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/ Battery Charging Systems / Welding Technology / Solar Electronics Operating Instructions TPS 320i / 400i / 500i MIG/MAG Power source 42,0426,0114,EN 009-05122013...
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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.
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Controls, connections and mechanical components Control panel.............................. General ..............................Safety..............................Control panel............................Connections, switches and mechanical components ................TPS 320i / 400i / 500i power source ..................... Operating concept Input options .............................. General ..............................Turning/pressing the adjusting dial ....................... Pressing buttons ...........................
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Connecting the mains cable........................General ..............................Stipulated mains cables ........................Connecting the mains cable - general ....................Commissioning the TPS 320i / 400i / 500i ....................Safety..............................General ..............................Fitting the system components (overview).................... Fixing the strain-relief device for the interconnecting hosepack ............
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...
Local regulations and national guidelines may require a residual current pro- protective device tective device when connecting equipment to the public grid. The type of residual current protective device recommended by Fronius for the equipment is indicated in the technical data. Protecting your- Persons involved with welding expose themselves to numerous risks, e.g.:...
harmful welding fumes and gases Anyone working on the workpiece while welding is in progress must wear suit- able protective clothing with 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.
If there is any doubt about whether the extraction system is powerful enough, then the measured toxic emission values should be compared with the permis- sible limit values. The following components are responsible, amongst other things, for the de- gree of toxicity of welding fumes: Metals used for the workpiece Electrodes Coatings...
Double the open circuit voltage of a power source can occur between the welding electrodes of two power sources. Touching the potentials of both elec- trodes 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.
EMC Device Clas- Devices in emission class A: sifications 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 sup- plied from the public low-voltage mains.
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 com- ponents. Covers and side panels may only be opened/removed while maintenance or repair work is being carried out.
All lifting accessories (straps, handles, chains, etc.) used in connection with the device or its components must be tested regularly (e.g. for mechanical damage, corrosion or changes caused by other environmental factors). The testing interval and scope of testing must comply with applicable national standards and directives as a minimum.
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 protec- tion shown on the rating plate.
Maintenance and It is impossible to guarantee that bought-in parts are designed and manufac- repair tured to meet the demands made of them, or that they satisfy safety require- ments. Use only original replacement and wearing parts (also applies to standard parts).
Copyright Copyright of these operating instructions remains with the manufacturer. The text and illustrations are all technically correct at the time of printing. We reserve the right to make changes. The contents of the operating instructions shall not provide the basis for any claims whatsoever on the part of the pur- chaser.
General Device concept The TPS 320i, TPS 400i and TPS 500i MIG/MAG power sources are completely 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.
The CMT process is suitable for: almost spatter-free MIG brazing Thin sheet welding with low warpage Joining of steel and aluminum (braze-welding) Application areas 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...
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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...
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.
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 sticks, hard drives without their own power supply, etc. 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.
Connections, switches and mechanical components TPS 320i / 400i / 500i power source (10) (11) (12) (13) Front Rear Function Mains switch for switching the power source on and off Control panel cover for protecting the control panel Control panel with display...
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 AlMg 5 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 processes 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 A warning symbol is superimposed onto the welding process in segment (1) if the current welding process is not compatible with the current welding program: Any unconfirmed error messages are shown in the status line.
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.
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 is designed to be used for MIG/MAG welding.
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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: x √3 1max 1max 1max...
Strain-relief devices for other cable cross-sections must be designed accordingly. Stipulated mains Power source Mains voltage Cable cross-section cables USA / Canada * Europe TPS 320i nc 3 x 400 V AWG 12 4G 2.5 mm² 3 x 460 V AWG 14 4G 2.5 mm² TPS 400i nc...
"O" position the power source is unplugged from the mains General Commissioning the TPS 320i / 400i / 500i power sources is described by reference to a manual gas-cooled MIG/MAG application. Fitting the system...
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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. hosepack Connecting the interconnecting hosepack to the power Connecting the interconnecting hosepack to the wire- source and cooling unit feed unit * (only if coolant connections are installed in the wire-...
Establishing a Plug the grounding (earthing) cable ground (earth) into the (-) current socket and twist to connection fasten it Use the other end of the grounding (earthing) cable to establish a connec- tion to the workpiece Connecting MIG/ Check that all cables, leads and hose- MAG welding packs are undamaged and correctly in- torches to the...
Close the wire drive cover Check that all connections are con- nected properly Other tasks Carry out the following steps in accordance with the wire-feed unit operating instructions: Insert the feed rollers in the wire-feed unit Insert the wirespool or basket-type spool with adapter in the wire-feed unit Feed in the wire electrode Set the contact pressure Adjust the brake...
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 suitable for welding aluminium materials. The spe- mode cial pattern of the welding current curve takes account of the high thermal conductivity of aluminium.
Move the mains switch to the I position A cooling unit connected to the system will begin to operate. For the best welding results, Fronius recommends that an R/L adjustment is carried out every time the device is switched on.
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Select the "Welding process" button in the left-hand ribbon Select the "Process" button in the right-hand ribbon An overview of the welding processes is displayed: MIG/MAG pulse synergic welding MIG/MAG standard synergic welding Select the desired welding process Setting the operating mode AlMg 5 Select the "Operating mode"...
Selecting the filler AlMg 5 metal AlMg 5 Select the "Welding process" button in the left-hand ribbon Select the "Filler metal" button in the right-hand ribbon. An overview of the filler metals is displayed. Press the "Change material settings" button The first step of the filler metal wizard is displayed: AlMg 5 AlMg 5...
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AlMg 5 AlMg 5 Select the desired wire diameter by turning the adjusting dial Press "Next" (or press the adjusting dial) The next step of the filler metal wizard is displayed: AlMg 5 AlMg 5 Select the desired shielding gas by turning the adjusting dial Press "Next"...
AlMg 5 AlMg 5 Press "Save" (or press the adjusting dial) The set welding program is applied and the filler metal overview is displayed. Setting the weld- AlMg 5 ing parameters Select the "Welding" button in the left-hand ribbon Select the desired welding parameter by turning the adjusting dial Press the adjusting dial to change the parameter The value of the parameter is displayed as a horizontal scale:...
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e.g. on the wire-feed unit The value of the selected parameter can now be changed. Turn the adjusting dial to change the parameter The adjusted value of the parameter is applied immediately. If one of the parameters feeder command value, sheet thickness, welding current or weld- ing voltage is changed during synergic welding, the other parameters are immediately ad- justed accordingly.
MIG/MAG welding AlMg 5 Select the "Welding" button in the left-hand ribbon CAUTION! Risk of injury and damage from electric shock and from the wire elec- trode 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.
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 the "Defaults"...
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A tick appears in the "EasyJobs on" tick box. Touch the "OK" button EasyJob mode is activated, the default settings are displayed. Select the "Welding" button in the left-hand ribbon The 5 EasyJob buttons are displayed. Saving EasyJob To save the current welding settings, touch one of the EasyJob buttons for about 3 operating points seconds The size and colour of the button changes.
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1 ~ 3 sec. Retrieving Easy- To retrieve a saved EasyJob operating point, touch the corresponding EasyJob button Job operating briefly (< 3 seconds) points The size and colour of the button changes briefly; it is then displayed with a tick. 1 <...
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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.
Welding parameters Welding parame- The following welding parameters for MIG/MAG pulse synergic welding can be set and dis- ters for MIG/MAG played by pressing the "Welding" button: pulse synergic welding Current recomm value 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 synergic welding can be set and ters for MIG/MAG displayed by selecting the "Welding" menu button: standard syner- gic welding Current recomm value 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.
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The real setting range depends on power source and wire feeder used and on the welding programm. The real setting range depends on the welding program. The maximum value depends on the wire feeder used.
Process parameters Overview The "Process parameters" menu button contains the following selection options: Start of welding / end of welding Gas setup Process control R/L alignment Components Process parame- The following parameters can be set and displayed for the start and end of welding: ters for start of welding / end of Starting current...
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Unit Setting range 0 - 9.9 Factory setting Slope 2 for setting the time during which the welding current is decreased or increased to the final current. Unit Setting range 0 - 9.9 Factory setting Final current for setting the final current so that heat build-up towards the end of welding is prevented and the crater is filled (in the case of aluminium) Unit...
Setting range 0 - 9.9 Factory setting Process parame- The following parameters can be set and displayed for the process control: ters for process regulation Fusion penetration stabiliser for setting the max. permitted change in the wire feed speed, so as to keep the fusion pen- etration stable or constant with variable stickout The fusion penetration stabiliser parameter is only available when the option WP PMC (Welding Process Puls Multi Control) or WP LSC (Welding Process Low Spatter Control)
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Select the "R/L adjustment" button The current welding circuit inductivity and welding circuit resistance values are displayed: AlMg 5 Touch "Next" (or press the adjusting dial or the torch trigger) The second step of the R/L adjustment wizard appears: AlMg 5 Make a ground (earth) connection to the workpiece Clean the workpiece surface before making a ground (earth) connection! Follow the displayed instructions...
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The third step of the R/L alignment wizard appears: AlMg 5 Remove the gas nozzle at the welding torch Follow the displayed instructions Touch "Next" (or press the adjusting dial or the torch trigger) The fourth step of the R/L alignment wizard appears: AlMg 5 Place the contact tube down firmly on the surface of the workpiece Press the torch key or “Next“...
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AlMg 5 > The R/L adjustment has been performed successfully. To finish the wizard press “Finish“ . Values: R = 1,3 mOhm (before: 1,7 mOhm) L = 5,0 µH (before: 4,0 µH Press "Finish" (or press the adjusting dial) Process parame- The following process parameters can be set and displayed for the system components of ters for compo- a welding device:...
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 the "Defaults" button in the left-hand ribbon Select the "Language" button An overview of the available languages is displayed. Language Select the desired language A small tick appears in the check box next to the language currently selected. Press "OK"...
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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No welding current mains switch is on and indicators are lit up Cause: Grounding (earthing) connection is incorrect Remedy: Check the grounding (earthing) connection and terminal for cor- rect polarity Cause: There is a break in the current cable in the welding torch Remedy: Replace welding torch Nothing happens when torch trigger is pressed...
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Remedy: Change the welding torch Cause: Wrong contact tip, or contact tip is worn out Remedy: Replace the contact tip Cause: Wrong wire alloy or wrong wire diameter Remedy: Check the wire electrode that has been inserted; check the weldability of the base metal Cause: The shielding gas is not suitable for this wire alloy Remedy:...
IMPORTANT: To update the firmware you need a PC or laptop that is connected to the firmware power source via Ethernet. Get latest firmware (e.g. from Fronius DownloadCenter) File format: rootX.X.XX-svnXXXX-official.ffw Establish Ethernet connection between PC/laptop and power source Transfer the firmware to the power source Disposal Dispose of in accordance with the applicable national and local regulations.
Technical data Special voltages For devices designed for special voltages, the technical data on the rating plate applies. For all machines with a permitted mains voltage of up to 460 V: The standard mains plug allows the user to operate with a mains voltage of up to 400 V. For mains voltages up to 460 V fit a mains plug permitted for such use or install the mains supply directly.
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 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 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 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 35 A slow-blow Mains voltage (U 380 V 400 V 460 V Max.
706 x 300 x 510 mm 27.8 x 11.8 x 20.1 in. Weight 36.5 kg 80.47 lb Max. shielding gas pressure 7.0 bar 101.49 psi Coolant Original Fronius Max. noise emission (L Interface to a 230/400 V, 50 Hz public grid...
706 x 300 x 510 mm 27.8 x 11.8 x 20.1 in. Weight 36.5 kg 80.47 lb Max. shielding gas pressure 7.0 bar 101.49 psi Coolant Original Fronius Max. noise emission (L Interface to a 230/400 V, 50 Hz public grid...
Dimensions l x w x h 706 x 300 x 510 mm 27.8 x 11.8 x 20.1 in. Weight 34.6 kg 76.28 lb Max. shielding gas pressure 9.0 bar 130.49 psi Coolant Original Fronius Max. noise emission (L Interface to public grid...
706 x 300 x 510 mm 27.8 x 11.8 x 20.1 in. Weight - kg - lb. Max. shielding gas pressure 9.0 bar 130.49 psi Coolant Original Fronius Max. noise emission (L Interface to a 230/400 V, 50 Hz public grid...
706 x 300 x 510 mm 27.8 x 11.8 x 20.1 in. Weight 38 kg 83.8 lb Max. shielding gas pressure 7.0 bar 101.49 psi Coolant Original Fronius Max. noise emission (L Interface to a 230/400 V, 50 Hz public grid...
706 x 300 x 510 mm 27.8 x 11.8 x 20.1 in. Weight 36.7 kg 80.9 lb Max. shielding gas pressure 7.0 bar 101.49 psi Coolant Original Fronius Max. noise emission (L Interface to a 230/400 V, 50 Hz public grid...
Dimensions l x w x h 706 x 300 x 510 mm 27.8 x 11.8 x 20.1 in. Weight 34.9 kg 76.94 lb Max. shielding gas pressure - bar - psi Coolant Original Fronius Max. noise emission (L Interface to public grid...
706 x 300 x 510 mm 27.8 x 11.8 x 20.1 in. Weight - kg - lb. Max. shielding gas pressure - bar - psi Coolant Original Fronius Max. noise emission (L Interface to a 230/400 V, 50 Hz public grid...
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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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