Fronius TPS 320i Operating Instructions Manual
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Fronius TPS 320i Operating Instructions Manual

Mig/mag power source
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/ Perfect Charging /
Perfect Welding
TPS 320i / 400i / 500i / 600i
TPS 400i LSC ADV
42,0426,0114,EN 025-11012018
/ Solar Energy
Operating Instructions
MIG/MAG Power source

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Summary of Contents for Fronius TPS 320i

  • Page 1 / 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 025-11012018...
  • Page 3 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.

  • Page 5: Table Of Contents

    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 ....................
  • Page 6 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.........................
  • Page 7 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 ....................
  • Page 8 Logging on - unlocking function, forgotten password................172 Changing password / logging off......................172 Settings ..............................173 Language selection..........................173 Status indicator ............................. 174 Fronius ..............................174 Current system data........................... 175 Current system data..........................175 Documentation............................176 Documentation............................176 Job-Data ..............................177 Job data ..............................
  • Page 9 Technical data............................201 Explanation of the term "duty cycle" ..................... 201 Special voltages............................ 201 TPS 320i ............................... 202 TPS 320i /nc ............................203 TPS 320i /600V/nc ..........................204 TPS 320i /MV/nc ........................... 205 TPS 400i ............................... 206 TPS 400i /nc ............................207 TPS 400i /600V/nc ..........................
  • Page 10 TPS 500i /nc ............................215 TPS 500i /600V/nc ..........................216 TPS 500i /MV/nc ........................... 217 TPS 600i ............................... 218 TPS 600i /nc ............................219 TPS 600i /600V/nc ..........................220 Spare parts list: TPS 320i / 400i / 500i / 600i .................... 221...

  • Page 11: Safety Rules

    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.

  • Page 12: Proper Use

    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...

  • Page 13: Obligations Of The Operator

    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.

  • Page 14: Noise Emission Values

    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.

  • Page 15: Danger From Flying Sparks

    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.

  • Page 16: Meandering Welding Currents

    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.

  • Page 17: Emc Measures

    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).
  • Page 18 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.

  • Page 19: Factors Affecting Welding Results

    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.

  • Page 20: Safety Measures At The Installation Location And During Transport

    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.

  • Page 21: Commissioning, Maintenance And Repair

    Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ig- nite 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 na- tional and international regulations.

  • Page 22: Safety Symbols

    (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.

  • Page 23: General Information

    General information...

  • Page 25: General

    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.

  • Page 26: Fcc Compliance

    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.
  • Page 27 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...

  • Page 28: Welding Processes, Procedures And Welding Characteristics For Mig/Mag Welding

    Welding processes, procedures and welding charac- teristics for MIG/MAG welding 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.

  • Page 29: Summary Of Mig/Mag Pulse Synergic Welding

    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...

  • Page 30: Summary Of The Pmc Process

    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-...

  • Page 31: System Components

    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.

  • Page 32: Opt/I Safety Stop Pl D Option

    + 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...
  • Page 33 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.

  • Page 35: Controls, Connections And Mechanical Components

    Controls, connections and mechani- cal components...

  • Page 37: Control Panel

    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.
  • Page 38 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)

  • Page 39: Connections, Switches And Mechanical Components

    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...

  • Page 41: Operating Concept

    Operating concept...

  • Page 43: Input Options

    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.

  • Page 44: Pressing Buttons

    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.

  • Page 45: Display And Status Line

    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...

  • Page 46: Status Bar

    Status bar The status bar is divided into segments and contains the following information: Current welding process Current operating mode Current welding program (material, shielding gas, characteristic and wire diameter) 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) Time and date Status bar –...

  • Page 47: Installation And Commissioning

    Installation and commissioning...

  • Page 49: Minimum Equipment Needed For Welding Task

    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.

  • Page 50: Automated Cmt Welding

    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.

  • Page 51: Before Installation And Commissioning

    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.

  • Page 52: Generator-Powered Operation

    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:...

  • Page 53: Connecting The Mains Cable

    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...

  • Page 54: Connecting The Mains Cable - General

    Connecting the CAUTION! Risk of injury and material damage due to short circuits. mains cable - Short circuits can occur between the phase conductors or between the phase general conductors and the ground conductor unless ferrules are used. Fit ferrules to all phase conductors in an exposed mains cable as well as the ground conductor.

  • Page 56: Commissioning The Tps 320I / 400I / 500I / 600I, Tps 400I Lsc Adv

    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.

  • Page 57: Tps 320I / 400I / 500I / 600I: Fitting The System Components (Overview)

    TPS 320i / 400i / 500i / 600i: Fitting the system components (overview)

  • Page 58: Tps 400I Lsc Adv: Fitting The System Components (Overview)

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

  • Page 59: Fixing The Strain-Relief Device For The Interconnecting Hosepack

    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.

  • Page 60: Correct Arrangement Of The Interconnecting Hosepack

    Carry out R/L calibration if the arrangement of an interconnecting hosepack changes (see page 107). 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.

  • Page 61: Connecting The Gas Cylinder

    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.

  • Page 62: Connecting Mig/Mag Welding Torches To The Wire-Feed Unit

    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.

  • Page 63: Other Tasks

    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...

  • Page 64: Locking And Unlocking The Power Source Using The Nfc Key

    Locking and unlocking the power source using the NFC key General remarks 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 un- locked.

  • Page 65: Welding

    Welding...

  • Page 67: Mig/Mag Modes

    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.

  • Page 68: 2-Step Mode

    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.

  • Page 69: Mig/Mag And Cmt Welding

    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.

  • Page 70: Setting The Welding Process And Operating Mode

    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.

  • Page 71: Selecting The Filler Metal And Shielding Gas

    Select "Mode" 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 Select "Welding process" Select "Filler metal" Select "Change material settings" Turn the adjusting dial and select the desired filler metal Select "Next"...

  • Page 72: 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. 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.

  • Page 73: Setting The Shielding Gas Flow Rate

    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.

  • Page 74: Mig/Mag And Cmt Welding Parameters

    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...

  • Page 75: Welding Parameters For Mig/Mag Standard Synergic Welding And Lsc Welding

    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.

  • Page 76: Welding Parameters For Mig/Mag Standard Manual Welding

    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...

  • Page 77: Easyjob Mode

    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"...

  • Page 78: Storing Easyjob Operating Points

    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.

  • Page 79: Deleting Easyjob Operating Points

    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.

  • Page 80: Job Mode

    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.

  • Page 81: Job Welding - Retrieving A Job

    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...

  • Page 82: Renaming A Job

    Renaming a job Select "Save as Job" (also works in Job mode) The job list is displayed. universal 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"...

  • Page 83: Deleting A Job

    Deleting a job Select "Save as Job" (also works in Job mode) The job list is displayed. universal 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"...

  • Page 84: Loading A Job

    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. universal Select "Save as Job"...

  • Page 85: Optimising A 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...

  • Page 86: Setting Correction Limits For A Job

    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:...
  • Page 87 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"...

  • Page 88: Pre-Settings For "Save As Job

    Pre-settings for "Pre-settings for "Save as Job"" is for setting the default values that are assumed for every "Save as Job" newly created job. Select "Process parameters" Select "JOB" An overview of the job functions is displayed. Select "Pre-settings for "Save as Job"" Confirm the displayed information The default settings for saving new jobs are displayed.
  • Page 89 Press the adjusting dial Select "Finish"...

  • Page 90: Tig Welding

    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.

  • Page 91: Tig Welding

    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.
  • Page 92 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.

  • Page 93: Igniting The Arc

    The value of the selected 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...

  • Page 94: Finishing Welding

    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...

  • Page 95: Mma Welding

    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.

  • Page 96: Mma Welding

    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.
  • Page 97 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.

  • Page 98: Welding Parameters For Manual Metal Arc Welding

    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 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 Welding parame-...

  • Page 99: Process Parameters

    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 – com- The "Process parameters" menu item has the following selection options under "Compo- ponents and nents &...

  • Page 100: Process Parameters, General

    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...
  • Page 101 Final current for setting the final current so that heat build-up towards the end of welding is prevented and the end crater is filled (in the case of aluminium) 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...

  • Page 102: Process Parameters For Gas Setup

    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...

  • Page 103: Process Parameters For Process Control

    Process parame- The following process parameters can be set and displayed for the process control: ters for process Penetration stabiliser control Arc length stabiliser Combination of penetration stabiliser and arc length stabiliser 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.
  • Page 104 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.

  • Page 105: Arc Length Stabilizer

    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.

  • Page 106: Combination Of Penetration Stabiliser And Arc Length Stabiliser

    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.

  • Page 107: R/L-Check / Alignment

    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 welding torch and torch...

  • Page 108: Process Parameters For Tig / Mma/Smaw Setup

    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-...
  • Page 109 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.
  • Page 110 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.
  • Page 111 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).

  • Page 112: Process Parameters For Synchropulse

    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...
  • Page 113 (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 %...

  • Page 114: Process Parameters For Process Mix

    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.
  • Page 115 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...
  • Page 116 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.

  • Page 117: Components And Monitoring Process Parameters

    Components and monitoring process parameters 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...

  • Page 118: System Calibration

    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.

  • Page 119: Setting Process Parameters For Arc Break Monitoring

    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.
  • Page 120 An overview of the process parameters for components and monitoring is displayed: Select "Arc break watchdog settings" The "Arc break watchdog settings" overview appears. Turn the adjusting dial and select the desired parameter Press the adjusting dial (blue background) Turn the adjusting dial to change the values of the parameter (blue background) Arc break reaction = ignore (deactivated): The power source remains active and no error message appears on the display.

  • Page 121: Process Parameters For Wire Stick Contact Tip

    Process parame- ters for wire stick contact tip Select "Process parameters" Select "Components & Monitoring" An overview of the process parameters for components and monitoring is displayed: Select "Wire stick contact tip" The overview "Wire stick contact tip - setup menu" is displayed. Turn the adjusting dial and select the desired parameter Press the adjusting dial (blue background) Turn the adjusting dial and change the value of the parameter (blue background)

  • Page 122: Process Parameters For Wire Stick Work Piece

    The welding process will be interrupted in the event of wire stick on the contact tip. IMPORTANT! Monitoring is only possible during dip transfer arc processes. Factory setting = ignore Filter time = 0.5 - 5.0 s Maximum duration without arc short circuit until welding is interrupted. Factory setting = 0.5 s Select "OK"...

  • Page 123: Process Parameter For Wire End Monitoring

    Select "Wire stick work piece" The overview "Wire stick workpiece - setup menu" is displayed. Turn the adjusting dial and select the desired parameter Press the adjusting dial (blue background) Turn the adjusting dial and change the value of the parameter (blue background) Wire stick on workpiece = ignore: Wire stick monitoring on the workpiece is deactivated.
  • Page 124 Select "Wire end monitoring" The overview "Wire end monitoring setup menu" is displayed. Turn the adjusting dial and select the desired parameter, depending on the type of wire end monitoring: Wire end reaction for OPT/i WF R WE ring sensor 4,100,878,CK Wire end reaction for OPT/i WF R WE drum...

  • Page 125: Process Parameters, Job

    Process parameters, Job Optimising job The following process parameters can be set for the job: process parame- ters Job parameter Torch mode For setting the welding mode Unit Setting range 2-step / 4-step / S2-step / S4-step Wire speed For adjusting the wire speed Unit m/min (ipm) Setting range...
  • Page 126 Weld-Start / Weld-End See page 100 Starting current Start arc length correction Starting current time Slope 1 Slope 2 Final current End arc length correction SFI HotStart Wire withdrawal Process control See page 103 Penetration stabilizer Arc length stabilizer SynchroPulse See page 112 SynchroPulse Delta wire feed...

  • Page 127: Process Parameters For Correction Limits

    Limit monitoring See page 128 (only in conjunction with the OPT/i Limit Mon- itoring option) Voltage set value Lower voltage limit Upper voltage limit Max. duration of voltage deviation Current set value Lower current limit Upper current limit Max. duration for current deviation Wire speed set value Lower wire speed limit Upper wire speed limit...

  • Page 128: Process Parameters For "Save As Job" Pre-Settings

    Lower arc length correction limit For setting the lower arc length correction limit for a job Unit Setting range -10.0 - 0.0 Factory setting Further information on optimising jobs can be found in the Job correction limits section, un- der Job Mode on page 86. Process parame- After confirming the displayed information, the following process parameters can be set for ters for "Save as...
  • Page 129 Upper current limit For setting the upper current limit as a function of the set value Unit Setting range 0.0 - 100.0 Factory setting Maximum duration of current deviation For setting the maximum duration of a current deviation Unit Setting range off / 0.1 - 10.0 Factory setting Lower wire speed limit...

  • Page 131: Defaults

    Defaults...

  • Page 133: Defaults

    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.

  • Page 134: Defaults - View

    Defaults - view 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.

  • Page 135: Setting Units/Standards

    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.

  • Page 136: Setting The Date And Time

    Setting the date and time Select "Defaults" Select "View" Select "Time & Date" An overview of the date and time is displayed. Turn the adjusting dial and select the desired parameter: Year / Month / Day / Hour / Minute (white background) Press the adjusting dial to change the parameter (blue background) Turn the adjusting dial and set the desired value (blue background)

  • Page 137: Retrieving System Data

    Retrieving sys- tem data Select "Defaults" Select "View" Select "System data" The current system data is displayed. Arc power from real-time values in kW IP delivers the correct mean value of the arc power due to the high sam- ple measuring rate during non-continuous welding processes. If the welding speed is known, the electrical energy input can be calcu- lated: E = IP / vs...
  • Page 138 Arc energy in kJ IE delivers the correct total arc energy due to the high sample measuring rate during non-continuous welding processes. The arc energy is total arc power during the entire welding time. If the weld seam length is known, the electrical energy input can be cal- culated: E = IE / L Electrical energy input in kJ/cm...

  • Page 139: Displaying Characteristics

    Displaying char- acteristics Select "Defaults" Select "View" Select "Synergic lines" The options for displaying the characteristics are displayed. Select desired display option Display current characteristics: Only the current characteristics are displayed 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.

  • Page 140: Defaults - System

    Defaults - System Retrieving device information Select "Defaults" Select "System" Select "Information" The device information is displayed. Select "OK" Restoring factory settings Select "Defaults"...

  • Page 141: Restoring The Website Password

    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. Restoring the website pass- word...

  • Page 142: Mode Setup: Activating The Special 4-Step Mode "Guntrigger", Special Display For Jobmaster And Torch Trigger Job Selection

    Mode Setup: Acti- In the default settings, the following special functions can be set under "Mode Setup": vating the special Special 4-step mode "Guntrigger" for a JobMaster welding torch * 4-step mode JobMaster special display for a JobMaster welding torch * "Guntrigger", Torch trigger job selection for a welding torch special display...
  • Page 143 Example: Job group 1: Job no. 3 / 4 / 5 Job no. 6 is not assigned ==> End of job group 1 Job group 2: Job no. 7 / 8 / 9 When welding starts, the job with the lowest number within the job group is automati- cally selected.

  • Page 144: Setting Network Parameters Manually

    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 "DHCP"...

  • Page 145: Power Source Configurations

    Power source configurations Select "Defaults" Select "System" Select "Power source configurations" The power source configuration is displayed. universal 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"...
  • Page 146 The text is applied and the power source configuration is displayed. Select "Store" to apply changes...

  • Page 147: Defaults - Documentation

    Defaults - Documentation Setting the sam- pling rate Only in conjunction with the OPT/i limit monitoring option 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;...

  • Page 148: Viewing The Logbook

    Viewing the log- book Only in conjunction with the OPT/i limit monitoring option Select "Defaults" Select "Documentation" Select "Logbook" The logbook is displayed. Weldings, events or both can be displayed with the "Weldings" and "Events" buttons. The following data is also logged: Welding operation number Welding voltage in V Date (ddmmyy)

  • Page 149: Activate/Deactivate Limit Value Monitoring

    Activate/deacti- vate limit value monitoring Only in conjunction with the OPT/i limit monitoring option Select "Defaults" Select "Documentation" Select "Limit monitoring" The settings for limit value monitoring are displayed. Press the adjusting dial Turn the adjusting dial and change the value for limit monitoring: off: The limit value monitoring is deactivated.

  • Page 150: Defaults - Administration

    Defaults - Administration General remarks User management is advisable if several users work with the same power source. User management works with different roles and the help of NFC keys. Users are assigned different roles depending on their level of training or qualifications. Explanation of Administrator terms used...

  • Page 151: Overview

    If no NFC key is assigned to the pre-defined user "admin", every NFC key will work to lock and unlock the power source (no user management, see "Locking and unlocking the power source using the NFC key", page 64). Overview User management consists of the following sections: Administrator and creating roles Creating a user...

  • Page 152: Administrator And Creating Roles

    Please proceed systematically when creating roles and NFC keys. tion for creating roles and users Fronius recommends creating one or two administrator keys. Without administrator rights, it may in the worst-case scenario no longer be possible to operate a power source. Procedure NOTE! Losing an NFC administrator key can lead to the power source becoming unusable, depending on the settings.
  • Page 153 Select "User management" User management is displayed, "administrator" is selected. Press the adjusting dial Turn the adjusting dial and select "admin" Press the adjusting dial Turn the adjusting dial and select "NFC card" Press the adjusting dial The information to be transferred to the NFC card is displayed. Follow the instructions displayed (hold the new NFC key on the NFC key reader and wait for confirmation of identifica- tion)

  • Page 154: Creating Roles

    Creating roles Select "Defaults" Select "Administration" Select "User management" User management appears. Select "create role" The keyboard is displayed. Use the keyboard to enter the desired role name (max. 20 characters) Select "OK" to confirm the user name / press the adjusting dial...
  • Page 155 Specify the functions that a user can carry out in this role Select functions by turning the adjusting dial Press the adjusting dial Select settings from the list Press the adjusting dial Select "OK" Executable functions within a role Function Setting range Role name Editing role name using the keyboard...
  • Page 156 Function Setting range Default setting Display Language Units / Standards Time & Date Easy job settings System data Characteristics System Information Restore factory settings Website password Mode Setup Remote Support Network settings Power source configurations TWIN setting Documentation Basic settings Logbook Limit value monitoring Administration...

  • Page 157: Copy Roles

    Function Setting range Automatic backup Signal visualisation User management Export & import Overview Update Welding process / function packages Characteristics overview Screenshot User website ... hidden ... read only ... read and write Copy roles Select "Defaults" Select "Administration" Select "User management" User management appears.
  • Page 158 Turn the adjusting dial and select the role to be copied Select "new from" Enter a name for the new role using the keyboard Select "OK" Specify executable functions for the role Select function by turning the adjusting dial Press the adjusting dial Select the settings for the functions from the list Select "OK"...

  • Page 159: Creating A User

    Creating a user Creating a user Select "Defaults" Select "Administration" Select "User management" User management appears. Select "create user" The keyboard is displayed. Use the keyboard to enter the desired user name (max. 20 characters) Select "OK" to confirm the user name / press the adjusting dial...

  • Page 160: Copying Users

    Enter further user data – Select parameters by turning the adjusting dial – Press the adjusting dial – Select role, language, unit and standard (norm) from the list – Enter first name, last name and web password by using the keyboard Turn the adjusting dial and select "NFC card"...
  • Page 161 Turn the adjusting dial and select the role to which the user to be copied is assigned Press the adjusting dial Turn the adjusting dial and select the user to be copied Select "new from" Enter a name for the new user using the keyboard Select "OK"...

  • Page 162: Editing Roles / Users, Deactivating User Management

    Editing roles / users, deactivating user management Editing roles Select "Defaults" Select "Administration" Select "User management" User management appears. Turn the adjusting dial and select the desired role Select "Edit user/role"...

  • Page 163: Deleting Roles

    The role will open, the functions can be adjusted: Select function by turning the adjusting dial Press the adjusting dial Change the role name using the keyboard Select the settings for the functions from the list Select "OK" If no user is assigned to a role, then the it is possible to start editing the role by pressing the adjusting dial.

  • Page 164: Editing Users

    Turn the adjusting dial and select the role to be deleted Select "Delete user/role" Confirm when prompted The role and all assigned users will be deleted. Editing users Select "Defaults" Select "Administration" Select "User management" User management appears.
  • Page 165 Turn the adjusting dial and select the role to which the user to be edited is assigned Press the adjusting dial The users assigned to the role are displayed. Turn the adjusting dial and select the user to be edited Select "Edit user/role"...

  • Page 166: Deleting Users

    Select "OK" Deleting users Select "Defaults" Select "Administration" Select "User management" User management appears. Turn the adjusting dial and select the role to which the user to be deleted is assigned Press the adjusting dial Turn the adjusting dial and select the user to be deleted Select "Delete user/role"...

  • Page 167: Deactivating User Management

    Confirm when prompted The user is deleted. Deactivating user Select the pre-defined "admin" user under Defaults / Administration / User manage- management ment Turn the adjusting dial and select "NFC card" 1234567890abcd Press the adjusting dial A confirmation prompt asking whether you want to delete or replace the NFC card is dis- played.

  • Page 169: Smartmanager - The Power Source Website

    SmartManager - The power source website...

  • Page 171: Smartmanager - The Power Source Website

    SmartManager - The power source website General remarks The power source has its own website: SmartManager. As soon as the power source is connected to a computer with the help of a network cable, or is integrated into a network, the power source's SmartManager can be retrieved using the power source's IP address.

  • Page 172: Logging On - Unlocking Function, Forgotten Password

    Send this verification file to Fronius Technical Support by e-mail: welding.techsupport@fronius.com Fronius will respond to each e-mail with a one-time unlocking file named as follows: response_SN[serial number]_YYYY_MM_DD_hhmmss.txt Save the unlocking file to your computer Click on "Search unlocking file"...

  • Page 173: Settings

    Settings Clicking on this symbol expands the display of characteristics, material specifications and certain welding parameters for the power source's Smart- Manager. The settings depend on which user is currently logged on. Language selec- The languages available for SmartManager can be displayed by clicking on tion the language abbreviation.

  • Page 174: Status Indicator

    Status indicator The current status of the power source is shown between the Fronius logo and displayed power source. Attention / Warning Fault on the power source * Power source is welding The power source is ready (online) The power source is not ready (offline) In the event of an error, a red error line complete with error number will be dis- played above the line with the Fronius logo.

  • Page 175: Current System Data

    Current system data Current system The welding system's current data is displayed, e.g. data Machine name Installation location Production building Cell Welding process Actual Welding current Welding voltage Wire speed Arc length correction Pulse/dynamic correction Current arc power Arc length stabilizer Penetration stabilizer Current arc energy Motor current 1...

  • Page 176: Documentation

    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.

  • Page 177: Job-Data

    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 Viewing and exporting as PDF also works when the OPT/i limit monitoring option is not available on the power source.

  • Page 178: Importing A Job

    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"...

  • Page 179: Power Source Settings

    Power source settings Power source set- The process parameters and defaults for the power source can be viewed and changed in tings the power source settings entry. Changing process parameters Select process parameters Click parameter group / welding parameter Alter the parameter value directly in the display field Save changes Changing defaults Select defaults...

  • Page 180: Backup & Restore

    Backup & Restore General remarks In the backup & restore entry all welding system data can be saved as a backup (e.g. current parameter settings, jobs, user characteristics, defaults, etc.), any backups will be restored to the welding system You can select which data you would like to be backed up automatically. Backup &...

  • Page 181: Automatic Backup

    Automatic back- Enter data for automatic backup Interval settings Interval: daily / weekly / monthly at: Time (hh:mm) Backup target Protocol: SFTB / SMB Server, port, storage location, domain/user, password Proxy settings Server, port, user, password Save changes Trigger automatic backup...

  • Page 182: User Management

    User management User manage- In the user management entry ment created roles and users are saved to the power source's user management, saved roles and users on the power source are transferred into user management. The available user management data on the power source is, therefore, overwritten. User management is created on a power source and can then be saved with the export/ import function and transferred to another power source.

  • Page 183: Signal Visualisation

    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 ...

  • Page 184: Overview

    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.

  • Page 185: Update

    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- ware version are displayed.

  • Page 186: Fronius Weldconnect

    Fronius Weld- The mobile application Fronius WeldConnect can also be called up in the "Update" entry. Connect Fronius WeldConnect helps welders, design engineers and work schedulers to estimate various welding parameters. Fronius WeldConnect Fronius WeldConnect is available in the following forms:...

  • Page 187: Function Packages

    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)

  • Page 188: Synergic Lines Overview

    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...

  • Page 189: Screenshot

    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;...

  • Page 190: Interface

    Interface Interface If a robot interface is available, the name of the interface will be displayed as an entry on the power source website. The following welding parameters can be displayed, edited, saved or deleted: Characteristic assignment (current allocation of program numbers to characteristics) Module configuration (network settings) Factory settings can be restored and the module can be restarted.

  • Page 191: Troubleshooting And Maintenance

    Troubleshooting and maintenance...

  • Page 193: Troubleshooting

    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.
  • Page 194 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...
  • Page 195 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:...
  • Page 196 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...

  • Page 197: Care, Maintenance And Disposal

    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 Download Center) File format: official_tpsi_x.x.x-xxxx.ffw Establish Ethernet connection between PC/laptop and power source...

  • Page 199: Appendix

    Appendix...

  • Page 201: Technical Data

    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.

  • Page 202: Tps 320I

    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...

  • Page 203: Tps 320I /Nc

    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...

  • Page 204: Tps 320I /600V/Nc

    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...

  • Page 205: Tps 320I /Mv/Nc

    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...

  • Page 206: Tps 400I

    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.

  • Page 207: Tps 400I /Nc

    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...

  • Page 208: Tps 400I /600V/Nc

    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...

  • Page 209: Tps 400I /Mv/Nc

    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.

  • Page 210: Tps 400I Lsc Adv

    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.

  • Page 211: Tps 400I Lsc Adv /Nc

    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%...

  • Page 212: Tps 400I Lsc Adv /600V/Nc

    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...

  • Page 213: Tps 400I Lsc Adv /Mv/Nc

    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...

  • Page 214: Tps 500I

    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.

  • Page 215: Tps 500I /Nc

    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...

  • Page 216: Tps 500I /600V/Nc

    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...

  • Page 217: Tps 500I /Mv/Nc

    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.

  • Page 218: Tps 600I

    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...

  • Page 219: Tps 600I /Nc

    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...

  • Page 220: Tps 600I /600V/Nc

    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)

  • Page 221: Spare Parts List: Tps 320I / 400I / 500I / 600I

    Spare parts list: TPS 320i / 400i / 500i / 600i...
  • Page 228 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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Tps 600iTps 400i lsc advTps 400iTps 500i

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