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/ Perfect Charging / Perfect Welding / Solar Energy Operating Instructions TPS 320i / 400i / 500i / 600i TPS 400i LSC ADV MIG/MAG Power source 42,0426,0114,EN 024-24052017...
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Thank you for the trust you have placed in our company and congratulations on buying this high-quality Fronius product. These instructions will help you familiarise yourself with the product. Reading the instructions carefully will enable you to learn about the many different features it has to offer.
Contents Safety rules ..............................Explanation of safety symbols ......................General ..............................Proper use ............................Mains connection ..........................Environmental conditions........................Obligations of the operator........................Obligations of personnel ........................Residual current protective device......................Protecting yourself and others ......................Noise emission values .......................... Danger from toxic gases and vapours ....................
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Connections, switches and mechanical components ................TPS 320i / 400i / 500i / 600i, TPS 400i LSC ADV power source ............Operating concept Input options .............................. General ..............................Turning/pressing the adjusting dial ....................... Pressing buttons ........................... Pressing on the display.........................
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MIG/MAG and CMT welding – overview....................Switching on the power source ......................Setting the welding process and operating mode ................. Selecting the filler metal and shielding gas................... Setting the welding parameters ......................Setting the shielding gas flow rate ......................MIG/MAG or CMT welding........................MIG/MAG and CMT welding parameters ....................
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Calling up the power source website ....................143 User password ............................143 Settings ..............................144 Language selection..........................144 Fronius ..............................145 Overview ..............................146 Overview ............................... 146 Expand all groups / Reduce all groups ....................146 Save as XML-file........................... 146 Update ...............................
Safety rules Explanation of DANGER! Indicates immediate and real danger. If it is not avoided, death or se- safety symbols rious injury will result. WARNING! Indicates a potentially dangerous situation. Death or serious injury may result if appropriate precautions are not taken. CAUTION! Indicates a situation where damage or injury could occur.
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 manufac- turer shall not be held liable for any damage arising from such usage. Proper use includes: carefully reading and following all the instructions given in the operating instructions...
Obligations of the The operator must only allow persons to work with the device who: operator are familiar with the fundamental instructions regarding safety at work and accident prevention and have been instructed in how to use the device have read and understood these operating instructions, especially the section "safety rules", and have confirmed as much with their signatures are trained to produce the required results.
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 protec- tive visor. wear stout footwear that provides insulation even in wet conditions.
The relevant material safety data sheets and manufacturer's specifications for the listed components should therefore be studied carefully. Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation area. Danger from fly- Flying sparks may cause fires or explosions. ing sparks Never weld close to flammable materials.
Operating the device on a grid without a ground conductor and in a socket without a ground conductor contact will be deemed gross negligence. The manufacturer shall not be held liable for any damage arising from such usage. If necessary, provide an adequate earth connection for the workpiece. Switch off unused devices.
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).
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During operation Ensure that all covers are closed and all side panels are fitted properly. Keep all covers and side panels closed. The welding wire emerging from the welding torch poses a high risk of injury (piercing of the hand, injuries to the face and eyes, etc.). Therefore always keep the welding torch away from the body (devices with wire-feed unit) and wear suitable protective goggles.
Factors affecting The following requirements with regard to shielding gas quality must be met if welding results the welding system is to operate in a correct and safe manner: Size of solid matter particles < 40 μm Pressure dew point < -20 °C Max.
Safety measures A device toppling over could easily kill someone. Place the device on a solid, at the installation level surface such that it remains stable location and dur- The maximum permissible tilt angle is 10°. ing transport Special regulations apply in rooms at risk of fire or explosion Observe relevant national and international regulations.
Used coolant must be disposed of properly in accordance with the relevant na- tional and international regulations. The coolant safety data sheet may be ob- tained from your service centre or downloaded from the manufacturer's website. Check the coolant level before starting to weld and while the system is still cool.
(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 rele- vant standards for Canada and the USA.
General Device concept The MIG/MAG power sources TPS 320i, TPS 400i, TPS 500i and TPS 600i are com- pletely digitised, microprocessor-controlled inverter power sources. The modular design and potential for sys- tem add-ons ensure a high degree of flexi- bility. The devices can be adapted to any specific situation.
FCC Compliance This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications.
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Safety symbols on the rating plate: Welding is dangerous. The following basic requirements must be met: Welders must be sufficiently qualified Suitable protective equipment must be used All persons not involved in the welding process must be kept at a safe distance Do not use the functions described here until you have thoroughly read and under- stood the following documents: these operating instructions...
Welding processes, processes and welding charac- teristics General TPSi power sources contain a selection of welding processes, procedures and welding characteristics that enable a wide range of materials to be processed in the most effective way. Welding charac- When selecting the filler metal, various process-optimised welding characteristics are teristics available depending on the welding process and shielding gas combination.
Special welding characteristic properties provided by additional hardware Additional hardware for the CMT welding process: Inverter module for alternating current processes Negatively poled process phase with low heat input and high deposi- tion rate Additional hardware for the MIG/MAG LSC welding process: Electronic switch for interrupting power Maximum reduction in current caused by opening the circuit in each required process phase...
Summary of the PMC = Pulse Multi Control PMC process 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 sta- ble arc and even fusion penetration. Summary of the LSC = Low Spatter Control LSC / LSC Ad-...
System components General The power sources can be operated with various system components and options. This makes it possible to optimise procedures and to simplify machine handling and operation, as necessitated by the particular field of application in which the power source is to be used.
+ 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...
OPT/i Safety Stop IMPORTANT! The safety function OPT/i Safety Stop PL d has been designed according PL d option 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.
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.
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Function 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. Adjusting dial with turn/press function For selecting elements, setting values and scrolling through lists Display (touchscreen)
Connections, switches and mechanical components TPS 320i / 400i / 500i / 600i, TPS 400i LSC ADV (10) power source (11) (12) (13) Front Rear Function Mains switch for switching the power source on and off Control panel cover for protecting the control panel...
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.
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.
Display and status line Display Function The status line provides details on: the current welding process the current operating mode the current welding program (material, shielding gas and wire diameter) active faults time and date Left-hand ribbon The left-hand ribbon contains the following buttons: Welding Welding process Process parameters...
Status line The status line is divided into segments and contains the following details: Current welding process Current operating mode Current welding program (material, shielding gas and wire diameter) Time and date Status bar – Cur- If the characteristic-dependent current limit is reached while MIG/MAG welding, a corre- rent limit reached sponding message appears in the status bar.
Minimum equipment needed for welding task General Depending on which welding process you intend to use, a certain minimum equipment lev- el 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.
Automated CMT Power source welding 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.
Before installation and commissioning Safety WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: these operating instructions all the operating instructions for the system components, especially the safe- ty rules Proper use The power source may only be used for MIG/MAG, MMA and TIG welding.
Generator-pow- The power source is generator-compatible. ered operation The maximum apparent power S of the power source must be known in order to select 1max the correct generator output. The maximum apparent power S of the power source is calculated as follows: 1max 3-phase devices: Single-phase devices:...
A manual water-cooled MIG/MAG application is used to describe how to commission 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.
Fixing the strain- relief device for the interconnect- ing hosepack Fixing the strain-relief device to the trolley Fixing the strain-relief device to the wire-feed unit Connecting the NOTE! There is no cooling unit present in the case of gas-cooled systems. There interconnecting is no need to attach the water connections in the case of gas-cooled systems.
Carry out R/L calibration if the arrangement of an interconnecting hosepack changes (see page 105). 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 WARNING! If gas cylinders topple over, there is a risk of very serious injury and gas cylinder damage. Place gas cylinders on a solid, level surface so that they remain stable. Secure gas cylinders to prevent them from toppling over. Observe the safety rules of the gas cylinder manufacturer.
Connecting MIG/ Check that all cables, leads and hose- MAG welding packs are undamaged and correctly in- torches to the sulated wire-feed unit Open the wire drive cover Open the clamping lever on the wire drive Check that the welding torch is correc- tly and completely tooled up.
Other tasks Carry out the following steps in accordance with the wirefeeder operating instructions: 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 performing an R/L alignment when starting the device for the first time and when any changes are made...
Locking and unlocking the power source using a keycard or key ring General The power source can be locked using a keycard or key ring, 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 un- locked.
MIG/MAG modes General WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: these operating instructions all the operating instructions for the system components, especially the safe- ty rules See the Setup menu for information on settings, setting range and units of measurement for the available parameters.
2-step mode "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 "Special 4-step mode" is particularly suitab- mode le for welding aluminium materials. The special slope of the welding current curve takes account of the high thermal conducti- vity of aluminium.
MIG/MAG and CMT welding Safety WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: these operating instructions all the operating instructions for the system components, especially the safe- ty rules WARNING! An electric shock can be fatal.
Setting the weld- Setting the welding process ing process and operating mode 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.
An overview of the operating modes is displayed: 2-step mode 4-step mode Special 2-step mode Special 4-step mode Select the desired operating mode Selecting the filler metal and shield- ing gas AlMg 5 Select "Welding process" Select "Filler metal" Select "change Materialsettings" Turn the adjusting dial and select the desired filler metal Select "Next"...
The selected filler metal and associated characteristics per welding process will be saved. Setting the weld- ing parameters 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.
Setting the Open the gas cylinder valve shielding gas Press the gas test button flow rate 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.
MIG/MAG and CMT welding parameters Welding parame- The following welding parameters for MIG/MAG pulse synergic welding, CMT welding and ters for MIG/MAG PMC welding can be set and displayed by pressing the "Welding" button: pulse synergic welding, for CMT Current welding and PMC welding Unit...
Welding parame- The following welding parameters for MIG/MAG standard synergic welding and LSC weld- ters for MIG/MAG ing can be set and displayed by selecting the "Welding" menu button: standard syner- gic welding and Current LSC welding Unit Setting range Depends on the welding process and welding program selected Before the start of welding, the device automatically displays a standard value based on the programmed parameters.
Welding parame- The following welding parameters for MIG/MAG standard manual welding can be set and ters for MIG/MAG displayed by selecting the "Welding" menu button: standard manual welding Voltage Unit Setting range Depends on the welding process and welding program selected Dynamic For influencing the short-circuiting dynamic at the instant of droplet transfer Setting range...
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 Easy- Job mode Select "Defaults"...
Storing EasyJob NOTE! EasyJobs are saved under job numbers 1 - 5 and can also be called up in operating points 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.
Deleting EasyJob To delete an EasyJob operating point, touch the relevant EasyJob button for approx- operating points imately 5 seconds The button first changes its size and colour; is displayed with a frame after about 3 seconds. The saved operating point is overwritten with the latest settings. is highlighted in red (= delete) after a total of 5 seconds.
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 set- tings.
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 - re- NOTE! Before retrieving a job, make sure that the welding system has been in- trieving a job...
Renaming a job 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"...
Deleting a job Select "Save as Job" (also works in Job mode) The job list is displayed. Turn the adjusting dial and select the job to be deleted Select "Delete Job" A confirmation prompt asking whether you really want to delete the job is displayed. Select "Yes"...
Loading a job The load job function can be used to load the data for a saved job or an EasyJob to the welding screen. The relevant data from the job is displayed in the welding parameters and can be changed, saved as a new job or EasyJob, or used to start welding. Select "Save as Job"...
Optimising a job Select "Process parameters" Select "JOB" An overview of the job functions is displayed. Select "Optimize Job" The overview of the most recently optimised job is displayed. Turn the adjusting dial and select either the job or the job welding parameters to be modified...
The choice between the job and the job welding parameters can also be made by touching the "Job number / Job parameter" button. Select job: Press the adjusting dial The job number is highlighted in blue and can now be changed. Turn the adjusting dial to select the job to be altered Press the adjusting dial to change the job Select job welding parameters:...
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Select "Correction limits" A list of the job correction limits for the last job opened is displayed. Turn the adjusting dial and select either the job or the job limits to be modified The choice between the job and the job limits can also be made by touching the "Job number / Job parameter"...
TIG welding Safety WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: these operating instructions all the operating instructions for the system components, especially the safe- ty rules WARNING! An electric shock can be fatal.
TIG welding CAUTION! Risk of injury and damage from electric shock. As soon as the mains switch is in the "I" position, the tungsten electrode of the welding torch is live. Make sure that the tungsten electrode does not touch any persons or electrically conductive or earthed parts (e.g.
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Previous page: MIG/MAG pulse synergic, MIG/MAG standard synergic, MIG/MAG PMC, MIG/MAG LSC, MIG/MAG standard manual, CMT and Job mode Select TIG The welding voltage is applied to the welding socket with a three second time lag. NOTE! Parameters that have been set on a system component control panel (e.g.
The value of the selected welding parameter can now be changed. Turn the adjusting dial and change the parameter Adjust the process parameters accordingly to make user- or application-specific set- tings on the welding system Open the gas stop valve on the TIG gas-valve torch Set the desired shielding gas flow rate on the pressure regulator Start welding (ignite the arc) Igniting the arc...
Raise the welding torch and pivot it into the normal position - the arc ignites Carry out welding Arc ignited - welding commences Finishing welding Lift the TIG gas-valve torch away from the workpiece until the arc goes out. IMPORTANT! To protect the tungsten electrode, ensure that the shielding gas at the end of welding flows for long enough to allow the tungsten electrode to cool sufficient- Close the gas stop valve on the TIG gas-valve torch...
MMA welding Safety WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: these operating instructions all the operating instructions for the system components, especially the safe- ty rules WARNING! An electric shock can be fatal.
MMA welding CAUTION! Risk of injury and damage from electric shock. As soon as the mains switch is in the "I" position, the rod electrode in the electrode holder is live. Make sure that the rod electrode does not touch any persons or electrically conductive or earthed parts (e.g.
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Previous page: MIG/MAG pulse synergic, MIG/MAG standard synergic, MIG/MAG PMC, MIG/MAG LSC, MIG/MAG standard manual, CMT and Job mode Select the MMA/SMAW welding process The welding voltage is applied to the welding socket with a three second time lag. If the MMA/SMAW welding process is selected, any cooling unit present is automatically deactivated.
Press the adjusting dial to change the welding parameter The value of the welding parameter is displayed as a horizontal scale: The value of the selected welding parameter can now be changed. Turn the adjusting dial and change the parameter Adjust the process parameters accordingly to make user- or application-specific set- tings on the welding system Start welding...
Process parameters Overview - Pro- The "Process parameters" menu button has the following selection options under "Com- cess parameters, mon": Common Weld-Start/Weld-End Gas-Setup Process control R/L-check/alignment TIG/MMA/SMAW Setup Synchropulse Process mix Overview – Pro- The "Process parameters" menu item has the following selection options under "Compo- cess parameters, nents": Components...
Process parameters, General Process parame- The following process parameters can be set and displayed for the start and end of weld- ters for start of ing: welding/end of welding Starting current for setting the starting current for MIG/MAG welding (e.g. aluminium welding start-up) Unit % (of welding current) Setting range...
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Unit % (of welding current) Setting range 0 - 200 Factory setting End arc length correction For correcting the arc length at the end of welding Unit % (of welding voltage) Setting range -10.0 - +10.0 Factory setting shorter arc length neutral arc length longer arc length Final current time...
Auto/0.90 - 20.00 Factory setting auto (the correction factor for standard gases from the Fronius weld- ing database is automatically set) Can only be used in conjunction with the OPT/i gas controller option In Job mode, the set values of the parameters listed above can be set individually for each job.
Penetration stabi- The penetration stabiliser is used to set the max. permitted change in the wire feed speed liser to ensure that the welding current and hence the fusion penetration is kept stable or con- stant with variable stick out. The penetration stabiliser parameter is only available when the WP PMC (Welding Pro- cess Pulse Multi Control) or WP LSC (Welding Process Low Spatter Control) option has been enabled on the power source.
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Penetration stabiliser = n m/min (activated) I [A] [m/min] t [s] < s Specifying a value for the penetration stabiliser ensures a constant arc length without large current variations if the stick out is changed (s ==> s The penetration (x ) remains virtually unchanged and stable.
Arc length stabi- Arc length stabilizer lizer The arc length stabilizer forces short arcs, advantageous for welding, via a short-circuit current control and keeps them stable even with a variable stick out or external interfer- ence. The arc length stabilizer welding parameter is only available on the power source if the WP PMC (Welding Process Pulse Multi Control) option has been enabled.
Arc length stabilizer with change of weld seam profile and position Arc length stabilizer not activated A change of weld seam profile or welding position can negatively affect the welding result Arc length stabilizer activated Since the number and duration of the short circuits is controlled, the properties of the arc stay the same if the weld seam profile or welding position is changed.
R/L-check / align- Align the welding circuit resistance (R) and welding circuit inductivity (L) if one of the fol- ment lowing components of the welding system is changed: Torch hosepacks Interconnecting hosepacks Grounding cables, welding power-leads Wirefeeders Welding torches, electrode holders PushPull units Prerequisites for R/L alignment: The welding system must be complete: closed welding circuit with torch and torch hose-...
Follow the displayed instructions Press the torch trigger / select "Next" / press the adjusting dial After a successful measurement, the current values are displayed. Select "Finish" / press the adjusting dial Process parame- The following process parameters can be set and displayed for the TIG and rod electrode ters for TIG / welding process: MMA/SMAW Set-...
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0.1 - 20.0 A/V Parameter "0.1 - 20" is used to set a drooping characteristic (drooping characteris- (5). The setting range extends from 0.1 A / V (very steep) tic with adjustable to 20 A / V (very flat). slope) Setting a flat characteristic (5) is only advisable for cellu- lose electrodes.
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Anti-stick to activate/deactivate the anti-stick function Unit Setting range off / on Factory setting As the arc becomes shorter, the welding voltage may drop so far that the rod electrode will tend to stick. This may also cause the rod electrode to burn out. The anti-stick function prevents the electrode from burning out.
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Sequence: Welding At the end of the welding action, briefly raise the welding torch The arc length is increased significantly. Lower the welding torch The arc length is reduced significantly The TIG Comfort Stop function is triggered Keep the welding torch at the same height The welding current is continuously decreased (downslope).
Process parame- The following process parameters can be set for SynchroPulse welding: ters for Synchro- Pulse (1) Synchropulse to activate/deactivate SynchroPulse Unit Setting range off / on Factory setting (2) Wire feed speed for setting the wire speed and therefore the welding power for SynchroPulse Unit m/min (ipm) Setting range...
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(7) Arc length correction low For correcting the arc length for SynchroPulse in the lower operating point (= average wire speed minus Delta wire feed) Unit Setting range -10.0 - +10.0 Factory setting short arc uncorrected arc length longer arc [m/min] 1 / F 25 %...
Process parame- The following process parameters for mixed processes can be set under "Process mix": ters for Process PMC mix I [A] [m/min] t [ms] Mixed process between PMC and LSC welding process. A cold LSC process phase follows a hot PMC process phase as part of a cycle.
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Wire feed speed Wire speed - taken from the welding parameters Unit m/min (ipm) Setting range 1.0 - 25.0 (40 - 985) The wire speed value can also be specified or changed in the Process mix parameters. Arc length correction is applied from the welding parameters Setting range -10.0 - +10.0...
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Upper and lower power time correction is used to define the relationship between hot and cold process phases. If the upper power time correction is increased, the process frequency reduces and the PMC process phase becomes longer. If the upper power time correction is reduced, the process frequency increases and the PMC process phase becomes shorter.
Process parameters, Components Process parame- The following process parameters can be set and displayed for the system components of ters for compo- a welding system: nents Cooling unit mode to determine whether a cooling unit is to be switched on or off, or operated automatically Setting range eco / auto / on / off (depending on the cooling unit) Factory setting...
How it works: Once the torch trigger is pressed, gas pre-flow begins immediately. Wirefeeding then be- gins, followed by ignition. If no current starts flowing before the specified length of wire has been fed, the power source cuts out automatically. To try again, press the torch trigger again.
Select "system adjust" If system calibration is required, the system calibration wizard starts. The first step in the system calibration wizard is displayed: Follow the displayed instructions To move to the next step in the wizard, select "Next" / press the adjusting dial When system calibration has been completed successfully, a confirmation to this effect is displayed.
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System calibration: DualPuls Select "Process parameters" Select "Components" An overview of the process parameters for components is displayed: Select "system adjust" If system calibration is required, the system calibration wizard starts. The first step in the system calibration wizard is displayed: Follow the displayed instructions To move to the next step in the wizard, select "Next"...
Setting process parameters for arc break moni- toring Select "Process parameters" Select "Components" An overview of the process parameters for components is displayed: Select "Arc break watchdog settings" An overview of the "Arc break watchdog settings" is displayed. Turn the adjusting dial and select the desired parameter Press the adjusting dial (blue background) Turn the adjusting dial to change the parameter values (blue background) Arc break reaction = ignore (deactivated):...
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Arc break reaction = error (activated): f the arc break fractures off and no current flow is detected within a set arc break pe- riod, the system shuts down automatically and an error message appears on the dis- play. Factory setting = ignore Arc break time = 0–2.00 s An error is output if the set period is exceeded.
Process parameters, Job Optimising job The following process parameters can be set for the job: process parame- ters Job parameters Wire speed To adjust the wire speed Unit m/min (ipm) Setting range 1.0–25.0 (40–985) Arc length correction For correcting the arc length Unit Setting range -10.0 –...
Process control See page 100 Penetration stabilizer Arc length stabilizer SynchroPulse See page 110 SynchroPulse Wire speed deviation Frequency Duty cycle (high) Arc length correction high Arc length correction low Process mix See page 112 Upper power time correction Lower power time correction Lower power correction Gas setup See page 100...
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Arc length correction Upper arc length correction limit To set the upper arc length correction limit for a job Unit Setting range 0.0–10.0 Factory setting Lower arc length correction limit To set the lower arc length correction limit for a job Unit Setting range -10.0–0.0...
Defaults General remarks NOTE! As a result of firmware updates, you may find that there are functions available on your unit that are not described in these operating instructions or vice versa. Certain illustrations may also differ slightly from the actual control elements on your device.
Setting the lan- guage Select "Defaults" Select "View" Select "Language" An overview of the available languages is displayed. Turn the adjusting dial and select the desired language Select "OK" / press the adjusting dial The welding parameters are displayed in the selected language. Setting Units/ Standards...
Select "Defaults" Select "View" Select "Units / Standards" An overview of units and standards is displayed. Select the desired unit Select the desired standard: Name of filler metal according to European standards (e.g. AlMg 5, CuSi3, Steel, etc.) Name of filler metal according to the American Welding Standard (e.g.
Select "OK" / press the adjusting dial The default display settings are displayed. Retrieving sys- tem data Select "Defaults" Select "View" Select "System data" The current system data is displayed. Current arc power in kW The arc power is the product of welding current and welding voltage and is used to calculate the electrical energy input: E = IP / vs Electrical energy input in kJ/cm...
Current motor current in A, wirefeeder 1 (wirefeeder next to the arc) Current motor current in A, wirefeeder 2 (e.g. the rear wirefeeder in a push-pull system) Current motor current in A, wirefeeder 3 (e.g. an unreeling wirefeeder in a push-pull system with unreeling wire- feeder) Current flow rate in l/min on the cooling unit (with built-in OPT/i CU flow temperature sensor option)
Select "View" Select "Synergic lines" The options for displaying the characteristics are displayed. Select desired display option Display current characteristics: This only displays the current characteristics in the material settings. Display replaced characteristics: Older characteristics that have been replaced are also displayed in the material set- tings as well as the current characteristics.
Restoring factory settings Select "Defaults" Select "System" Select "Restore factory settings" A confirmation prompt for the factory settings is displayed. Select "Yes" to reset the values to their factory settings The process parameters and machine preset values are reset to the factory settings, an overview of the machine presets is displayed.
Select "System" Select "Website password" A confirmation prompt asking whether you really want to reset the website password is dis- played. Select "Yes" to reset the website password The website password is reset to the factory setting: User name = admin Password = admin The system overview of the default settings is displayed.
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Special 4-step = Guntrigger With a JobMaster welding torch and with special 4-step mode selected, this function allows you to change jobs via the torch trigger during welding. Job changing takes place within defined job groups. A job group is defined by the next non-programmed job. Example: Job group 1: Job no.
Setting network parameters man- ually Select "Defaults" Select "System" Select "Network Setup" The network setup overview is displayed. If DHCP is enabled, the IP address, Network mask and Standard gateway network param- eters are greyed out and cannot be adjusted. Turn the adjusting dial and select "DCHP"...
Power source configurations Select "Defaults" Select "System" Select "Power source configurations" The power source configuration is displayed. Turn the adjusting dial and select a configuration location Press the adjusting dial The keyboard is displayed. Use the keyboard to enter the desired text (max. 20 characters) Select "OK"...
The text is confirmed and the power source configuration is displayed. Select "Store" to apply changes Documentation: Setting the sam- pling rate Select "Defaults" Select "Documentation" Select "Basic settings" The basic settings documentation is displayed. Press the adjusting dial Turn the adjusting dial and change the sampling rate value: Sampling rate is deactivated;...
Documentation: Viewing the log- book Select "Defaults" Select "Documentation" Select "Logbook" The logbook is displayed. It currently only displays welding operations. The following data is also logged: Welding operation number Welding voltage in V Date (ddmmyy) Wire speed in m/min Time (hhmmss) Arc energy in kJ (for details see page 130)
Power source website General The power sources have a separate website. As soon as the power source is integrated into a network, the power source website can be called up using the power source IP address. Depending on the system configuration and software upgrades, the power source website contains the following entries: Overview Job data...
Settings The display of characteristics, material specifications and certain welding parameters can be expanded on the power source website by clicking on this symbol. An alternative unit or standard can also be displayed in addition to the units and standards set on the power source. Example: The unit "metric"...
Overview Overview In the overview entry, all welding system components and options are displayed with all available information, e.g. firmware version, item number, serial number, production date, etc. Expand all Click the "Expand all groups" button to show more details of the individual system compo- groups / Reduce nents.
To restart the power source, click on "Yes" The power source restarts; the display goes black for a short time. The Fronius logo is shown on the power source display during the restart. Once the update has been completed successfully, confirmation and the current firm-...
Fronius WeldWiz- The Fronius WeldWizard can also be called up in the “Update” entry. The Fronius Weld- Wizard helps welders, design engineers and work schedulers to estimate various welding parameters. Fronius WeldWizard The Fronius WeldWizard is available in the following forms:...
Screenshot Screenshot In the Screenshot entry, a digital image of the power source display can be created at any time, irrespective of the navigation or set values. Click on "Create screenshot" to capture a screenshot of the display A screenshot of the currently displayed settings is created. Different functions are available for saving the screenshot depending on the browser used;...
Backup & Restore Backup & Restore In the Backup & Restore entry, all the welding system data can be saved as a backup (e.g. current parameter settings, jobs, user characteristics, defaults, etc.). existing backups can be re-saved in the welding system. Backup (start Click on "Start backup"...
Function Packages Function Packag- In the Function Packages entry, the function packages, special characteristics, options, etc., present on the power source are displayed. New function packages can also be uploaded. Welding Packag- Under Welding Packages, the welding packages present on the power source are dis- played with their respective item numbers, e.g.: WP Standard, (MIG/MAG standard synergic welding) WP Pulse (MIG/MAG pulse synergic welding)
Job-Data Job data If the OPT/i Jobs option is available on the power source, the following is possible in the Job data entry: Existing welding system jobs can be viewed Existing welding system jobs can be optimised Jobs stored externally can be transferred to the welding system Existing jobs in the welding system can be exported as a PDF or CSV file Job overview The job overview lists all jobs stored in the welding system.
Creating a new job Click on "Create new job" Enter job data Click on "OK" to apply the new job Importing a job This function allows jobs stored externally to be transferred to the welding system, provid- ed the OPT/i Jobs option is available on the power source. Click on "Search Job-file"...
Synergic lines overview Characteristics In the Characteristics overview entry: overview Available characteristics in the welding system can be displayed: (Available characteristics button). Possible characteristics in the welding system can be displayed: (Possible characteristics button). You can search for, sort and filter the displayed characteristics at any time. The following information is displayed for the characteristics: Status Replaced by...
Documentation Documentation The welding data for the last 100 welding operations is displayed in the Documentation en- try. The welding data display can be filtered by a certain period using the "Time filter" button. To do so, the date (yyyy mm dd) and time (hh mm) are entered in the format from – to in each case.
Signal visualisation Signal visualis- Signal visualisation is only available if a robot interface is present. ation To display the signal visualisation correctly, IE 10 or another modern browser is required. The signals and commands transferred via a robot interface are displayed. IN ...
Troubleshooting General The power sources are equipped with an intelligent safety system, meaning it has been possible to dispense with nearly all fuses. After a possible malfunction has been remedied, the power source can be used again as normal. Possible malfunctions, warning notices or status codes are shown on the display as plain text dialogues.
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Cause: Mains fuse is faulty Remedy: Change the mains fuse No welding current mains switch is on, overtemperature is displayed Cause: Overload; the duty cycle has been exceeded Remedy: Check duty cycle Cause: Thermostatic automatic circuit breaker has been tripped Remedy: Wait until the power source automatically comes back on after the end of the cooling phase...
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Cause: Welding torch is faulty Remedy: Change the welding torch Cause: Gas solenoid valve faulty Remedy: Replace gas solenoid valve Poor weld properties Cause: Incorrect welding and/or correction parameters Remedy: Check the settings Cause: Poor grounding (earthing) connection Remedy: Ensure good contact to workpiece Cause: Inadequate or no protective gas shield Remedy:...
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Cause: The feed rollers are not suitable for the wire electrode being used Remedy: Use suitable feed rollers Cause: Feed rollers have the wrong contact pressure Remedy: Optimise the contact pressure Wirefeed problems when using long hosepacks Cause: Incorrect arrangement of hosepack Remedy: Arrange the hosepack in as straight a line as possible, avoid tight bends...
IMPORTANT! To update the firmware you need a PC or laptop that is connected to the ware power source via an Ethernet network. Get latest firmware (e.g. from the Fronius DownloadCenter) File format: official_tpsi_x.x.x-xxxx.ffw Establish Ethernet connection between PC/laptop and power source...
Technical data Explanation of Duty cycle (D.C.) is the proportion of time in a 10-minute cycle at which the device may be the term "duty cy- operated at its rated output without overheating. cle" NOTE! The D.C. values specified on the rating plate are based on an ambient temperature of 40°C.
TPS 320i Mains voltage (U 400 V Max. effective primary current (I 12.3 A 1eff Max. primary current (I 19.4 A 1max Mains fuse protection 35 A slow-blow Mains voltage tolerance +/- 15% Mains frequency 50/60 Hz Cos phi (1) 0.99...
TPS 320i /nc Mains voltage (U 380 V 400 V 460 V Max. effective primary current (I 12.7 A 12.3 A 11.4 A 1eff Max. primary current (I 20.1 A 19.4 A 18.0 A 1max Mains fuse protection 35 A slow-blow...
TPS 320i /600V/nc Mains voltage (U 575 V Max. effective primary current (I 10.6 A 1eff Max. primary current (I 16.7 A 1max Mains fuse protection 35 A slow-blow Mains voltage tolerance +/-10% Mains frequency 50/60 Hz Cos phi (1) 0.99...
TPS 320i /MV/nc Mains voltage (U 200 V 230 V Max. effective primary current (I 22.0 A 19.0 A 1eff Max. primary current (I 34.7 A 30.1 A 1max Mains fuse protection 35 A slow-blow Mains voltage (U 380 V...
TPS 400i Mains voltage (U 400 V Max. effective primary current (I 15.9 A 1eff Max. primary current (I 25.1 A 1max Mains fuse protection 35 A slow-blow Mains voltage tolerance +/-15% Mains frequency 50/60 Hz Cos phi (1) 0.99 Max.
TPS 400i /nc Mains voltage (U 380 V 400 V 460 V Max. effective primary current (I 16.5 A 15.9 A 14.6 A 1eff Max. primary current (I 26.1 A 25.1 A 23.5 A 1max Mains fuse protection 35 A slow-blow Mains voltage tolerance +/- 15% Mains frequency...
TPS 400i /600V/nc Mains voltage (U 575 V Max. effective primary current (I 14.3A 1eff Max. primary current (I 22.6 A 1max Mains fuse protection 35 A slow-blow Mains voltage tolerance +/-10% Mains frequency 50/60 Hz Cos phi (1) 0.99 Recommended earth-leakage circuit breaker Type B Welding current range (I...
TPS 400i /MV/nc Mains voltage (U 200 V 230 V Max. effective primary current (I 30.5 A 26.4 A 1eff Max. primary current (I 48.2 A 41.6 A 1max Mains fuse protection 35 A slow-blow Mains voltage (U 380 V 400 V 460 V Max.
TPS 400i LSC Mains voltage (U 400 V Max. effective primary current (I 16.4 A 1eff Max. primary current (I 25.1 A 1max Mains fuse protection 35 A slow-blow Mains voltage tolerance +/-15% Mains frequency 50/60 Hz Cos phi (1) 0.99 Max.
TPS 400i LSC Mains voltage (U 380 V 400 V 460 V ADV /nc Max. effective primary current (I 17.1 A 16.4 A 14.8 A 1eff Max. primary current (I 27.0 A 25.9 A 23.4 A 1max Mains fuse protection 35 A slow-blow Mains voltage tolerance +/-15%...
TPS 400i LSC Mains voltage (U 575 V ADV /600V/nc Max. effective primary current (I 14.3 A 1eff Max. primary current (I 22.6 A 1max Mains fuse protection 35 A slow-blow Mains voltage tolerance +/-10% Mains frequency 50/60 Hz Cos phi (1) 0.99 Recommended earth-leakage circuit breaker Type B...
TPS 400i LSC Mains voltage (U 200 V 230 V ADV /MV/nc Max. effective primary current (I 30.5 A 26.4 A 1eff Max. primary current (I 48.2 A 41.6 A 1max Mains fuse protection 35 A slow-blow Mains voltage (U 380 V 400 V 460 V...
TPS 500i Mains voltage (U 400 V Max. effective primary current (I 23.7 A 1eff Max. primary current (I 37.5 A 1max Mains fuse protection 35 A slow-blow Mains voltage tolerance +/- 15% Mains frequency 50/60 Hz Cos phi (1) 0.99 Max.
TPS 500i /nc Mains voltage (U 380 V 400 V 460 V Max. effective primary current (I 24.5 A 23.7 A 21.9 A 1eff Max. primary current (I 38.8 A 37.5 A 34.7 A 1max Mains fuse protection 35 A slow-blow Mains voltage tolerance -10/+15% Mains frequency...
TPS 500i /600V/nc Mains voltage (U 575 V Max. effective primary current (I 19.7 A 1eff Max. primary current (I 31.2 A 1max Mains fuse protection 35 A slow-blow Mains voltage tolerance +/-10% Mains frequency 50/60 Hz Cos phi (1) 0.99 Recommended earth-leakage circuit breaker Type B...
TPS 500i /MV/nc Mains voltage (U 200 V 230 V Max. effective primary current (I 43.5 A 37.4 A 1eff Max. primary current (I 68.8 A 59.2 A 1max Mains fuse protection 63 A slow-blow Mains voltage (U 380 V 400 V 460 V Max.
50 kg / 100.2 lb. Max. shielding gas pressure 7.0 bar / 101.5 psi Coolant Original Fronius Max. noise emission (LWA) 83 dB (A) Interface to a 230/400 V, 50 Hz public grid Discuss the matter with the grid operator before connecting the device to the public...
47.0 kg / 103.6 lb. Max. shielding gas pressure 7.0 bar / 101.49 psi Coolant Original Fronius Max. noise emission (LWA) 83 dB (A) Interface to a 230/400 V, 50 Hz public grid Discuss the matter with the grid operator before connecting the device to the public...
Dimensions (l x w x h) 706 x 300 x 510 mm 27.8 x 11.8 x 20.1 in. Weight 42.0 kg 92.6 lb. Max. shielding gas pressure 7 bar 101.49 psi Coolant Original Fronius Max. noise emission (LWA) 83 dB (A)
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FRONIUS INTERNATIONAL GMBH Froniusplatz 1, A-4600 Wels, Austria Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940 E-Mail: sales@fronius.com www.fronius.com www.fronius.com/addresses Under http://www.fronius.com/addresses you will find all addresses of our Sales & service partners and Locations...
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