TPS 320i, TPS 400i, TPS 500i, TPS 600i Operating Instructions

1. Safety rules

1. Safety rules

• injury or death to the operator or a third party,
• damage to the device and other material assets belonging to the operating company,
• inefficient operation of the device.

• be suitably qualified,
• have sufficient knowledge of welding and
• read and follow these operating instructions carefully.

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

• must be in a legible state,
• must not be damaged,
• must not be removed,
• must not be covered, pasted or painted over.

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

1. Safety rules

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

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

• carefully reading and following all the instructions given in the operating instructions
• studying and obeying all safety and danger notices carefully
• performing all stipulated inspection and maintenance work.

• Thawing out pipes
• Charging batteries
• Starting engines

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

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

1. Safety rules

Devices with a higher rating may affect the energy quality of the mains due to their current consumption.

• Connection restrictions
• Criteria with regard to the maximum permissible mains impedance ^*)
• Criteria with regard to the minimum short-circuit power requirement ^*)

^*) at the interface with the public grid
see "Technical data"

In this case, the plant operator or the person using the device should check whether the device may be connected, where appropriate by discussing the matter with the power supply company.

IMPORTANT! Ensure that the mains connection is earthed properly

1. Safety rules

Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage.

• during operation: -10 °C to + 40 °C (14 °F to 104 °F)
• during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)

• up to 50% at 40 °C (104 °F)
• up to 90% at 20 °C (68 °F)

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

1. Safety rules

• 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.

Checks must be carried out at regular intervals to ensure that operators are working in a safety-conscious manner.

1. Safety rules

• to observe the basic instructions regarding safety at work and accident prevention
• to read these operating instructions, especially the "Safety rules" section and sign to confirm that they have understood them and will follow them.

Before leaving the workplace, ensure that people or property cannot come to any harm in your absence.

1. Safety rules

Local regulations and national guidelines may require a residual current protective device when connecting equipment to the public grid.
The type of residual current protective device recommended by the manufacturer for the equipment is indicated in the technical data.

1. Safety rules

• flying sparks and hot pieces of metal
• Arc radiation, which can damage eyes and skin

• Hazardous electromagnetic fields, which can endanger the lives of those using cardiac pacemakers

• Risk of electrocution from mains current and welding current

• Greater noise pollution

• Harmful welding fumes and gases

• Flame-resistant
• Insulating and dry
• Covers the whole body, is undamaged and in good condition
• Safety helmet
• Trousers with no turn-ups

• 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 protective visor
• Wear stout footwear that provides insulation even in wet conditions
• Protect the hands with suitable gloves (electrically insulated and providing protection against heat)
• Wear ear protection to reduce the harmful effects of noise and to prevent injury

• Make them aware of all the dangers (risk of dazzling by the arc, injury from flying sparks, harmful welding fumes, noise, possible risks from mains current and welding current, etc.)
• Provide suitable protective equipment
• Alternatively, erect suitable safety screens/curtains.

1. Safety rules

The device generates a maximum sound power level of <80 dB(A) (ref. 1pW) when idling and in the cooling phase following operation at the maximum permissible operating point under maximum rated load conditions according to EN 60974-1.

It is not possible to provide a workplace-related emission value during welding (or cutting) as this is influenced by both the process and the environment. All manner of different welding parameters come into play, including the welding process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the power range, the type of weld metal, the resonance characteristics of the workpiece, the workplace environment, etc.

1. Safety rules

The fumes produced during welding contain harmful gases and vapours.

Welding fumes contain substances that cause cancer, as stated in Monograph 118 of the International Agency for Research on Cancer.

Use at-source extraction and a room extraction system.
If necessary, use a welding torch with an integrated extraction device.

Keep your face away from welding fumes and gases.

• must not be breathed in
• must be extracted from the working area using appropriate methods.

Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least 20 m³ per hour at all times.

Otherwise, a welding helmet with an air supply must be worn.

If there is any doubt about whether the extraction capacity is sufficient, the measured toxic emission values should be compared with the permissible limit values.

• Metals used for the workpiece
• Electrodes
• Coatings
• Cleaners, degreasers, etc.
• Welding process used

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

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

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

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

1. Safety rules

Flying sparks may cause fires or explosions.

Never weld close to flammable materials.

Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the arc, or alternatively covered with an approved cover.

A suitable, tested fire extinguisher must be available and ready for use.

Sparks and pieces of hot metal may also get into adjacent areas through small gaps or openings. Take appropriate precautions to prevent any danger of injury or fire.

Welding must not be performed in areas that are subject to fire or explosion or near sealed tanks, vessels or pipes unless these have been prepared in accordance with the relevant national and international standards.

Do not carry out welding on containers that are being or have been used to store gases, propellants, mineral oils or similar products. Residues pose an explosive hazard.

1. Safety rules

An electric shock is potentially life threatening and can be fatal.

Do not touch live parts either inside or outside the device.

During MIG/MAG welding and TIG welding, the welding wire, the wire spool, the feed rollers and all pieces of metal that are in contact with the welding wire are live.

Always set the wirefeeder up on a sufficiently insulated surface or use a suitable, insulated wirefeeder holder.

Make sure that you and others are protected with an adequately insulated, dry base or cover for the earth or ground potential. This base or cover must extend over the entire area between the body and the earth or ground potential.

All cables and leads must be secured, undamaged, insulated and adequately dimensioned. Replace loose connections and scorched, damaged, or inadequately dimensioned cables and leads immediately.
Use the handle to ensure the power connections are tight before every use.
In the case of power cables with a bayonet connector, rotate the power cable around the longitudinal axis by at least 180° and pretension.

Do not wrap cables or leads around the body or parts of the body.

• never be immersed in liquid for cooling
• never be touched when the welding system is switched on.

Double the open circuit voltage of a welding system can occur between the welding electrodes of two welding systems. Touching the potentials of both electrodes at the same time may be fatal under certain circumstances.

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

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

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

If necessary, provide adequate earthing for the workpiece.

Switch off unused devices.

Wear a safety harness if working at height.

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

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

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

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

1. Safety rules

• Fire hazard
• Overheating of parts connected to the workpiece
• Damage to ground conductors
• Damage to device and other electrical equipment

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

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

Position the device with sufficient insulation against electrically conductive environments, such as insulation against conductive floor or insulation to conductive racks.

If power distribution boards, twin-head mounts, etc., are being used, note the following: The electrode of the welding torch / electrode holder that is not used is also live. Make sure that the welding torch / electrode holder that is not used is kept sufficiently insulated.

In the case of automated MIG/MAG applications, ensure that only an insulated wire electrode is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeeder.

1. Safety rules

• Are only designed for use in industrial settings
• Can cause line-bound and radiated interference in other areas

• Satisfy the emissions criteria for residential and industrial areas. This is also true for residential areas in which the energy is supplied from the public low-voltage mains.

EMC device classification as per the rating plate or technical data.

1. Safety rules

In certain cases, even though a device complies with the standard limit values for emissions, it may affect the application area for which it was designed (e.g. when there is sensitive equipment at the same location, or if the site where the device is installed is close to either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rectify the situation.

• Safety devices
• Network, signal and data transfer lines
• IT and telecommunications devices
• Measuring and calibrating devices

1. Mains supply
   • If electromagnetic interference arises despite the correct mains connection, additional measures are necessary (e.g. use of a suitable line filter)
2. Welding power-leads
   • must be kept as short as possible
   • must be laid close together (to avoid EMF problems)
   • must be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
   • If necessary, establish an earth connection using suitable capacitors.
5. Shield, if necessary
   • Shield other devices nearby
   • Shield the entire welding installation

1. Safety rules

• Effects on the health of persons in the vicinity, e.g. those with pacemakers and hearing aids
• Individuals with pacemakers must seek advice from their doctor before approaching the device or any welding that is in progress
• For safety reasons, maintain as large a distance as possible between the welding power-leads and the head/torso of the welder
• Do not carry welding power-leads and hosepacks over the shoulders or wind them around any part of the body

1. Safety rules

• Fans
• Cogs
• Rollers
• Shafts
• Wire spools and welding wires

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

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

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

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

Therefore, always keep the welding torch away from the body (devices with wirefeeder) and wear suitable protective goggles.

Never touch the workpiece during or after welding - risk of burns.

Slag can jump off cooling workpieces. The specified protective equipment must therefore also be worn when reworking workpieces, and steps must be taken to ensure that other people are also adequately protected.

Welding torches and other parts with a high operating temperature must be allowed to cool down before handling.

Special provisions apply in areas at risk of fire or explosion
- observe relevant national and international regulations.

Welding systems for work in areas with increased electrical risk (e.g. near boilers) must carry the ‘Safety’ sign. However, the welding system must not be located in such areas.

Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting coolant flow or return lines.

Observe the information on the coolant safety data sheet when handling coolant. The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer’s website.

Use only suitable load-carrying equipment supplied by the manufacturer when transporting devices by crane.

• Hook chains or ropes onto all suspension points provided on the load-carrying equipment.
• Chains and ropes must be at the smallest angle possible to the vertical.
• Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).

If the wirefeeder is attached to a crane holder during welding, always use a suitable, insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).

If the device has a carrying strap or handle, this is intended solely for carrying by hand. The carrying strap is not to be used if transporting with a crane, counterbalanced lift truck or other mechanical hoist.

All lifting tackle (straps, handles, chains, etc.) used in connection with the device or its components must be tested regularly (e.g. for mechanical damage, corrosion or changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national standards and directives as a minimum.

Odourless and colourless shielding gas may escape unnoticed if an adapter is used for the shielding gas connection. Prior to assembly, seal the device-side thread of the adapter for the shielding gas connection using suitable Teflon tape.

1. Safety rules

• Solid particle size < 40 µm
• Pressure condensation point < -20 °C
• Max. oil content < 25 mg/m³

Use filters if necessary.

1. Safety rules

Shielding gas cylinders contain gas under pressure and can explode if damaged. As the shielding gas cylinders are part of the welding equipment, they must be handled with the greatest of care.

Protect shielding gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked flames, sparks and arcs.

Mount the shielding gas cylinders vertically and secure according to instructions to prevent them falling over.

Keep the shielding gas cylinders well away from any welding or other electrical circuits.

Never hang a welding torch on a shielding gas cylinder.

Never touch a shielding gas cylinder with an electrode.

Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.

Only use shielding gas cylinders suitable for the application in hand, along with the correct and appropriate accessories (regulator, hoses and fittings). Only use shielding gas cylinders and accessories that are in good condition.

Turn your face to one side when opening the valve of a shielding gas cylinder.

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

If the shielding gas cylinder is not connected, leave the valve cap in place on the cylinder.

The manufacturer's instructions must be observed as well as applicable national and international regulations for shielding gas cylinders and accessories.

1. Safety rules

Risk of suffocation from the uncontrolled escape of shielding gas

Shielding gas is colourless and odourless and, in the event of a leak, can displace the oxygen in the ambient air.

• Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/hour.
• Observe safety and maintenance instructions on the shielding gas cylinder or the main gas supply.
• Close the shielding gas cylinder valve or main gas supply if no welding is taking place.
• Check the shielding gas cylinder or main gas supply for uncontrolled gas leakage before every start-up.

1. Safety rules

• The maximum permissible tilt angle is 10°.

• Observe relevant national and international regulations.

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

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

When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft. 7.69 in.) to ensure that cooling air can flow in and out freely.

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

Do not lift or transport operational devices. Switch off and disconnect devices from the grid before transport or lifting.

• Wirefeeder
• Wirespool
• Shielding gas cylinder

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

1. Safety rules

• injury or death to the operator or a third party
• damage to the device and other material assets belonging to the operator
• inefficient operation of the device

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

Never bypass or disable safety devices.

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

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

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

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

Only use suitable original coolant from the manufacturer.

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

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

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

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

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

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

1. Safety rules

It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made of them, or that they satisfy safety requirements.

• Use only original spare and wearing parts (also applies to standard parts).
• Do not carry out any modifications, alterations, etc. to the device without the manufacturer's consent.
• Components that are not in perfect condition must be replaced immediately.
• When ordering, please give the exact designation and part number as shown in the spare parts list, as well as the serial number of your device.

The housing screws provide the ground conductor connection for earthing the housing parts.
Only use original housing screws in the correct number and tightened to the specified torque.

1. Safety rules

The manufacturer recommends that a safety inspection of the device be performed at least once every 12 months.

The manufacturer recommends that the welding system be calibrated during the same 12-month period.

• after any changes are made
• after any additional parts are installed, or after any conversions
• after repair, care and maintenance are carried out
• at least every twelve months.

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

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

1. Safety rules

Devices with the CE mark satisfy the essential requirements of the low-voltage and electromagnetic compatibility directives (e.g. relevant product standards of the EN 60 974 series).

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

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

1. Safety rules

• backing up any changes made to the factory settings
• saving and retaining personal settings

1. Safety rules

Copyright of these operating instructions remains with the manufacturer.

Text and illustrations were accurate at the time of printing, subject to change.
We are grateful for suggestions for improvement and information regarding any discrepancies in the operating instructions.

1. General information

The TPS 320i, TPS 400i, TPS 500i and TPS 600i MIG/MAG welding machines are completely digitised, microprocessor-controlled inverter welding machines.

The modular design and ability to add system extensions ensure a high degree of flexibility. The devices can be adapted to any specific situation.

1. General information
2. General

The TPS 320i, TPS 400i, TPS 500i and TPS 600i MIG/MAG welding machines are completely digitised, microprocessor-controlled inverter welding machines.

The modular design and ability to add system extensions ensure a high degree of flexibility. The devices can be adapted to any specific situation.

1. General information
2. General

Depending on the device firmware, in some cases "power source" may still be shown on the display.

Power source = welding machine

1. General information
2. General

The central control and regulation unit of the welding machines is coupled with a digital signal processor. The central control and regulation unit and the signal processor control the entire welding process.
During the welding process, the actual data is measured continuously and the device responds immediately to any changes. Rule algorithms ensure that the desired target state is maintained.

• A precise welding process
• Exact reproducibility of all results
• Excellent weld properties

1. General information
2. General

The devices are used in workshops and industry for manual and automated applications with classical steel, galvanised sheets, chrome/nickel and aluminium.

The welding machines are designed for:

• Automotive and component supply industry
• Machine manufacturing and rail vehicle construction
• Chemical plant construction
• Equipment construction
• Shipyards, etc.

1. General information
2. General

FCC
This equipment complies with the limit values for an EMC device class A digital device pursuant to Part 15 of the FCC Rules. These limit values are intended to provide an adequate level of protection against harmful emissions when the device is being used in an industrial environment. This device generates and uses high-frequency energy and can cause interference to radio communications if it is not installed and used according to the Operating Instructions.
The use of this device in residential areas will probably cause harmful interference, in which case the user will be obliged to correct the interference at their own expense.

FCC ID: QKWSPBMCU2

Industry Canada RSS
This device complies with the Industry Canada licence-exempt RSS standards. Its use is subject to the following conditions:

IC: 12270A-SPBMCU2

EU
Conformity with Directive 2014/53 / EU - Radio Equipment Directive (RED)

When installing the antennae to be used for this transmitter, it is essential to maintain a minimum distance of 20 cm from all people. They must not be set up or operated together with another antenna or another transmitter. To comply with exposure to radio frequency guidelines, the operating conditions of the transmitter must be available to OEM integrators and end users.

ANATEL / Brazil
This device is operated on a secondary basis. It has no protection against harmful interference, even from devices of the same type.
This device cannot cause interference in systems operated on a primary basis.
This device complies with ANATEL's specific absorption rate limit values in relation to exposure to high frequency electric, magnetic and electromagnetic fields.

IFETEL / Mexico
Operation of this device is subject to the following two conditions:

NCC / Taiwan
In accordance with NCC regulations for low-power radio frequency devices:

Article 12
A certified low-power radio frequency device must not change the frequency, increase the power or alter the characteristics and functions of the original structure without approval.

Article 14
The use of low-power radio frequency devices must not adversely affect flight safety and communications.
A detected malfunction must be deactivated and corrected immediately until no malfunction is present.
The notice in the preceding paragraph refers to radio communications operated in accordance with the provisions of the Telecommunications Act. Low-power radio frequency devices must withstand interference from legitimate communications or radiological, electrical radio frequency devices for industrial, scientific and medical applications.

Thailand

1. General information
2. General

The Bluetooth® word mark and logos are registered trademarks owned by Bluetooth SIG, Inc. and any use of such marks by Fronius International GmbH is under license. Other trademarks and trade names are those of their respective owners.

1. General information
2. General

Warning notices and safety symbols are affixed to welding machines with the CSA test mark for use in North America (USA and Canada). These warning notices and safety symbols must not be removed or painted over. They warn against incorrect operation, as this may result in serious injury and damage.

Safety symbols on the rating plate:

Welding is dangerous. The following basic requirements must be met:

• Welders must be sufficiently qualified
• Suitable protective equipment must be used
• All persons not involved in the welding process must be kept at a safe distance
  

Do not use the functions described here until you have fully read and understood the following documents:

• These operating instructions
• All the operating instructions for the system components, especially the safety rules

1. General information

The welding machines can be operated with various system components and options. This makes it possible to optimise procedures and to simplify machine handling and operation, depending on the field of application for the welding machine.

1. General information
2. System components

The welding machines can be operated with various system components and options. This makes it possible to optimise procedures and to simplify machine handling and operation, depending on the field of application for the welding machine.

1. General information
2. System components

Also:

• Welding torches
• Grounding cable and electrode cable
• Dust filter
• Additional current sockets

1. General information
2. System components

OPT/i TPS 2.SpeedNet Connector
Optional second SpeedNet connection socket

Factory-fitted on the rear of the welding machine (but can also be installed on the front of the welding machine).

OPT/i TPS 4x Switch SpeedNet
Option if more than one additional SpeedNet connection socket is required.

IMPORTANT! The OPT/i TPS 4x Switch SpeedNet option cannot be operated in conjunction with the OPT/i TPS 2. SpeedNet Connector option. If the OPT/i TPS 2.SpeedNet Connector option is installed in the welding machine, it must be removed.

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

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

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

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

The OPT/i TPS 2. NT241 CU1400 option is installed in TPS 600i welding machines as standard.

OPT/i TPS motor supply +
If 3 or more drive motors are to be operated in the welding system, the OPT/i TPS motor supply + option must be installed in the TPS 320i - 600i welding machines.

OPT/i TPS dust filter

IMPORTANT! Use of the OPT/i TPS dust filter option on TPS 320i - 600i welding machines shortens the duty cycle.

OPT/i TPS 2. plus socket PC
Optional second (+) current socket (Power Connector) on the front of the welding machine

OPT/i TPS 2. ground socket
Optional second (-) current socket (Dinse) on the rear of the welding machine

OPT/i TPS 2. plus socket DINSE
Optional second (+) current socket (Dinse) on the front of the welding machine

OPT/i TPS 2.ground socket PC
Optional second (-) current socket (Power Connector) on the rear of the welding machine

OPT/i ground socket PC front
Optional (-) current socket (Power Connector) on the front of the welding machine - is fitted instead of the standard current socket with bayonet latch.

OPT/i SpeedNet Repeater
Signal amplifier if interconnecting hosepacks or connections from the welding machine to the wirefeeder are more than 50 m in length

Arc air gouging torch KRIS 13
Electrode holder with compressed air connection for arc air gouging

OPT/i Synergic Lines
Option for enabling all special characteristics available on TPSi welding machines;
this also automatically enables special characteristics created in future.

OPT/i GUN Trigger
Option for special functions in conjunction with the torch trigger

OPT/i Jobs
Option to view, create, edit, delete, export and import jobs in SmartManager
For details, see from page (→).

OPT/i Documentation
Option for the documentation function

OPT/i Interface Designer
Option for individual interface configuration

OPT/i WebJobEdit
The Web Job Editor can be used in conjunction with OPT/i Jobs to edit the jobs in a robot teach panel. The browser of the robot or a computer can directly access the Web Job Editor web page.

OPT/i Limit Monitoring
Option for specifying the limit values for the welding current, welding voltage and wire speed

OPT/i Custom NFC - ISO 14443A
Option to use a customer-specific frequency band for key cards

OPT/i CMT Cycle Step
Option for an adjustable, cyclical CMT welding process

OPT/i OPC-UA
Standardised data interface protocol

OPT/i MQTT
Standardised data interface protocol

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

OPT/i Touch Sense Adv.
The following functions are available with this option:

• Fault- and soiling-insensitive gas nozzle position search
• Detection of whether the wire electrode or gas nozzle has touched the component during position searching
• Short circuit monitoring between gas nozzle and contact tip
• Automatic monitoring of whether the gas nozzle touches the component or whether a short circuit occurs between the gas nozzle and the contact tip in welding mode / during wire threading / in teach mode / with WireSense

OPT/i SenseLead
Additional hardware option for improved voltage measurement when multiple arcs weld on one component.

OPT/i CU Interface
Interface for CU 4700 and CU 1800 cooling units

OPT/i SynchroPulse 10 Hz
To increase the SynchroPulse frequency from 3 Hz to 10 Hz

OPT/i WeldCube Navigator
Software for creating digital instructions for manual welding processes to be followed by welders.
The welder is guided through the welding instructions by WeldCube Navigator.

1. General information
2. System components

IMPORTANT! The OPT/i Safety Stop PL d safety function has been designed according to EN ISO 13849-1:2008 + AC:2009 as category 3.
This requires a two-channel feed of the input signal.
Bridging of the two-channel operation (e.g. with a shorting bar) is not permitted and will result in loss of the PL d.

Functional description

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

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

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

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

Various welding packages, welding characteristics and welding processes are available with TPSi welding machines that enable a wide range of materials to be effectively welded.

1. Welding packages, welding characteristics and welding processes

Various welding packages, welding characteristics and welding processes are available with TPSi welding machines that enable a wide range of materials to be effectively welded.

1. Welding packages, welding characteristics and welding processes
2. Welding packages

Various welding packages, welding characteristics and welding processes are available with TPSi welding machines that enable a wide range of materials to be effectively welded.

1. Welding packages, welding characteristics and welding processes
2. Welding packages

The following welding packages are available for TPSi welding machine:

Standard Welding Package
4,066,012
(enables MIG/MAG standard synergic welding)

Pulse Welding Package
4,066,013
(enables MIG/MAG pulse synergic welding)

LSC Welding Package *
4,066,014
(enables the LSC process)

PMC Welding Package **
4,066,015
(enables the PMC process)

CMT Welding Package ***
4,066,016
(enables the CMT process)

ConstantWire Welding Package
4,066,019
(enables constant current or constant voltage operation during brazing)

IMPORTANT! A TPSi welding machine without welding packages only offers the following welding processes:

• MIG/MAG standard manual welding
• TIG welding
• Manual metal arc welding

1. Welding packages, welding characteristics and welding processes

Depending on the welding process and shielding gas mix, various process-optimised welding characteristics are available when selecting the filler metal.

Examples of welding characteristics:

• MIG/MAG 3700 PMC Steel 1,0mm M21 - arc blow *
• MIG/MAG 3450 PMC Steel 1,0mm M21 - dynamic *
• MIG/MAG 3044 Pulse AlMg5 1.2 mm I1 - universal *
• MIG/MAG 2684 Standard Steel 0.9 mm M22 - root *

The additional designation (*) next to the welding process provides information about the special properties and use of the welding characteristic.
The description of the characteristics is set out as follows:

Designation
Process
Properties

AC additive ¹⁾
PMC, CMT

Characteristic for welding bead onto bead in adaptive structures
The characteristic changes the polarity cyclically to keep heat input low and achieve more stability with a higher deposition rate.

AC heat control ¹⁾
PMC, CMT

The characteristic changes the polarity cyclically to keep the heat input into the component low. The heat input into the component can be additionally controlled by appropriate correction parameters.

AC universal ¹⁾
PMC, CMT

The characteristic changes the polarity cyclically to keep the heat input into the component low and is ideal for all standard welding tasks.

additive
CMT

Characteristics with reduced heat input and greater stability at a higher deposition rate for welding bead onto bead in adaptive structures

ADV ²⁾
CMT

Also required:
Inverter module for an alternating current process

Negatively poled process phase with low heat input and high deposition rate

ADV ²⁾
LSC

Also required:
Electronic switch for interrupting power

Maximum reduction in current caused by opening the circuit in each desired process phase

Only in conjunction with TPS 400i LSC ADV

ADV braze
CMT

Characteristics for brazing processes (reliable wetting and good flow of braze material)
Almost no welding spatter occurs in dip transfer arc area. The characteristic is ideal for long hosepacks and return lead cables.

arc blow
PMC

Characteristic to avoid arc breaks due to arc blow.

ADV root
LSC Advanced

Characteristics for root passes with powerful arc.
Almost no welding spatter occurs in dip transfer arc area. The characteristic is ideal for long hosepacks and return lead cables.

ADV universal
LSC Advanced

Characteristic for all standard welding tasks, with almost no welding spatter in the dip transfer arc area. The characteristic is ideal for long hosepacks and return lead cables.

arcing
Standard

Characteristics for a special type of hardfacing on a wet or dry surface
(e.g. grinding rollers in the sugar and ethanol industries)

base
standard

Characteristics for a special type of hardfacing on a wet or dry surface
(e.g. grinding rollers in the sugar and ethanol industries)

braze
CMT, LSC, PMC

Characteristic for brazing processes (reliable wetting and good flow of braze material)

braze+
CMT

Characteristic for brazing processes with the special Braze+ gas nozzle and high brazing speed (gas nozzle with narrow opening and high flow rate)

CC/CV
CC/CV

Characteristic with constant current or constant voltage curve for operating the welding machine with a power supply unit. A wirefeeder is not required.

cladding
CMT, LSC, PMC

Characteristics for overlay welding with low penetration, low dilution and wide weld seam flow for improved wetting

constant current
PMC

Constant current characteristic
For applications where no arc length control is required (stickout changes are not compensated)

CW additive
PMC, ConstantWire

Characteristic with constant wire speed progression for the additive production process
With this characteristic, no arc is ignited, the welding wire is only fed as filler metal.

dynamic
CMT, PMC, Puls, Standard

Characteristic for deep penetration and reliable root fusion at high welding speeds

dynamic +
PMC

Characteristic with short arc length for high welding speeds with arc length control independent of the material surface.

edge
CMT

Characteristic for welding corner seams with targeted energy input and high welding speed

flanged edge
CMT

Characteristic for welding flange welds with targeted energy input and high welding speed

galvanized
CMT, LSC, PMC, Puls, Standard

Characteristics for galvanised sheet surfaces (low risk of zinc pores and reduced penetration)

galvannealed
PMC

Characteristics for iron-zinc-coated material surfaces

gap bridging
CMT, PMC

Characteristic for the best gap-bridging ability due to very low heat input

hotspot
CMT

Characteristic with hot start sequence, specially for plug welds and MIG/MAG spot weld joints

mix ^{2) / 3)}
PMC

Also required:
Pulse and PMC welding packages

Characteristic for generating a rippled weld.
The heat input into the component is specifically controlled by the cyclical process change between pulsed and dip transfer arc.

LH fillet weld
PMC

Characteristics for LaserHybrid fillet weld applications
(laser + MIG/MAG process)

LH flange weld
PMC

Characteristics for LaserHybrid corner weld applications
(laser + MIG/MAG process)

LH Inductance
PMC

Characteristics for LaserHybrid applications with high welding circuit inductance
(laser + MIG/MAG process)

LH lap joint
PMC, CMT

Characteristics for LaserHybrid lap joint applications
(laser + MIG/MAG process)

marking
Characteristics for marking conductive surfaces

Characteristic for marking electrically conductive surfaces.
Marking is performed by low power spark erosion and a reversing wire movement.

mix ^{2) / 3)}
CMT

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

Characteristic for producing a rippled weld.
The heat input into the component is specifically controlled by the cyclical process change between pulsed arc or CMT.

mix drive ²⁾
PMC

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

Characteristic for producing a rippled weld by means of a cyclical process interruption of the pulsed arc and an additional wire movement

multi arc
PMC

Characteristic for components being welded by several arcs each influencing the other Ideal for increased welding circuit inductance or mutual welding circuit coupling.

open root
LSC, CMT

Characteristic with powerful arc, especially suitable for root passes with air gap

PCS ³⁾
PMC

The characteristic changes directly from a pulsed arc to a concentrated spray arc above a certain power. The advantages of pulsed and spray arcs combined in a single characteristic.

PCS mix
PMC

The characteristic changes cyclically between a pulsed or spray arc to a dip transfer arc, depending on the power range. It is especially suitable for vertical-up welds due to the alternating hot and then cold, supporting process phase.

pin
CMT

Characteristic for welding brads to an electrically conductive surface
The retraction movement of the wire electrode and the set current curve progression define the appearance of the pin.

pin picture
CMT

Characteristic for welding brads with a spherical end onto an electrically conductive surface, especially for creating pin pictures.

pin print
CMT

Characteristic for writing texts, patterns or markings on electrically conductive component surfaces
Writing takes place by positioning individual dots the size of a welding droplet.

pin spike
CMT

Characteristic for welding brads with pointed ends onto an electrically conductive surface.

pipe
PMC, Pulse, Standard

Characteristics for pipe applications and positional welding on narrow gap applications

pipe cladding
PMC, CMT

Characteristics for overlay welding of outer pipe claddings with little penetration, low dilution and wide weld seam flow

retro
CMT, Puls, PMC, Standard

The characteristic has the same weld properties as the predecessor TransPuls Synergic (TPS) series.

ripple drive ²⁾
PMC

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

Characteristic for producing a rippled weld by means of a cyclical process interruption of the pulsed arc and an additional wire movement.
The weld rippling characteristics are similar to that of TIG welds.

root
CMT, LSC, Standard

Characteristics for root passes with powerful arc

seam track
PMC, Pulse

Characteristic with amplified current control, especially suitable for the use of a seam tracking system with external current measurement.

TIME
PMC

Characteristic for welding with very long stickout and TIME shielding gases to increase the deposition rate.
(TIME = Transferred Ionized Molten Energy)

TWIN cladding
PMC

MIG/MAG tandem characteristics for overlay welding with low penetration, low dilution and wide weld seam flow for improved wetting.

TWIN multi arc
PMC

MIG/MAG tandem characteristic for components being welded by several arcs each influencing the other. Ideal for increased welding circuit inductance or mutual welding circuit coupling.

TWIN PCS
PMC

The MIG/MAG tandem characteristic changes from a pulsed arc directly to a concentrated spray arc above a certain power. The two arcs are not synchronised.

TWIN universal
PMC, Pulse, CMT

MIG/MAG tandem characteristic for all standard welding tasks, optimised for the mutual magnetic interaction of the arcs. The two arcs are not synchronised.

universal
CMT, PMC, Puls, Standard

The characteristic is ideal for all standard welding tasks.

weld+
CMT

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

1. Welding packages, welding characteristics and welding processes
2. Welding characteristics

Depending on the welding process and shielding gas mix, various process-optimised welding characteristics are available when selecting the filler metal.

Examples of welding characteristics:

• MIG/MAG 3700 PMC Steel 1,0mm M21 - arc blow *
• MIG/MAG 3450 PMC Steel 1,0mm M21 - dynamic *
• MIG/MAG 3044 Pulse AlMg5 1.2 mm I1 - universal *
• MIG/MAG 2684 Standard Steel 0.9 mm M22 - root *

The additional designation (*) next to the welding process provides information about the special properties and use of the welding characteristic.
The description of the characteristics is set out as follows:

Designation
Process
Properties

AC additive ¹⁾
PMC, CMT

Characteristic for welding bead onto bead in adaptive structures
The characteristic changes the polarity cyclically to keep heat input low and achieve more stability with a higher deposition rate.

AC heat control ¹⁾
PMC, CMT

The characteristic changes the polarity cyclically to keep the heat input into the component low. The heat input into the component can be additionally controlled by appropriate correction parameters.

AC universal ¹⁾
PMC, CMT

The characteristic changes the polarity cyclically to keep the heat input into the component low and is ideal for all standard welding tasks.

additive
CMT

Characteristics with reduced heat input and greater stability at a higher deposition rate for welding bead onto bead in adaptive structures

ADV ²⁾
CMT

Also required:
Inverter module for an alternating current process

Negatively poled process phase with low heat input and high deposition rate

ADV ²⁾
LSC

Also required:
Electronic switch for interrupting power

Maximum reduction in current caused by opening the circuit in each desired process phase

Only in conjunction with TPS 400i LSC ADV

ADV braze
CMT

Characteristics for brazing processes (reliable wetting and good flow of braze material)
Almost no welding spatter occurs in dip transfer arc area. The characteristic is ideal for long hosepacks and return lead cables.

arc blow
PMC

Characteristic to avoid arc breaks due to arc blow.

ADV root
LSC Advanced

Characteristics for root passes with powerful arc.
Almost no welding spatter occurs in dip transfer arc area. The characteristic is ideal for long hosepacks and return lead cables.

ADV universal
LSC Advanced

Characteristic for all standard welding tasks, with almost no welding spatter in the dip transfer arc area. The characteristic is ideal for long hosepacks and return lead cables.

arcing
Standard

Characteristics for a special type of hardfacing on a wet or dry surface
(e.g. grinding rollers in the sugar and ethanol industries)

base
standard

Characteristics for a special type of hardfacing on a wet or dry surface
(e.g. grinding rollers in the sugar and ethanol industries)

braze
CMT, LSC, PMC

Characteristic for brazing processes (reliable wetting and good flow of braze material)

braze+
CMT

Characteristic for brazing processes with the special Braze+ gas nozzle and high brazing speed (gas nozzle with narrow opening and high flow rate)

CC/CV
CC/CV

Characteristic with constant current or constant voltage curve for operating the welding machine with a power supply unit. A wirefeeder is not required.

cladding
CMT, LSC, PMC

Characteristics for overlay welding with low penetration, low dilution and wide weld seam flow for improved wetting

constant current
PMC

Constant current characteristic
For applications where no arc length control is required (stickout changes are not compensated)

CW additive
PMC, ConstantWire

Characteristic with constant wire speed progression for the additive production process
With this characteristic, no arc is ignited, the welding wire is only fed as filler metal.

dynamic
CMT, PMC, Puls, Standard

Characteristic for deep penetration and reliable root fusion at high welding speeds

dynamic +
PMC

Characteristic with short arc length for high welding speeds with arc length control independent of the material surface.

edge
CMT

Characteristic for welding corner seams with targeted energy input and high welding speed

flanged edge
CMT

Characteristic for welding flange welds with targeted energy input and high welding speed

galvanized
CMT, LSC, PMC, Puls, Standard

Characteristics for galvanised sheet surfaces (low risk of zinc pores and reduced penetration)

galvannealed
PMC

Characteristics for iron-zinc-coated material surfaces

gap bridging
CMT, PMC

Characteristic for the best gap-bridging ability due to very low heat input

hotspot
CMT

Characteristic with hot start sequence, specially for plug welds and MIG/MAG spot weld joints

mix ^{2) / 3)}
PMC

Also required:
Pulse and PMC welding packages

Characteristic for generating a rippled weld.
The heat input into the component is specifically controlled by the cyclical process change between pulsed and dip transfer arc.

LH fillet weld
PMC

Characteristics for LaserHybrid fillet weld applications
(laser + MIG/MAG process)

LH flange weld
PMC

Characteristics for LaserHybrid corner weld applications
(laser + MIG/MAG process)

LH Inductance
PMC

Characteristics for LaserHybrid applications with high welding circuit inductance
(laser + MIG/MAG process)

LH lap joint
PMC, CMT

Characteristics for LaserHybrid lap joint applications
(laser + MIG/MAG process)

marking
Characteristics for marking conductive surfaces

Characteristic for marking electrically conductive surfaces.
Marking is performed by low power spark erosion and a reversing wire movement.

mix ^{2) / 3)}
CMT

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

Characteristic for producing a rippled weld.
The heat input into the component is specifically controlled by the cyclical process change between pulsed arc or CMT.

mix drive ²⁾
PMC

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

Characteristic for producing a rippled weld by means of a cyclical process interruption of the pulsed arc and an additional wire movement

multi arc
PMC

Characteristic for components being welded by several arcs each influencing the other Ideal for increased welding circuit inductance or mutual welding circuit coupling.

open root
LSC, CMT

Characteristic with powerful arc, especially suitable for root passes with air gap

PCS ³⁾
PMC

The characteristic changes directly from a pulsed arc to a concentrated spray arc above a certain power. The advantages of pulsed and spray arcs combined in a single characteristic.

PCS mix
PMC

The characteristic changes cyclically between a pulsed or spray arc to a dip transfer arc, depending on the power range. It is especially suitable for vertical-up welds due to the alternating hot and then cold, supporting process phase.

pin
CMT

Characteristic for welding brads to an electrically conductive surface
The retraction movement of the wire electrode and the set current curve progression define the appearance of the pin.

pin picture
CMT

Characteristic for welding brads with a spherical end onto an electrically conductive surface, especially for creating pin pictures.

pin print
CMT

Characteristic for writing texts, patterns or markings on electrically conductive component surfaces
Writing takes place by positioning individual dots the size of a welding droplet.

pin spike
CMT

Characteristic for welding brads with pointed ends onto an electrically conductive surface.

pipe
PMC, Pulse, Standard

Characteristics for pipe applications and positional welding on narrow gap applications

pipe cladding
PMC, CMT

Characteristics for overlay welding of outer pipe claddings with little penetration, low dilution and wide weld seam flow

retro
CMT, Puls, PMC, Standard

The characteristic has the same weld properties as the predecessor TransPuls Synergic (TPS) series.

ripple drive ²⁾
PMC

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

Characteristic for producing a rippled weld by means of a cyclical process interruption of the pulsed arc and an additional wire movement.
The weld rippling characteristics are similar to that of TIG welds.

root
CMT, LSC, Standard

Characteristics for root passes with powerful arc

seam track
PMC, Pulse

Characteristic with amplified current control, especially suitable for the use of a seam tracking system with external current measurement.

TIME
PMC

Characteristic for welding with very long stickout and TIME shielding gases to increase the deposition rate.
(TIME = Transferred Ionized Molten Energy)

TWIN cladding
PMC

MIG/MAG tandem characteristics for overlay welding with low penetration, low dilution and wide weld seam flow for improved wetting.

TWIN multi arc
PMC

MIG/MAG tandem characteristic for components being welded by several arcs each influencing the other. Ideal for increased welding circuit inductance or mutual welding circuit coupling.

TWIN PCS
PMC

The MIG/MAG tandem characteristic changes from a pulsed arc directly to a concentrated spray arc above a certain power. The two arcs are not synchronised.

TWIN universal
PMC, Pulse, CMT

MIG/MAG tandem characteristic for all standard welding tasks, optimised for the mutual magnetic interaction of the arcs. The two arcs are not synchronised.

universal
CMT, PMC, Puls, Standard

The characteristic is ideal for all standard welding tasks.

weld+
CMT

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

1. Welding packages, welding characteristics and welding processes

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

1. Welding packages, welding characteristics and welding processes
2. Welding methods and processes

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

1. Welding packages, welding characteristics and welding processes
2. Welding methods and processes

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

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

Intermediate arc
The intermediate arc alternates irregularly between short circuits and spray transitions. This results in increased spatter. It is not possible to use this arc effectively, so it is better to avoid it.

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

1. Welding packages, welding characteristics and welding processes
2. Welding methods and processes

PMC = Pulse Multi Control

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

1. Welding packages, welding characteristics and welding processes
2. Welding methods and processes

LSC = Low Spatter Control

LSC is a low-spatter dip transfer arc process. Before the short circuit bridge is broken, the current is lowered and re-ignition takes place at significantly lower welding current values.

1. Welding packages, welding characteristics and welding processes
2. Welding methods and processes

SynchroPulse is available for all processes (standard/pulsed/LSC/PMC).
Due to the cyclical change of welding power between two operating points, SynchroPulse achieves a flaking seam appearance and non-continuous heat input.

1. Welding packages, welding characteristics and welding processes
2. Welding methods and processes

CMT = Cold Metal Transfer

A special CMT drive unit is required for the CMT process.

The reversing wire movement in the CMT process results in a droplet detachment with improved dip transfer arc properties.
The advantages of the CMT process are as follows

• Low heat input
• Less spattering
• Reduced emissions
• High process stability

The CMT process is suitable for:

• Joint welding, cladding and brazing – particularly in the case of high requirements in terms of heat input and process stability
• Light-gauge sheet welding with minimal distortion
• Special connections, such as copper, zinc, and steel/aluminium

1. Welding packages, welding characteristics and welding processes
2. Welding methods and processes

CMT Cycle Step is a further development of the CMT welding process. A special CMT drive unit is also required for this process.

CMT Cycle Step is the welding process with the lowest heat input.
The CMT Cycle Step welding process switches cyclically between CMT welding and pauses of an adjustable duration.
These pauses in the welding process lower the heat input; the continuity of the weld seam is maintained.
Individual CMT cycles are also possible. The size of the CMT spot welds is determined by the number of CMT cycles.

1. Welding packages, welding characteristics and welding processes
2. Welding methods and processes

The SlagHammer function is implemented in all steel characteristics.
In conjunction with a CMT drive unit WF 60i CMT, slag is knocked off the weld seam and wire electrode end by a reversing wire movement without arc before welding.
Knocking off the slag ensures reliable and precise ignition of the arc.

A wire buffer is not required for the SlagHammer function.
The SlagHammer function is automatically executed if a CMT drive unit is present in the welding system.

An active SlagHammer function is displayed in the status bar below the SFI symbol.

1. Welding packages, welding characteristics and welding processes
2. Welding methods and processes

With stitch welding, all welding processes can be cyclically interrupted. This facilitates targeted control of the heat input.
Welding time, pause time and the number of interval cycles can be set individually (e.g. for producing a rippled weld seam, for tacking light-gauge sheets or for longer pause times for simple, automatic spot welding mode).

Stitch welding is possible with any operating mode.
In special 2-step mode and special 4-step mode, no interval cycles are performed during the start and end phases. The interval cycles are only executed in the main process phase.

1. Welding packages, welding characteristics and welding processes
2. Welding methods and processes

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

Advantages:

• React to real component deviations
• No re-training - time and cost savings
• No need to calibrate TCP and sensor

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

The CMT Welding Package is not required for WireSense.

1. Welding packages, welding characteristics and welding processes
2. Welding methods and processes

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

1. Welding packages, welding characteristics and welding processes
2. Welding methods and processes

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

Applications:

• Removing shrink holes, pores or slag inclusions from workpieces
• Detaching sprue or finishing entire workpiece surfaces in casting operations
• Edge preparation for heavy plates
• Preparation and repair of welds
• Working out root passes or defects
• Production of air gaps

IMPORTANT! Arc air gouging is only possible on steel materials!

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.

1. Controls, connections and mechanical components

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.

1. Controls, connections and mechanical components
2. Control panel

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.

1. Controls, connections and mechanical components
2. Control panel

1. Controls, connections and mechanical components
2. Control panel

43,0001,3547

1. Controls, connections and mechanical components
2. Control panel

Touch the display

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

Turn the adjusting dial

Select elements on the display Change values For certain parameters, a value changed by turning the adjusting dial is applied automatically without having to press the adjusting dial.

Press the adjusting dial

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

Press the button

	Press the wire threading button to thread the wire electrode into the welding torch hosepack without an accompanying flow of gas or current. The display shows an animated graphic with motor current, motor power and wire length fed.
	When the gas-test button is pressed, gas will flow out for 30 seconds. Press again to end the process prematurely. The display shows an animated graphic with the remaining gas flow time.

1. Controls, connections and mechanical components

1. Controls, connections and mechanical components
2. Display and status line

1. Controls, connections and mechanical components
2. Display and status line

The status bar is divided into segments and contains the following information:

		Arc length stabilizer
		Penetration stabilizer
		SynchroPulse
		Spatter Free Ignition, SlagHammer, SFI HotStart
		CMT Cycle Step (only in combination with the CMT welding process)
		Interval
	Symbol lights up green: Process function is active
	Symbol is grey: Process function is available but is not being used for welding

(5)	Bluetooth/WLAN status indicator (certified devices only) Symbol lights up blue: Active connection to a Bluetooth device Symbol is grey: Bluetooth device detected, no active connection or Intermediate arc indicator

		Teaching - active operation
		Teaching - contact with workpiece detected
		TouchSensing - active operation
		TouchSensing - contact with workpiece detected
		WireSense - active operation
		WireSense - edge detected

(7)	Currently logged-on user (with active user management) or the key symbol when the welding machine is locked (e.g. when the profile/role "locked" is active)
(8)	Time and date

Additional information on the characteristic (3) and for SynchroPulse, SFI, etc. (4) can be called up using the respective buttons.

1. Controls, connections and mechanical components
2. Display and status line

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

The information appears.

Further information on the current limit can be found in the Troubleshooting section on page (→)

1. Controls, connections and mechanical components
2. Display and status line

1

The display is shown in full screen mode:

2Exit full screen mode:

With a few default settings and the setting options via the status bar, the welding machine can be fully operated in full-screen mode for manual applications.

1. Controls, connections and mechanical components
2. Display and status line

If there are more than six parameters in a menu, the parameters are divided into several pages.
Navigate between several pages using the "Next page" and "Previous page" buttons:

Example: Process parameters / Common - Next page

Example: Process parameters / Common - Previous page

1. Controls, connections and mechanical components
2. Display and status line

Animated graphics are shown on the display for certain parameters.
These animated graphics change when the value of the parameter is changed.

Example: Welding parameters for pulse correction -10 / 0 / +10

Example: Process parameters / Process control / Penetration stabilizer 0 / 0.1 / 10.0

1. Controls, connections and mechanical components
2. Display and status line

1. Controls, connections and mechanical components

Front

Rear

1. Controls, connections and mechanical components
2. Connections, switches and mechanical components

Front

Rear

Depending on the welding process, a certain minimum equipment level is required in order to work with the welding machine.
The welding processes and the corresponding minimum equipment for the welding operation are described in the following.

1. Installation and commissioning

Depending on the welding process, a certain minimum equipment level is required in order to work with the welding machine.
The welding processes and the corresponding minimum equipment for the welding operation are described in the following.

1. Installation and commissioning
2. Minimum equipment needed for welding task

Depending on the welding process, a certain minimum equipment level is required in order to work with the welding machine.
The welding processes and the corresponding minimum equipment for the welding operation are described in the following.

1. Installation and commissioning
2. Minimum equipment needed for welding task

• Welding machine
• Return lead cable
• MIG/MAG welding torch, gas-cooled
• Shielding gas supply
• Wirefeeder
• Interconnecting hosepack
• Wire electrode

1. Installation and commissioning
2. Minimum equipment needed for welding task

• Welding machine
• Cooling unit
• Return lead cable
• MIG/MAG welding torch, water-cooled
• Shielding gas supply
• Wirefeeder
• Interconnecting hosepack
• Wire electrode

1. Installation and commissioning
2. Minimum equipment needed for welding task

• Welding machine
• Robot interface or field bus connection
• Return lead cable
• MIG/MAG robot welding torch or automatic MIG/MAG welding torch
  
  A cooling unit is also required with water-cooled robot or machine welding torches.
  
• Shielding gas connection (shielding gas supply)
• Wirefeeder
• Interconnecting hosepack
• Wire electrode

1. Installation and commissioning
2. Minimum equipment needed for welding task

• Welding machine
• Standard, Pulse and CMT welding packages enabled on the welding machine
• Return lead cable
• PullMig CMT welding torch incl. CMT drive unit and CMT wire buffer
  
  IMPORTANT! For water-cooled CMT applications, a cooling unit is also required!
  
• OPT/i PushPull
• Wirefeeder
• CMT interconnecting hosepack
• Wire electrode
• Shielding gas connection (shielding gas supply)

1. Installation and commissioning
2. Minimum equipment needed for welding task

• Welding machine
• Standard, Pulse and CMT welding packages enabled on the welding machine
• Robot interface or field bus connection
• Return lead cable
• CMT welding torch incl. CMT drive unit
• Cooling unit
• Unreeling wirefeeder (WFi REEL)
• Interconnecting hosepack
• Torch hosepack
• Wirefeeding hose
• Media splitter (e.g. SB 500i R, SB 60i R)
• CMT wire buffer (included with SB 60i R)
• Wire electrode
• Shielding gas connection (shielding gas supply)

1. Installation and commissioning
2. Minimum equipment needed for welding task

• Welding machine with built-in OPT/i TPS 2nd plus socket installed
• Return lead cable
• TIG gas-valve torch
• Shielding gas connection (shielding gas supply)
• Filler metal (depending on the application)

1. Installation and commissioning
2. Minimum equipment needed for welding task

• Welding machine with built-in OPT/i TPS 2nd plus socket installed
• Return lead cable
• Electrode holder with welding power-lead
• Rod electrodes

1. Installation and commissioning
2. Minimum equipment needed for welding task

• Welding machine with built-in OPT/i TPS 2nd plus socket installed
• Return lead cable 120i PC
• PowerConnector - Dinse adapter
• Arc air gouging torch KRIS 13
• Compressed air supply

1. Installation and commissioning

1. Installation and commissioning
2. Before installation and commissioning

1. Installation and commissioning
2. Before installation and commissioning

The welding machine may only be used for MIG/MAG, MMA and TIG welding. Any use above and beyond this purpose is deemed improper. The manufacturer shall not be liable for any damage resulting from such use.

• Following all the instructions contained in the operating instructions
• Performing all stipulated inspection and maintenance work

1. Installation and commissioning
2. Before installation and commissioning

• Protection against solid foreign bodies larger than Ø 12.5 mm (0.49 in.)
• Protection against spraywater at any angle up to 60° from the vertical

The device can be set up and operated outdoors in accordance with protection class IP23. Direct moisture (e.g., from rain) must be avoided.

The ventilation channel is a very important safety device. When selecting the setup location, ensure that the cooling air can enter or exit unhindered through the vents on the front and back. Any electrically conductive dust (e.g., from grinding work) must not be allowed to be sucked directly into the system.

1. Installation and commissioning
2. Before installation and commissioning

• The devices are designed for the mains voltage specified on the rating plate.
• Devices with a rated welding voltage of 3 x 575 V must be operated on three-phase systems with earth neutral.
• If your version of the appliance does not come with mains cables and mains plugs ready-fitted, these must be fitted by a qualified person in accordance with national standards.
• The fuse protection for the mains lead is indicated in the technical data.

1. Installation and commissioning
2. Before installation and commissioning

The welding machine is generator-compatible.

The maximum apparent power S_1max of the welding machine must be known in order to select the correct generator output.
The maximum apparent power S_1max of the welding machine is calculated for 3-phase devices as follows:

S_1max = I_1max x U₁ x √3

See device rating plate or technical data for I_1max and U₁ values

The generator apparent power S_GEN needed is calculated using the following rule of thumb:

S_GEN = S_1max x 1.35

A smaller generator may be used when not welding at full power.

IMPORTANT! The generator apparent power S_GEN must always be higher than the maximum apparent power S_1max of the welding machine.

1. Installation and commissioning
2. Before installation and commissioning

• Trolleys
• Cooling units
• Wire-feed unit holders
• Wire-feed units
• Interconnecting hosepacks
• Welding torches
• etc.

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

1. Installation and commissioning

If no mains cable is connected, a mains cable that is suitable for the connection voltage must be fitted before commissioning.
A universal strain-relief device for cable diameters from 12-30 mm (0.47-1.18 in.) is fitted to the welding machine.

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

1. Installation and commissioning
2. Connecting the mains cable

If no mains cable is connected, a mains cable that is suitable for the connection voltage must be fitted before commissioning.
A universal strain-relief device for cable diameters from 12-30 mm (0.47-1.18 in.) is fitted to the welding machine.

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

1. Installation and commissioning
2. Connecting the mains cable

Welding machine
mains voltage: USA & Canada * | Europe

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

TPS 320i /MV/nc
3 x 230 V: AWG 10 | 4 G 4
3 x 460 V: AWG 14 | 4 G 2.5

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

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

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

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

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

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

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

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

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

AWG = American wire gauge

1. Installation and commissioning
2. Connecting the mains cable

1. Installation and commissioning
2. Connecting the mains cable

IMPORTANT! The ground conductor should be approx. 30 mm (1.18 in.) longer than the phase conductors.

1

Cut the strain-relief device to length according to the cable outer diameter

2

3

4

Slotted screwdriver

5

6

7

1. Installation and commissioning

1. Installation and commissioning
2. Commissioning the TPS 320i / 400i / 500i / 600i

1. Installation and commissioning
2. Commissioning the TPS 320i / 400i / 500i / 600i

The commissioning process for the TPS 320i / 400i / 500i / 600i welding machine is described using a manual gas-cooled MIG/MAG application as an example.

The following illustrations show an overview of how the individual system components are put together.
For detailed information about the individual steps, please refer to the respective system component operating instructions.

1. Installation and commissioning
2. Commissioning the TPS 320i / 400i / 500i / 600i

1. Installation and commissioning
2. Commissioning the TPS 320i / 400i / 500i / 600i

1

Fixing the strain-relief device to the trolley

2

Fixing the strain-relief device to the wirefeeder

1. Installation and commissioning
2. Commissioning the TPS 320i / 400i / 500i / 600i

1

Connecting the interconnecting hosepack to the welding machine and cooling unit

2

Connecting the interconnecting hosepack to the wirefeeder

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

1. Installation and commissioning
2. Commissioning the TPS 320i / 400i / 500i / 600i

Correct arrangement of the interconnecting hosepack

IMPORTANT!

• The duty cycle value (D.C.) for the interconnecting hosepack can only be attained when the interconnecting hosepacks are laid correctly.
• Carry out R/L alignment if the arrangement of an interconnecting hosepack changes (see page (→)).
• 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.

1. Installation and commissioning
2. Commissioning the TPS 320i / 400i / 500i / 600i

Fixing the gas cylinder on the trolley

1Place the gas cylinder on the base of the trolley

2Secure the gas cylinder by fixing the cylinder strap around the upper part of the cylinder (but not around the neck) to prevent it from toppling over

3Take the protective cap off the gas cylinder

4Briefly open the gas cylinder valve to remove any dust or dirt

5Inspect the seal on the gas pressure regulator

6Screw the pressure regulator onto the gas cylinder and tighten it

7Connect the shielding gas hose of the interconnecting hosepack to the pressure regulator using the gas hose

1. Installation and commissioning
2. Commissioning the TPS 320i / 400i / 500i / 600i

NOTE!

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

Use a separate return lead cable for each welding machine

Keep the plus cable and return lead cable together as long and as close as possible

Physically separate the welding circuits of individual welding machines

Do not route several return lead cables in parallel;
if parallel routing cannot be avoided, keep a minimum distance of 30 cm between the welding circuits

Keep the return lead cable as short as possible, provide a large cable cross-section

Do not cross return lead cables

Avoid ferromagnetic materials between the return lead cable and the interconnecting hosepack

Do not wind up return lead cables - coil effect!
Lay long return lead cables in loops

Do not route return lead cables in iron pipes, metal cable conduits or on steel beams, avoid cable ducts;
(routing of plus cables and return lead cables together in an iron pipe does not cause any problems)

If there are several return lead cables, keep the grounding points on the component as far away from one another as possible and prevent crossed current paths from occurring underneath the individual arcs.

Use compensated interconnecting hosepacks (interconnecting hosepacks with integrated return lead cable)

1Plug the return lead cable into the (-) current socket and twist to fasten it

2Use the other end of the return lead cable to establish a connection to the workpiece

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

1. Installation and commissioning
2. Commissioning the TPS 320i / 400i / 500i / 600i

1Check that all cables, leads and hosepacks are undamaged and correctly insulated

2Open the wire drive cover

3Open the clamping lever on the wire drive

4Check that the welding torch is properly equipped. Insert it - marking at the top first - into the welding torch connection on the wirefeeder.

5Close the clamping lever on the wire drive

*	On water-cooled welding torches:

6Connect the coolant flow hose to the coolant flow connection (blue)

7Connect the coolant return hose to the coolant return connection (red)

8Close the wire drive cover

9Check that all connections are connected properly

1. Installation and commissioning
2. Commissioning the TPS 320i / 400i / 500i / 600i

IMPORTANT! For optimum welding results, the manufacturer recommends performing an R/L alignment when starting the device for the first time and when any changes are made to the welding system. More information on R/L alignment can be found under "Welding mode" in the "Process parameters" section of the "Welding mode" chapter (page (→)).

1. Installation and commissioning
2. Commissioning the TPS 320i / 400i / 500i / 600i

If contact is made with the earth during wire threading, the wire electrode is automatically stopped.

When the torch trigger is pressed once, the wire electrode moves forwards 1 mm.

With a push wire feeding system:
If contact is made with the workpiece during threading, the wire play in the inner liner is measured. If the measurement is successful, a wire play value is entered in the event logbook, which is used to control the system.

1. Installation and commissioning

NFC key = NFC card or NFC key ring

The welding machine 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 welding machine to be locked and unlocked.

The welding machine must be switched on before it can be locked or unlocked.

1. Installation and commissioning
2. Locking and unlocking the welding machine using the NFC key

NFC key = NFC card or NFC key ring

The welding machine 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 welding machine to be locked and unlocked.

The welding machine must be switched on before it can be locked or unlocked.

1. Installation and commissioning
2. Locking and unlocking the welding machine using the NFC key

Locking the welding machine

The key symbol appears on the display.

The key symbol is then displayed in the status bar.

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

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

Unlocking the welding machine

The crossed-out key symbol appears on the display.

The key symbol no longer appears in the status bar.
All welding machine functions are fully available again.

See the Setup menu for information on settings, setting range and units of measurement for the available parameters.

1. Welding

See the Setup menu for information on settings, setting range and units of measurement for the available parameters.

1. Welding
2. MIG/MAG modes

See the Setup menu for information on settings, setting range and units of measurement for the available parameters.

1. Welding
2. MIG/MAG modes

Press the torch trigger | Hold the torch trigger | Release the torch trigger

GPr
Gas pre-flow

I-S
Starting-current phase: the base material is heated up rapidly, despite the high thermal dissipation that occurs at the start of welding

t-S
Starting current time

Start arc length correction

SL1
Slope 1: the starting current is steadily lowered until it reaches the welding current

I
Welding-current phase: uniform thermal input into the base material, whose temperature is raised by the advancing heat

I-E
Final current phase: to prevent any local overheating of the base material due to heat build-up towards the end of welding. This eliminates any risk of weld seam drop-through.

t-E
Final current time

End arc length correction

SL2
Slope 2: the welding current is steadily lowered until it reaches the final current

GPo
Gas post-flow

SPt
Spot welding time

A detailed explanation of the parameters can be found in the section headed "Process parameters".

1. Welding
2. MIG/MAG modes

• Tacking work
• Short weld seams
• Automated and robot welding

1. Welding
2. MIG/MAG modes

"4-step mode" is suitable for longer weld seams.

1. Welding
2. MIG/MAG modes

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

1. Welding
2. MIG/MAG modes

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

1. Welding
2. MIG/MAG modes

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

1. Welding

1. Welding
2. MIG/MAG and CMT welding

1. Welding
2. MIG/MAG and CMT welding

The "MIG/MAG and CMT welding" section comprises the following steps:

• Switching on the welding machine
• Selecting the welding process and operating mode
• Selecting the filler metal and shielding gas
• Setting the welding and process parameters
• Setting the shielding gas flow rate
• MIG/MAG or CMT welding

1. Welding
2. MIG/MAG and CMT welding

A cooling unit connected to the welding system will begin to operate.

IMPORTANT! For optimum welding results, the manufacturer recommends performing an R/L alignment when starting the device for the first time and when any changes are made to the welding system.
More information on R/L alignment can be found under "R/L alignment" in the MIG/MAG process parameters chapter (page (→)).

1. Welding
2. MIG/MAG and CMT welding

An overview of the welding processes is displayed.

An overview of the operating modes is displayed.

1. Welding
2. MIG/MAG and CMT welding

Welding process and operating mode can alternatively be set via the menu bar.

An overview of the welding processes is displayed.
Different welding processes are available depending on the model of welding machine or function packages installed.

An overview of the operating modes is displayed:

• 2-step mode
• 4-step mode
• Special 2-step mode
• Special 4-step mode
• Spot welding

1. Welding
2. MIG/MAG and CMT welding

The confirmation step of the filler metal wizard is displayed:

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

1. Welding
2. MIG/MAG and CMT welding

The value of the parameter is displayed as a horizontal scale, the parameter is illustrated by means of an animated graphic:

e.g. welding current parameter

The value of the selected parameter can now be changed.

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

1Select the currently selected welding process line in the status bar

2Set welding parameters and process parameters for both welding process lines

1. Welding
2. MIG/MAG and CMT welding

1. Welding
2. MIG/MAG and CMT welding

Each time at the end of welding, the welding data is saved depending on the setting; Hold or Mean is shown on the display (see also page (→)).

1. Welding

Spot welding is used on welded joints on overlapping sheets that are only accessible on one side.

Procedure for producing a welding spot:

1. Welding
2. Spot and stitch welding

Spot welding is used on welded joints on overlapping sheets that are only accessible on one side.

Procedure for producing a welding spot:

1. Welding
2. Spot and stitch welding

Procedure for stitch welding:

Notes on stitch welding

With PMC characteristics, the setting of the SFI parameter influences the re-ignition behaviour in interval operation:

SFI = on
Re-ignition takes place with SFI.

SFI = off
Re-ignition takes place by means of touchdown ignition.

For aluminium alloys, SFI is always used for pulse and PMC ignition. SFI ignition cannot be deactivated.

If the SlagHammer function is stored on the selected characteristic, faster and more stable SFI ignition takes place in conjunction with a CMT drive unit and a wire buffer.

1. Welding

The following welding parameters for MIG/MAG pulse synergic welding and PMC welding can be set and displayed by selecting "Welding":

Wire speed ¹⁾

0.5 - max. ^{2) 3)} m/min / 19.69 - max ^{2) 3)} ipm.

Material thickness ¹⁾

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

Current ¹⁾ [A]

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. The actual value is displayed during welding.

Arc length correction
for correcting the arc length;

-10 - +10
Factory setting: 0

- ... shorter arc length
0 ... neutral arc length
+ ... longer arc length

If the arc length correction is adjusted, the welding voltage changes, but the welding current and wire speed remain the same.

On the display, the voltage value with unchanged arc length correction (1), the voltage value corresponding to the currently set arc length correction (2) and the symbol of an active arc length correction (3) are displayed.

Pulse correction
For correcting the pulsing energy of a pulsed arc

-10 - +10
Factory setting: 0

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

1. Welding
2. MIG/MAG and CMT welding parameters

The following welding parameters for MIG/MAG pulse synergic welding and PMC welding can be set and displayed by selecting "Welding":

Wire speed ¹⁾

0.5 - max. ^{2) 3)} m/min / 19.69 - max ^{2) 3)} ipm.

Material thickness ¹⁾

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

Current ¹⁾ [A]

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. The actual value is displayed during welding.

Arc length correction
for correcting the arc length;

-10 - +10
Factory setting: 0

- ... shorter arc length
0 ... neutral arc length
+ ... longer arc length

If the arc length correction is adjusted, the welding voltage changes, but the welding current and wire speed remain the same.

On the display, the voltage value with unchanged arc length correction (1), the voltage value corresponding to the currently set arc length correction (2) and the symbol of an active arc length correction (3) are displayed.

Pulse correction
For correcting the pulsing energy of a pulsed arc

-10 - +10
Factory setting: 0

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

1. Welding
2. MIG/MAG and CMT welding parameters

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

Wire speed ¹⁾

0.5 - max. ^{2) 3)} m/min / 19.69 - max ^{2) 3)} ipm.

Material thickness ¹⁾

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

Current ¹⁾ [A]

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. The actual value is displayed during welding.

Arc length correction
for correcting the arc length;

-10 - +10
Factory setting: 0

- ... shorter arc length
0 ... neutral arc length
+ ... longer arc length

If the arc length correction is adjusted, the welding voltage changes, but the welding current and wire speed remain the same.

On the display, the voltage value with unchanged arc length correction (1), the voltage value corresponding to the currently set arc length correction (2) and the symbol of an active arc length correction (3) are displayed.

Dynamic correction
for setting the short circuit current and the current to short-circuit break-up

-10 - +10
Factory setting: 0

-10
harder arc (higher current in case of short-circuit break-up, increased welding spatter)

+10
softer arc (lower current in case of short-circuit break-up, less welding spatter forms)

1. Welding
2. MIG/MAG and CMT welding parameters

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

Voltage ¹⁾ [V]

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

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

Wire speed ¹⁾
for setting a harder, more stable arc

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

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

0 - 10
Factory setting: 1.5

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

1. Welding
2. MIG/MAG and CMT welding parameters

1. Welding

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.

If there is a robot interface in the welding system, the EasyJob buttons are not displayed, the EasyJob mode is greyed out and cannot be activated.

1. Welding
2. EasyJob mode

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.

If there is a robot interface in the welding system, the EasyJob buttons are not displayed, the EasyJob mode is greyed out and cannot be activated.

1. Welding
2. EasyJob mode

The overview to activate/deactivate EasyJob mode is displayed.

EasyJob mode is activated and the default settings are displayed.

Five EasyJob buttons are displayed for the welding parameters.

1. Welding
2. EasyJob mode

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

The settings have now been stored. The most recently stored settings will be active. An active EasyJob is shown with a tick on the EasyJob button.
Unoccupied EasyJob buttons are shown in dark grey.
For occupied EasyJobs, the button number is shown in white.

1. Welding
2. EasyJob mode

The size and colour of the button changes briefly; it is then displayed with a tick.

If a tick is not displayed after touching an EasyJob button, this means that there is no operating point saved under this button.

1. Welding
2. EasyJob mode

The button

• First changes its size and colour;
• Is displayed with a frame after about 3 seconds;
  The saved operating point is overwritten with the current settings.
• Is highlighted in red (= delete) after a total of 5 seconds.

The EasyJob operating point has been deleted.

* ... highlighted in red

1. Welding
2. EasyJob mode

With this function, any stored job can be loaded as an EasyJob in the welding menu without switching to Job Mode.

The overview to activate/deactivate EasyJob mode is displayed.

EasyJob mode is activated and the default settings are displayed.

In the welding parameters, the "Load Job" button is also displayed in the right-hand menu bar.

The list of stored jobs is displayed.

The job is loaded in the welding menu, the welding machine is not in Job Mode.

1. Welding

Up to 1000 jobs can be stored and reproduced on the welding machine.
This eliminates the need to manually document the welding parameters.
Job Mode thereby increases the quality of automated and manual applications.

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

1. Welding
2. Job mode

Up to 1000 jobs can be stored and reproduced on the welding machine.
This eliminates the need to manually document the welding parameters.
Job Mode thereby increases the quality of automated and manual applications.

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

1. Welding
2. Job mode

The job list is displayed.

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

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

The next free job number is displayed.

The keyboard is displayed.

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

1. Welding
2. Job mode

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

IMPORTANT! "Job" is the only parameter that can be altered in Job Mode; all the other welding parameters are read-only.

1. Welding
2. Job mode

The job list is displayed.

The keyboard is displayed.

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

1. Welding
2. Job mode

The job list is displayed.

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

The job is deleted, the job list is displayed.

1. Welding
2. Job mode

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.

The job list is displayed.

The load job information is shown.

The data for the selected job is loaded onto the welding screen.

The data for the loaded job can now be used for welding (no job mode), changed, or be saved as a new job or an EasyJob.

1. Welding
2. Job mode

An overview of the job functions is displayed.

The overview of the most recently optimised job is displayed.

4Turn the adjusting dial and select either the job or the job welding parameters to be modified

The choice between the job and the job welding parameters can also be made by touching the "Job number / Job parameter" button.

Select job:

• Press the adjusting dial
  
  The job number is highlighted in blue and can now be changed.
  
• Turn the adjusting dial to select the job to be altered
• Press the adjusting dial to change the job

Select job welding parameters:

• Turn the adjusting dial and select the parameter to be changed
• Press the adjusting dial
  
  The value of the parameter is highlighted in blue and can now be changed.
  
• Turn the adjusting dial; the amended value is applied immediately
• Press the adjusting dial to select other parameters

1. Welding
2. Job mode

Individual correction limits for welding power and arc length can be defined for each job.
If correction limits are defined for a job, the welding power and arc length for the job in question can be corrected within the defined limits while welding.

An overview of the job functions is displayed.

A list of the job correction limits for the last job opened is displayed.

4Turn 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" 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 limits:

• Turn the adjusting dial and select the desired limit group
• Press the adjusting dial
  
  The selected limit group opens.
  
• Turn the adjusting dial and select the top or bottom limit
• Press the adjusting dial
  
  The value of the limit parameter is highlighted in blue and can now be changed.
  
• Turn the adjusting dial; the amended value is applied immediately
• Press the adjusting dial to select other limit parameters

1. Welding
2. Job mode

Pre-settings for "Save as Job" are used to set the default values that are assumed for every newly created job.

An overview of the job functions is displayed.

The default settings for saving new jobs are displayed.

1. Welding
2. Job mode

If a WF 25i Dual double-head wirefeeder is in the welding system, the following parameters are also available:

• Welding process line
  Process parameters / Job / Optimize Job / Welding process parameters
• Ignore welding process line
  Process parameters / JOB / Presettings for "Save as Job" / Double-head wirefeeder

Welding process line
The parameter assigns a welding process line to the job:

1
The job can only be welded on welding process line 1.

2
The job can only be welded on welding process line 2.

Ignore
The job can be used by both welding process lines.
The welding process line is selected by means of the torch trigger, status bar, buttons on the WF Dual or remote control.

Selecting a job automatically activates the associated welding process line.
The job can be selected from both welding process lines.

For jobs created on a firmware version < 4.0.0, the parameter is automatically set to "ignore" during a firmware update.

If another robot double-head option is in the system in automated applications in place of the WF Dual, the parameter is not present.
The welding process line is selected via the robot interface.

Ignore weld process line
The parameter specifies which default value is used for the welding process line when creating a job.

No
The welding process line is taken from the currently active welding process line when creating a job (can be changed).

Yes
The welding process line is initially filled with "ignore" when a job is created (can be changed).

The parameter is set to "No" by default; when creating a job, the currently active welding process line is always adopted.
The parameter is not displayed in automated welding systems and has no effect.

1. Welding

1. Welding
2. TIG welding

1. Welding
2. TIG welding

IMPORTANT! For TIG welding, the OPT/i TPS 2nd plus socket option must be installed on the welding machine.

1. Welding
2. TIG welding

Alternatively, the welding process can also be selected via the status bar (compare with the selection described from page (→)).

An overview of the welding processes is displayed.
Different welding processes are available depending on the model of welding machine or function packages installed.

The welding voltage is applied to the welding socket with a three second time lag.

The TIG welding parameters are displayed.

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

The value of the selected parameter can now be changed.

1. Welding
2. TIG welding

The welding arc is ignited by touching the workpiece with the tungsten electrode.

1. Welding
2. TIG welding

1. Welding

1. Welding
2. MMA welding

1. Welding
2. MMA welding

IMPORTANT! A return lead cable with a PowerConnector is required for MMA welding. For other return lead cables the OPT/i TPS 2nd plus socket option must be installed on the welding machine.

1. Welding
2. MMA welding

Alternatively, the welding process can also be selected via the status bar (compare with the selection described from page (→)).

An overview of the welding processes is displayed.
Different welding processes are available depending on the model of welding machine or function packages installed.

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. It is not possible to switch it on.

The MMA welding parameters are displayed.

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

The value of the selected parameter can now be changed.

1. Welding
2. MMA welding

The following welding parameters for MMA welding can be set and displayed under "Welding":

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

0-100
Factory setting: 20

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

Main current [A]

Setting range: depends on the welding machine being used

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

Starting current 
for setting a starting current value in the range 0-200% of the set welding current in order to avoid slag inclusions or incomplete fusion.
The starting current depends on the electrode type.

0-200%
Factory setting: 150%

The starting current is active for the starting current time set under the process parameters.

1. Welding

1. Welding
2. Arc Air Gauging

1. Welding
2. Arc Air Gauging

IMPORTANT! A return lead cable with PowerConnector and a cable cross-section of 120 mm² is required for arc air gouging. For other return lead cables without a PowerConnector the OPT/i TPS 2nd plus socket option must be installed on the welding machine.
A PowerConnector - Dinse adapter is also required for connecting the arc air gouging torch.

1. Welding
2. Arc Air Gauging

If the MMA/SMAW welding process is selected, any cooling unit present is automatically deactivated. It is not possible to switch it on.

The arc air gouging parameters are displayed.

The tilt angle of the carbon electrode and the gouging speed determine the depth of an air gap.

The arc air gouging parameters are the same as the welding parameters for MMA welding, see page (→).

Process parameters / Common ... see page (→)

Process parameters / Components & Monitoring ... see page (→)

Process parameters / JOB ... see page (→)

1. Process parameters

Process parameters / Common ... see page (→)

Process parameters / Components & Monitoring ... see page (→)

Process parameters / JOB ... see page (→)

1. Process parameters
2. Overview

Process parameters / Common ... see page (→)

Process parameters / Components & Monitoring ... see page (→)

Process parameters / JOB ... see page (→)

1. Process parameters

1. Process parameters
2. Process parameters, General

1. Process parameters
2. Process parameters, General

The following process parameters can be set and displayed for the start and end of welding:

Special 2/4 step parameters

Starting current 
for setting the starting current for MIG/MAG welding (e.g. aluminium welding start-up)

0 - 400% (of welding current)
Factory setting: 135%

Start arc length correction
for correcting the arc length at the start of welding

-10 - -0.1 / auto / 0.0 - 10.0
Factory setting: auto

- ... shorter arc length
0 ... neutral arc length
+ ... longer arc length

auto:
the value set in the welding parameters is taken over

Starting current time
for setting the length of time the starting current is to be active 

off / 0.1 - 10.0 s
Factory setting: off

Slope 1 
for setting the time during which the starting current is decreased or increased to the welding current

0.0 - 9.9 s
Factory setting: 1.0 s

Slope 2 
for setting the time during which the welding current is decreased or increased to the final current.

0.0 - 9.9 s
Factory setting: 1.0 s

Final current 
for setting the final current so that

1. heat build-up towards the end of welding is prevented and
2. the end-crater can be filled when welding aluminium

0 - 400% (of welding current)
Factory setting: 50%

End arc length correction
for correcting the arc length at the end of welding

-10 - -0.1 / auto / 0.0 - 10.0
Factory setting: auto

- ... shorter arc length
0 ... neutral arc length
+ ... longer arc length

auto:
the value set in the welding parameters is taken over

Final current time
for setting the length of time for which the final current is to be active

off / 0.1 - 10.0 s
Factory setting: off

SFI parameters

SFI
to activate / deactivate the function SFI (Spatter Free Ignition - spatter-free ignition of the arc)

SFI causes an almost spatter-free ignition of the arc due to a controlled starting current curve with synchronised wire retraction movement.

off / on
Factory setting: off

SFI HotStart
for setting a HotStart time in conjunction with SFI ignition

During SFI ignition, a spray arc phase occurs within the set HotStart time. This increases the heat input irrespective of the mode, thus ensuring deeper penetration right from the very start of welding.

off / 0.01 - 2.00 s
Factory setting: off

Manual parameters

Ignition current (manual) 
for setting the ignition current for MIG/MAG standard manual welding

100 - 550 A (TPS 320i, TPS 320i C)
100 - 600 A (TPS 400i)
100 - 650 A (TPS 500i, TPS 600i)
Factory setting: 500 A

Wire withdrawal (manual) 
for setting the wire withdrawal value (= composite value based on backward movement of wire and a time) for MIG/MAG standard manual welding.
The wire withdrawal depends on the features of the welding torch.

0.0 - 10.0
Factory setting: 0.0

Wire withdrawal

Wire withdrawal 
For setting the wire withdrawal value (= composite value based on backward movement of wire and a time).
The wire withdrawal depends on the features of the welding torch.

0.0 - 10.0
Factory setting: 0.0

1. Process parameters
2. Process parameters, General

The following process parameters can be set and displayed for Gas-Setup:

Gas pre flow 
for setting the gas flow time before the arc is ignited

0-9.9  s
Factory setting: 0.1 s

Gas postflow 
for setting the gas flow time after the arc has gone out

0-60 s
Factory setting: 0.5 s

Gas factor 
dependent on the shielding gas used
(only in conjunction with the OPT/i gas controller option)

auto / 0.90-20.00
Factory setting: auto
(the correction factor is automatically set for standard gases from the Fronius welding database)

Command value gas
Shielding gas flow rate
(only in conjunction with an OPT/i gas controller option in the wirefeeder)

off / auto / 0.5-30.0 l/min
Factory setting: 15.0 l/min

Settings for "auto" command value gas
When set to "auto", the command value gas automatically adjusts to the current welding current within a set current range.

Lower current
for setting the lower current range limit

0-max. A
Factory setting: 50 A

Command value gas at lower current

0.5-30.0 l/min
Factory setting: 8.0 l/min

Upper current
for setting the upper current range limit

0-max. A
Factory setting: 400 A

Command value gas at upper current

0.5-30.0 l/min
Factory setting: 25.0 l/min

In Job Mode, the set values of the parameters listed above can be stored individually for each job.

1. Process parameters
2. Process parameters, General

The following process parameters can be set and displayed for the process control:

• Penetration stabiliser
• Arc length stabiliser
• Combination of penetration stabiliser and arc length stabiliser

1. Process parameters
2. Process parameters, General

The penetration stabilizer is used to set the max. permitted change in the wire speed to ensure that the welding current and hence the penetration are kept stable or constant with variable stickout.

The penetration stabilizer parameter is only available when the WP PMC (Welding Process Pulse Multi Control) or WP LSC (Welding Process Low Spatter Control) option has been enabled on the welding machine.

0.0-10.0 m/min (ipm)
Factory setting: 0 m/min

auto
A value of 10 m/min is stored for all characteristics, the penetration stabilizer is activated.

0
The penetration stabilizer is not activated.
The wire speed remains constant.

0.1-10.0
The penetration stabilizer is activated.
The welding current remains constant.

Application examples

Penetration stabilizer = 0 m/min (not activated)

Penetration stabilizer = 0 m/min (not activated)

Changing the contact tube distance (h) alters the resistance in the welding circuit due to the longer stickout (s₂).
The constant voltage control for constant arc length causes a reduction in the mean current value and hence a smaller penetration (x₂).

Penetration stabilizer = n m/min (activated)

Penetration stabilizer = n m/min (activated)

Specifying a value for the penetration stabilizer ensures a constant arc length without large current variations if the stickout is changed (s₁ ==> s₂).
The penetration (x₁, x₂) remains virtually unchanged and stable.

Penetration stabilizer = 0.5 m/min (activated)

Penetration stabilizer = 0.5 m/min (activated)

To minimise the change in welding current if the stickout is changed (s₁ ==> s₃), the wire speed is increased or reduced by 0.5 m/min.
In the example shown, the stabilising effect is obtained without a change in current up to the set value of 0.5 m/min (Position 2).

I ... Welding current v_D  ... Wire speed

1. Process parameters
2. Process parameters, General

Arc length stabilizer
The arc length stabilizer forces short arcs, advantageous for welding, via a short-circuit current control and keeps them stable even with a variable stickout or external interference.

The arc length stabilizer welding parameter is only available if the WP PMC (Welding Process Pulse Multi Control) option has been enabled on the welding machine.

0.0 / auto / 0.1-5.0 (effect of stabilizer)
Factory setting: 0.0

0.0
The arc length stabilizer is deactivated.

auto

• For inert gases (100% Ar, He, etc.) a value = 0 is stored.
• For the remaining materials / gas combinations, a characteristic-dependent value between 0.2-0.5 is stored.
• From a wire speed of 16 m/min a value = 0 is stored

0.1-5.0
The arc length stabilizer is activated.
The arc length is decreased until short circuits start to occur.

Application examples

Arc length stabilizer = 0 / 0.5 / 2.0

  Arc length stabilizer = 0

  Arc length stabilizer = 0.5

  Arc length stabilizer = 2

Arc length stabilizer = 0 / 0.5 / 2.0

Activating the arc length stabilizer reduces the arc length until short circuits start to occur. The advantages of a short, stable and controlled arc can be used more effectively as a result.

Increasing the arc length stabilizer causes a further shortening of the arc length (L1 ==> L2 ==> L3). The advantages of a short, stable and controlled arc can be used more effectively.

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.

I ... Welding current v_D ... Wire speed U ... Welding voltage

1. Process parameters
2. Process parameters, General

Example: Stick out change

Arc length stabilizer without penetration stabilizer

The advantages of a short arc are maintained even if the stick out is changed, since the short-circuit properties stay the same.

Arc length stabiliser with penetration stabilizer

If the stick out is changed with the penetration stabilizer activated, the penetration also stays the same.
The short circuit behaviour is controlled by the arc length stabilizer.

I ... Welding current v_D ... Wire speed U ... Welding voltage

1. Process parameters
2. Process parameters, General

The following process parameters can be set for SynchroPulse welding:

(1) SynchroPulse 
to activate/deactivate SynchroPulse

off / on
Factory setting: on

(2) Wire speed
for setting the average wire speed and therefore the welding power for SynchroPulse

e.g. 2-25 m/min (ipm)
(depending on wire speed and welding characteristic)
Factory setting: 5.0 m/min

(3) Delta wire feed
for setting the Delta wire feed:
with SynchroPulse, the set wire speed is alternately increased/decreased by the Delta wire feed. The parameters concerned adapt themselves to this wire speed acceleration/delay accordingly.

0.1-6.0 m/min / 5-235 ipm
Factory setting: 2.0 m/min

(4) Frequency
for setting the frequency for SynchroPulse

0.5-10.0 Hz
Factory setting: 3.0 Hz

(5) Duty Cycle (high) 
for weighting the duration of the higher operating point in a SynchroPulse period

10-90%
Factory setting: 50 Hz

(6) Arc correction high 
for correcting the arc length for SynchroPulse in the upper operating point (= average wire speed plus Delta wire speed)

-10.0-+10.0
Factory setting: 0.0