list is displayed.

100

Turn the adjusting dial and select the job to be deleted

Select "Delete Job"

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

Select "Yes" to delete the selected job

The job is deleted, the job list is displayed.

To exit, select "Cancel"

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

Specifications and Main Features

Frequently Asked Questions

User Manual